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CROSS REFERENCE TO RELATED APPLICATIONS
This Application claims priority of Taiwan Patent Application No. 103126733, filed on Aug. 5, 2014, the entirety of which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to an optical structure, and in particular to an anti-reflection structure suitable in multiple electronic devices such as displays and solar cells for providing, for example, anti-reflection and anti-smudge functions.
Description of the Related Art
When an electronic device, for example a mobile phone, is used in a bright environment, a reflection of the ambient light of the bright environment on the electronic device may be trigger a trouble like that making the content of the electronic device is difficult to read. In addition, reflection of the ambient light can occur at surfaces of electronic devices such as a display surface of a television, a display surface of a monitor or a solar cell, thereby making it hard for the user to read or degrading the electrical performance of the electronic device.
Accordingly, an anti-reflection coating technique is used in the art to improve the above reflection issues caused by ambient light. Usually one or two thin coating layers are formed on the surface of a transparent substrate in a vacuum chamber to reduce the interference of the reflection of the ambient light. However, since the anti-reflection coating is usually formed on a surface exposed to the environment, such that anti-reflection coating layer is easily affected by dirt and the operations of the users, and therefore defacement and damage can happen to the anti-reflection coating layer, thereby affecting the lifespan of the electronic device. It is desirable to provide an anti-reflection structure with improved mechanical strength and smudge-proof ability of the anti-reflection coating.
BRIEF SUMMARY OF THE INVENTION
An exemplary anti-reflection structure comprises a substrate comprising a planar portion and a protrusion portion disposed over the planar portion, and a coating layer disposed over the substrate. In one embodiment, the protrusion portion is integrated with the planar portion, and the coating layer covers the protrusion portion and the planar portion.
An exemplary electronic device comprises a first substrate, a second substrate disposed over the first substrate, and a liquid-crystal layer, a touch-sensing layer, or a photovoltaic element disposed between the first substrate and the second substrate. In one embodiment, the second substrate comprises the above anti-reflection structure.
A detailed description is given in the following embodiments with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention can be more fully understood by reading the subsequent detailed description and examples with references made to the accompanying drawings, wherein:
FIGS. 1-4 are schematic cross-sectional views showing a method for forming an anti-reflection structure according to an embodiment of the invention;
FIG. 5 is a schematic cross-sectional view showing an anti-reflection structure according to another embodiment of the invention;
FIG. 6 is a schematic cross-sectional view showing an anti-reflection structure according to yet another embodiment of the invention;
FIG. 7 is a schematic cross-sectional view showing an electronic device according to an embodiment of the invention, comprising the anti-reflection structure shown in FIG. 4 ;
FIG. 8 is a schematic cross-sectional view showing an electronic device according to another embodiment of the invention, comprising the anti-reflection structure shown in FIG. 4 ;
FIG. 9 is a schematic cross-sectional view showing an electronic device according to yet another embodiment of the invention, comprising the anti-reflection structure shown in FIG. 4 ; and
FIG. 10 is a schematic cross-sectional view showing an electronic device according to another embodiment of the invention, comprising the anti-reflection structure shown in FIG. 4 .
DETAILED DESCRIPTION OF THE INVENTION
The following description is of the embodiment of carrying out the invention. This description is made for the purpose of illustrating the general principles of the invention and should not be taken in a limiting sense. The scope of the invention is best determined by reference to the appended claims.
FIGS. 1-4 are schematic cross-sectional views showing a method for forming an anti-reflection structure according to an embodiment of the invention.
As shown in FIG. 1 , a substrate 100 is provided first. The substrate 100 may comprise transparent material such as glass, polymethylmethacrylate (PMMA), polyethylene terephthalate (PET), or polyimide (PI). Next, a plurality of spheres 102 having the similar diameter D1 are disposed on a surface of the substrate 100 by methods such as Langmuir-Blodgett coating (LB coating), Langmuir-Schaefer coating (LS coating), dip coating, or self-assembly monolayers (SAMs), but they are not limited thereto. As shown in FIG. 1 , the diameter D1 of the spheres 102 can be about 200-400 nm, and the spheres 102 may have a tolerance of plus or minus 25% on the diameter D1. The spheres 102 may comprise materials such as polystyrene (PS), polyethylene (PE), polyvinylchloride (PVC) or SiO 2 . The spheres 102 disposed on the substrate 100 are close to each other, such that the spheres 102 physically contact with each.
In FIG. 2 , an etching process 104 is performed next on the structure shown in FIG. 1 . The etching process 104 can be, for example, a dry etching such as a plasma etching, and the etchants (not shown) used in the etching process 104 can be adjusted according to the material of the spheres 102 . In one embodiment, the etching process 104 may use etchants comprising trifluoromethane (CHF 3 ) or tetrafluoromethane (CF 4 ) when the spheres 102 comprising polyvinylchloride (PVC). During the etching process 104 , the etchants not only penetrate space between the spheres 102 to isotropically remove portions of the substrate 100 under the spheres 102 , but also simultaneously isotropically removes portions of the spheres 102 .
As shown in FIG. 3 , after the etching process 104 shown in FIG. 2 is performed, another etching process (not shown), for example a wet etching process, is then performed to remove the portions of the spheres 102 remaining on the substrate 100 and clean the substrate 100 . In one embodiment, etchants (not shown) such as sulfuric acid and hydrogen peroxide can be used to remove the portions of the sphere 102 remaining over the substrate 100 and clean the substrate 100 as the spheres 102 comprise polyvinylchloride (PVC).
As shown in FIG. 3 , the substrate 100 being processed by the above etching processes now forms a substrate 100 ′, having a protrusion portion 100 b and a planar portion 100 a underlying the protrusion portion 100 b . The protrusion portion 100 b comprises a plurality of first protrusions 101 a , and the protrusion portion 100 b and the planar portion 100 a underlying the protrusion portion 100 b are formed of the same transparent materials and are integrated with each other. The first protrusion portions 101 a may have a cross-section of a semicircular or semicircular-like configuration similar to portions of the surface of the spheres 102 . The first protrusion portions 101 a may have a width (also entitled as D1) of about 195-400 nm similar with the diameter D1 of the spheres 102 and a height H1 of about 50-250 nm. It should be noted that the first protrusions 101 a are closely proximate to each other, such that the first protrusions 101 a physically contact with each other.
In FIG. 4 , a coating layer 106 is next formed over the structure shown in FIG. 3 . The coating layer 106 can be, for example, an anti-smudge layer. In one embodiment, the coating layer 106 may comprise materials such as per-fluorinated polyethers (PFPE), alkylflouride, or alkylhalide, and can be conformably formed over the exposed surface of the protrusion portion 100 b and the planar portion 100 a of the substrate 100 ′ shown in FIG. 3 by methods such as dip coating, spray coating or evaporation. In addition, the coating layer 106 may have a thickness of about 1-100 nm.
Herein, as shown in FIG. 4 , an exemplary anti-reflection structure is substantially fabricated. FIG. 4 illustrates an exemplary anti-reflection structure, in which the adjacent first protrusions 101 a formed over the substrate 100 ′ made of transparent material form an anti-reflection structure similar to a moth-eye structure, such that the anti-reflection structure is able to reduce reflection in the visible light wavelength band and has a reflectivity no greater than 0.65% in the visible light wavelength band (400-800 nm).
In addition, in the anti-reflection structure shown in FIG. 4 , due to formation of the coating layer 106 , the surface of the coating layer 106 may have a contact angle greater than 110° and 55° to liquids such as water and n-hexadecane, respectively, thereby having anti-smudge and self-cleaning properties.
Moreover, since the protrusion portion 100 b and the planar portion 100 a of the substrate 100 ′ of the anti-reflection structure shown in FIG. 4 are integrated with each other and are made of the same material, such that the protrusion portion 100 b and the planar portion 100 a are well connected and show a mechanical property greater than the conventional anti-reflection structure made of a transparent substrate and an anti-reflection coating of different materials formed thereon. Accordingly, the anti-reflection structure shown in FIG. 4 also has good wear-resistance properties.
FIG. 5 is a schematic cross-sectional view showing an anti-reflection structure according to another embodiment of the invention. The anti-reflection structure shown in FIG. 5 is modified from the anti-reflection structure shown in FIG. 4 . For the purpose of simplicity, only differences between the anti-reflection structures shown in FIGS. 4-5 are discussed bellow.
As shown in FIG. 5 , the protrusion portion 100 b is disposed over the planar portion 100 a of the substrate 100 ′ of the anti-reflection structure, and comprises a plurality of first protrusions 101 a and a plurality of second protrusions 101 b . The second protrusions 101 b have a height H2 and a width D2 greater than that of the first protrusions 101 a . Fabrication of the second protrusions 101 b can be formed by using the plurality of spheres 102 having two kinds of spheres of different sizes, and the spheres 102 may comprise a plurality of first spheres (not shown) having a diameter D1 of about 195-400 nm, and a plurality of second spheres (not shown) having a diameter D2 of about 280-400 nm, and the fabrications shown in FIGS. 2-4 are performed to form the anti-reflection structure shown in FIG. 5 . The first protrusions 101 a may have a cross-section of semicircular or semicircular-like configuration substantially similar with the first spheres (not shown), and have a width (also shown as D1) of about 195-400 nm and a height H1 of about 50-250 nm. The second protrusions 101 b may have a cross-section of a semicircular or semicircular-like configuration substantially similar with the second spheres (not shown) and have a width (shown as D2) of about 280-400 nm and a height H2 of about 50-250 nm.
It should be noted that the first protrusions 101 a and the second protrusions 101 b are closely proximate to each other, such that the first protrusions 101 a and the second protrusions 101 b physically contact with each other.
In one embodiment, the amount of first spheres (not shown) used for forming the anti-reflection structure shown in FIG. 5 is about 0.1-99% of the total amount of the spheres 102 , and the amount of second spheres (not shown) used for forming the anti-reflection structure shown in FIG. 5 is about 0.1-99% of the total amount of spheres 102 , such that the first protrusions 101 a in the anti-reflection structure occupy about 0.1-99.9% of the total surface of a total area, and the second protrusions 101 b of the anti-reflection structure occupy about 0.1-99.9% of the total surface of the total area.
FIG. 6 is a schematic cross-sectional view showing an anti-reflection structure according to yet another embodiment of the invention. The anti-reflection structure shown in FIG. 6 is modified from the anti-reflection structure shown in FIG. 4 . For the purpose of simplicity, only differences between the anti-reflection structures shown in FIGS. 4 and 6 are discussed bellow.
As shown in FIG. 6 , the protrusion portion 100 b is disposed over the planar portion 100 a of the substrate 100 ′ of the anti-reflection structure, and comprises a plurality of first protrusions 101 a , a plurality of second protrusions 101 b , and a plurality of third protrusions 101 c . The third protrusions 101 c have a height H3 and a width D3 greater than that of the first protrusions 101 a and the second protrusion 101 b , and the second protrusions 101 b have a height H2 and a width D2 greater than that of the first protrusions 101 a.
Fabrication of the first protrusions 101 a , the second protrusions 101 b , and the protrusions 101 c can be formed by using the plurality of spheres 102 having three kinds of spheres of different sizes, and the spheres 102 may comprise a plurality of first spheres (not shown) having a diameter D1 of about 195-245 nm, a plurality of second spheres (not shown) having a diameter D2 of about 280-330 nm, and a plurality of third spheres (not shown) having a diameter D3 of about 350-400 nm, and the fabrications shown in FIGS. 2-4 are performed next to form the anti-reflection structure shown in FIG. 6 .
The first protrusions 101 a may have a semi-sphere or semi-sphere like cross-sectional configuration substantially similar with the first spheres (not shown), and have a width (also shown as D1) of about 195-245 nm and a height H1 of about 50-250 nm. The second protrusions 101 b may have a cross-section of a semicircular or semicircular-like configuration substantially similar with the second spheres (not shown) and have a width (shown as D2) of about 280-330 nm and a height H2 of about 50-250 nm. The third protrusions 101 c may have a cross-section of a semicircular or semicircular-like configuration substantially similar with the third spheres (not shown) and have a width (shown as D3) of about 350-400 nm and a height H3 of about 50-250 nm. It is noted that the first protrusions 101 a , the second protrusions 101 b , and the third protrusions 101 c are closely proximate to each other, such that the first protrusions 101 a , the second protrusions 101 b , and the third protrusions 101 c physically contact with each other.
In one embodiment, an amount the first spheres (not shown) used for forming the anti-reflection structure shown in FIG. 6 is about 60-98% of the total amount of the spheres 102 , the second spheres (not shown) used for forming the anti-reflection structure shown in FIG. 6 is about 1-20% of the total amount of the spheres 102 , and the third spheres (not shown) used for forming the anti-reflection structure shown in FIG. 6 is about 1-20% of the total amount of the spheres 102 , such that the first protrusions 101 a in the anti-reflection structure occupy about 60-98% of the total surface of a total area, the second protrusions 101 b of the anti-reflection structure occupy about 1-20% of the total surface of the total area, and the third protrusions 101 c of the anti-reflection structure occupy about 1-20% of the total surface of the total area.
Similarly, the anti-reflection structures shown in FIG. 5-6 also have the properties of low reflection rate, anti-smudge and self-clean as that of the anti-reflection structure shown in FIG. 4 , and have a mechanical strength greater than the conventional anti-reflection structure made of a transparent substrate and an anti-reflection coating of different materials formed thereon.
FIG. 7 is a schematic cross sectional view showing an electronic device 200 according to an embodiment of the invention, using the anti-reflection structure shown in FIG. 4 .
As shown in FIG. 7 , the electronic device 200 can be used in applications such as display devices and comprises a first substrate 210 , a second substrate 240 , a liquid crystal layer 220 disposed between the first substrate 210 and the second substrate 240 , and a color filter layer 230 disposed on a surface of second substrate 240 adjacent to the liquid crystal layer 220 .
In this embodiment, the second substrate 240 can be a transparent substrate contacting the surroundings and may thus have the anti-reflection structure shown in FIG. 4 , such that the electronic device 200 having the anti-reflection structure shown in FIG. 4 may have the properties of low reflection rate, anti-smudge and self-clean as that of the anti-reflection structure shown in FIG. 4 , and have a mechanical property greater than the conventional anti-reflection structure made of a transparent substrate and an anti-reflection coating of different materials formed thereon. Herein, due to the purpose of simplicity, components in the second substrate 240 are similar with that shown in FIG. 4 and are not described in detail. Other components in the electronic device 200 can be components used in a conventional liquid crystal display device, and are not described here in detail.
FIG. 8 is a schematic cross sectional view showing an electronic device 300 according to another embodiment of the invention, using the anti-reflection structure shown in FIG. 4 .
As shown in FIG. 8 , the electronic device 300 can be used in applications such as touch-sensing type display devices and comprises a first substrate 310 , a second substrate 360 , a third substrate 350 disposed between the first substrate 310 and the second substrate 360 , a liquid crystal layer 320 disposed between the first substrate 310 and the third substrate 350 , a plurality of touch-sensing elements 330 disposed over a surface of the first substrate 310 adjacent to the liquid crystal layer 320 , and a color filter layer 340 disposed over a surface of the third substrate 350 adjacent to the liquid crystal layer 320 . The space between the second substrate 360 and the third substrate 350 is filled with air or optical glues to separate the second substrate 360 and the third substrate 350 .
In this embodiment, the second substrate 360 can be a transparent substrate contacting the surroundings and may thus have the anti-reflection structure shown in FIG. 4 , such that the electronic device 300 having the anti-reflection structure shown in FIG. 4 may have the properties of low reflection rate, anti-smudge and self-clean as that of the anti-reflection structure shown in FIG. 4 , and have a mechanical property greater than the conventional anti-reflection structure made of a transparent substrate and an anti-reflection coating of different materials formed thereon. Herein, for the purpose of brevity, components in the second substrate 360 are similar with that shown in FIG. 4 and are not described in detail here. Other components in the electronic device 300 can be components used in conventional touch-sensing type liquid crystal display device, and are not described here in detail.
FIG. 9 is a schematic cross sectional view showing an electronic device 400 according to an embodiment of the invention, using the anti-reflection structure shown in FIG. 4 .
As shown in FIG. 9 , the electronic device 400 can be used in applications such as solar cell devices and comprises a first substrate 414 , a second substrate 402 , and an electrode layer 412 , a photovoltaic element 450 and a transparent conductive layer 404 sequentially disposed on the first substrate 414 and located between the first substrate 414 and the second substrate 402 . In one embodiment, the photovoltaic element 450 comprises an n-type amorphous silicon layer 410 , and intrinsic amorphous silicon layer 408 , and a p-type amorphous silicon layer 406 sequentially stacked over the electrode layer 412 .
In this embodiment, the second substrate 402 can be a transparent substrate contacting the surroundings and may thus have the anti-reflection structure shown in FIG. 4 , such that the electronic device 400 having the anti-reflection structure shown in FIG. 4 may have the properties of low reflection rate, anti-smudge and self-clean as that of the anti-reflection structure shown in FIG. 4 , and have a mechanical property greater than the conventional anti-reflection structure made of a transparent substrate and an anti-reflection coating of different materials formed thereon. Herein, due to the purpose of simplicity, components in the second substrate 402 are similar with that shown in FIG. 4 and are not described in detail here. Other components in the electronic device 400 that are components used in conventional solar cell devices are not described here in detail.
FIG. 10 is a schematic cross sectional view showing an electronic device 500 according to yet another embodiment of the invention, using the anti-reflection structure shown in FIG. 4 .
As shown in FIG. 10 , the electronic device 500 can be used in applications such as touch-sensing modules and comprises a first substrate 502 , a second substrate 506 , and a touch-sensing layer 504 disposed between the first substrate 502 and the second substrate 506 . In this embodiment, the second substrate 506 can be a transparent substrate contacting the surroundings and may thus have the anti-reflection structure shown in FIG. 4 , such that the electronic device 500 having the anti-reflection structure shown in FIG. 4 may have the properties of a low reflection rate, anti-smudge and self-clean as that of the anti-reflection structure shown in FIG. 4 , and have a mechanical property greater than the conventional anti-reflection structure made of a transparent substrate and an anti-reflection coating of different materials formed thereon. Herein, due to the purpose of simplicity, components in the second substrate 506 are similar with that shown in FIG. 4 and are not described in detail here.
The anti-reflection structure used in the electronic devices 200 , 300 , 400 , and 500 shown in FIGS. 7-10 , respectively, is not limited to that shown in FIG. 4 . In other embodiments, the anti-reflection structure shown in FIGS. 5-6 can be also used in the electronic devices 200 , 300 , 400 , and 500 shown in FIGS. 7-10 .
While the invention has been described by way of example and in terms of the preferred embodiments, it is to be understood that the invention is not limited to the disclosed embodiments. On the contrary, it is intended to cover various modifications and similar arrangements (as would be apparent to those skilled in the art). Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements.
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An anti-reflection structure includes a substrate including a planar portion, a protrusion portion disposed over the planar portion, and a coating layer, wherein the protrusion portion is integrated with the planar portion, and the coating layer conformably covers the planar portion and the protrusion portion.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This invention is directed to a fan coil unit for commercial and residential air conditioners which can utilize a primary pan or convector tray of the type disclosed in U.S. Pat. No. 4,856,672 granted on Aug. 15, 1989 entitled CONDENSATION PAN/CONVECTOR TRAY FOR FAN COIL UNIT; U.S. Pat. No. 4,986,087 granted on Jan. 22, 1991 entitled FAN COIL UNIT; and Application Serial No. 07/642,767 filed Jan. 18, 1991 entitled A FAN COIL UNIT, now pending, all in the name of John T. Sullivan
BACKGROUND OF THE INVENTION
Residential and commercial air conditioners include as a part thereof a fan coil unit located within a housing which includes a coil through which refrigerant (liquid or gas, such as Freon) is pumped. The coil is normally supported above a condensation pan, convector tray or primary pan having one or more openings through which air is blown by one or more fans powered by motors which are supported below and from the primary pan. The air passing through the coil creates condensation on the coil which drips down, upon and into the primary pan and is then conducted by an appropriate outlet through a discharge pipe into a secondary pan and/or an associated drain.
Such conventional primary pans are generally made from galvanized metal and rust with relative ease. The fasteners (nuts and bolts and/or rivets) which connect the fan and/or fan housings to the primary pan are also generally made from metal and rust with equal relative ease. Once the primary pan and/or the fasteners rust, the condensation/water normally accumulating therein and draining properly therefrom, cannot do so. Instead the condensation/condensate can, for example, drip through the rusted galvanized primary pan and/or the fasteners into the underlying motor(s) which drives the fan(s) thereby causing the motor to short-out. The fan motor itself is normally supported by a metallic bracket and excessive rusting of the primary pans/metal fasteners will cause the fan support brackets to rust. Excessive rusting coupled with the centrifugal force of the fan motor would cause wobble, undesirable increased noise, and could eventually result in the brackets breaking or sufficiently loosening such that the motors and pans simply fall from the primary pan.
Excessive rust also blocks or reduces normal drainage which results in condensate accumulating in the primary pan to such an extent that the same overflows and causes damage. For example, conventional fan coil units are normally mounted on floors or in ceilings in hotels, motels and the like. Obviously, if a primary pan outlet becomes blocked and the condensate overflows, it will damage the ceiling and/or walls or the underlying floor and associated rugs. Accordingly, concern is not simply limited to fan coil unit damage, but extends to structural damage of the commercial or residential structure.
U.S. Pat. No. 4,856,672 and U.S. Pat. No. 4,986,087 each disclose structure which reduces rust and fungus growth associated with conventional galvanized metal primary pans and their associated sponge rubber seals o rubber gaskets which deteriorate and virtually break-down into "dust" or similar extremely small particles which block or reduce the drainage of condensate from the pans and also results in fungus growth which in turn causes undesirable odors. The latter patents overcome these disadvantages by constructing the primary pans from synthetic polymeric material and utilizing a baffle to close a gap between the bottom of the condensation coil and the primary pan. Since the air which normally passes through this gap can now not pass therethrough due to the baffle, the efficiency of the overall unit is appreciably increases and the absence of metal, sponge rubber seals and rubber gaskets prevents deterioration which in turn reduces/eliminates the aforementioned damage.
The latter patents also avoid the fungus/odor problem by admixing biocides or preservative additives with the polymeric material from which the primary pans are formed. The latter reduces mildew, odors, etc.
SUMMARY OF THE INVENTION
The present invention is directed to additional novel and innovative structural aspects of a fan coil unit by not only providing a primary pan constructed from in situ molded polymeric/copolymeric material, but also providing in association therewith a novel bellows in the form of a plate which is slidable relative to the primary pan. A bottom or lower portion of the coil rests upon the plate or bellows and the plate is also urged in a direction away from the primary pan to essentially clamp the coil between the plate or bellows and an associated portion of the fan coil unit housing. Preferably the plate is urged away from a bottom wall of the primary pan by utilizing a strip of resilient foam polymeric/copolymeric material which is sandwiched between the plate and the bottom wall of the primary pan within a telescopic coupling therebetween. The telescopic coupling between a pair of upward projecting ribs of the primary pan bottom wall and a downwardly directed projection of the plate readily accommodates and locates the coil relative to the housing.
In further accordance with the invention the plate upon which the coil rests is also provided with one or more channels in which condensate can collect due to the temperature differential between an upper surface of the plate upon which the coil rests and a lower surface thereof. This condensate can then flow from the condensation channels through either or both opposite ends thereof into the primary pan and from the latter is then conducted to an appropriate drain.
With the above and other objects in view that will hereinafter appear, the nature of the invention will be more clearly understood by reference to the following detailed description, the appended claims and the several views illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a fan coil unit constructed in accordance with this invention with a front wall thereof broken away for clarity, and illustrates a housing defining a chamber, a primary pan in the chamber, a coil above the primary pan, and a motor and fan/fan housing unit below and secured to the primary pan.
FIG. 2 is an enlarged cross-sectional view taken generally along line 2--2 of FIG. 1, and illustrates details of the primary pan and a slidably mounted baffle disposed between the coil and the primary pan.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A novel fan coil unit of the present invention is illustrated in FIG. 1 of the drawings, and is generally designated by the reference numeral 10.
The fan coil unit 10 includes a housing 11, a condensation/ evaporation coil 12, a primary pan, condensation pan or convector tray 13, a fan housing 14, a fan motor 15 and a fan motor mounting bracket (not shown) securing the fan motor 15 to the primary pan 13.
The housing 11 defines a chamber (unnumbered) which is divided into a first or upper chamber portion 17 (FIG. 2) and a second or lower chamber portion 18 by the primary pan 13.
A conventional filter 20 spans an opening (unnumbered) formed in a bottom wall (not shown) of the housing 11 while a top wall 21 includes a plurality of grates or openings 23. When the fan motor 15 is energized, air is drawn from the exterior through the bottom wall (not shown), the filter 20 into and through the fan housing 14 through axial openings 19 (FIG. 1) thereof and through an opening 24 (FIG. 2) of the primary pan defined by an upstanding generally polygonal wall 25 which telescopically receives therein a like polygonally contoured outlet throat 26 of the fan housing 14. The air exits the throat 26 of the fan housing 14, enters the chamber 17 beneath the coil 12, and passes through the coil 12 in the manner indicated by the unumbered headed arrows associated therewith. As air passes through the condensation/evaporator coil 12, moisture condenses from the air forming condensate C which drips into the primary pan 13 from which it exits through a discharge port 27 projecting from a bottom wall 28 of the primary pan 13 at either or both of the opposite ends thereof adjacent side walls 33, 34 (FIG. 1) of the housing 11. A hose 35 (FIG. 1) passes through an opening (unnumbered) of the wall 34 and discharges into a secondary tray 36 which is connected to a drain by another pipe or conduit 37.
The primary pan 13 includes a peripheral wall defined by opposite upstanding side walls 41, 42, the latter of which has a downturned flange 43 upon which is slidingly retained a metallic reinforcing member 44 which extends the length of the flange 43 between opposite end walls 45, 46 (FIGS. 2 and 2, respectively) of the pan 13. The metallic reinforcing member 44 prevent the primary pan 13 from deflecting longitudinally. Apertures 47 (FIG. 2) are provided in the end walls 45, 46 through which fasteners pass for securing the primary pan 13 to the walls 33, 34. An upper edge portion (unnumbered) of the side wall 41 is also suitably secured to frame members (not shown) of the housing 11, as more fully disclosed in the latter-identified patents and application, for additionally retaining the various components within the housing 11. The bottom wall 28 of the pan 13 further includes bottom wall portions 38, 39 which define a generally obtuse angle therebetween and with the intersection thereof define a low point of the primary pan 13 in its installed position (FIG. 2). The discharge port or spout 27 is, of course, located at the low point or the point of merger between the wall portions 38, 39 to facilitate complete drainage or condensation C from the primary pan 13.
Bridging means, generally designated by the reference numeral 50, close a gap (unnumbered) generally formed between the bottom or bottom portion of the coil 12 and the bottom wall 28 of the primary pan 13. The bridging means 50 is a relatively slidable connection defined by a plate or plate member 51 and a pair of generally parallel upstanding ribs 52, 53 projecting upwardly from the bottom wall portion 39 of the bottom wall 28. The plate member 51 spans the entire distance between the end walls 45, 46, as do the ribs 52, 53.
The plate member 51 is formed from synthetic polymeric/copolymeric plastic material which is vacuum-molded or extrusion-molded in a conventional manner. The hot polymeric/copolymeric plastic material is, however, admixed with preservatives which function to protect the polymeric material from attack by microorganisms. The microbiological attach of the polymer can lead to the loss of aesthetic appearance, mildew, odors, embrittlement and permanent product failure. Of several different preservative additives or biocides which are admixed with the polymeric material prior to the vacuum or extrusion molding thereof into the primary tray 13, the preferred biocides are 2-nm-octyl-r-isothiazolin-3-one and 10,10' bisphenoxarsine. As the condensation C droplets form and drop upon the plate member 51, the biocide therein will be leached or absorbed from the polymeric material and prevent the disadvantages heretofore noted, particularly fungus growth, mildew, odor, virus and bacteria formation.
The plate member 51 includes a base 54, an upstanding leg 55 and a downwardly directed projection 56. The upstanding leg 55 and the downwardly directed projection 56 include means 57 in the form elongated channels which extend generally the length of the plate member 51. When the fan coil unit is operating in the air conditioning mode, condensate C forms in the manner heretofore described. In addition, the relatively cold bottom or lower end portion of the coil 12 is in contact with the upper surface of the plate member 51, whereas opposite surfaces are subject to ambient temperature, and this temperature differential would normally cause condensation to form on the warmer surface of the plate member 51 opposite the surface contacted by the coil 12. However, because of the channels 57, some of the condensate formed on the lower surface of the plate member 54 will actually be formed within the channels 57 and will flow axially outwardly therefrom, and discharge immediately the discharge port or spout 27. Thus, this condensate will not collect upon the bottom wall 28 but will be immediately discharged, thus reducing the overall amount of condensate which might be collected by the primary pan 13 and accordingly reducing the adverse effects thereof.
Obviously, should the plate member 51 become worn or broken, it can be readily replaced simply by substituting another like plate member 51 therefor. Furthermore, over a considerable length of time the biocide within the plate member 51 can be bleached therefrom which, of course, offers two possible scenarios. The first is that biocide tablets or powder can simply be placed upon the bottom wall 28 of the primary pan 13, but more effective would be simply replacing the plate member 51 and substituting a new biocide-ladened plate member 51 therefor.
The plate member 51 also effectively closes the gap (unnumbered) between the bottom of the coil 12 and the bottom wall 28 of the primary pan 13 under a variety of misalignment or missizing situations. For example, if the coil 12 had to be replaced and another coil close to but not the identical size was used as a replacement, the plate member 51 could move inwardly or outwardly relative to and between the ribs. However, if the coil 12 were shorter (vertically) than that illustrated, the plate member 51 would have to be urged upwardly, and means generally designated by the reference numeral 60 in the form of a resilient strip of foam polymeric/copolymeric material is sandwiched between the projection 56 of the plate member 51 and the wall portion 39 of the bottom wall 28 between the ribs 52, 53 of the latter. The strip of compressible foam material 60 is preferably fully compressed when installed and, therefore, continuously biases the plate member 51 in an upward direction, as viewed in FIG. 2. Thus, should a shorter coil 12 replace the illustrated coil, minor variations in size can be accommodated by the plate member 51 being urged or slid upwardly by the inherent expanding nature of the resilient foam polymeric material 60. Thus, in this fashion, the plate member 51 will be continuously biased or urged into intimate contact with the coil 12 to thereby maintain the gap (unnumbered) heretofore defined between the bottom of the coil 12 and the bottom wall 28 of the primary pan 13 closed and to assure that an upper end of the coil 12 is maintained in intimate contact with an associated supporting surface (not shown) of the fan coil unit housing 11.
Although a preferred embodiment of the invention has been specifically illustrated and described herein, it is to be understood that minor variations may be made in the apparatus without departing from the spirit and scope of the invention, as defined the appended claims.
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A fan coil unit includes a primary pan having an opening through which air is directed by a fan within a fan housing suspended from the primary pan, the condensation coil is positioned above the primary pan through which the air passes causing condensation to collect upon and fall from the condensation coil into the primary pan and from the latter to a drain. A gap between a lower edge of the coil and the primary pan is bridged by a slidable connection which includes a plate and a resilient member to at all times urge the plate in a direction toward the coil.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/740,243 filed Nov. 29, 2005.
FIELD OF THE INVENTION
[0002] The invention relates to a clamping system for securing a sheet of automotive glass over existing window opening in a vehicle door.
BACKGROUND OF THE INVENTION
[0003] Emergency Response Teams (ERT) are trained in numerous rescue and/or take-down manoeuvres wherein the ERT officers are required to remove and/or stun the occupants of an automobile or vehicle. These manoeuvres often require breaking the automobile side windows in order to gain access-to the occupants. Therefore, during training exercises a vehicle can be used a maximum of four times (for standard four-door vehicles) to recreate the exercise. Once the windows have been destroyed, the officers participating in the training can no longer practice destroying the window as they approach the vehicle. At this point, the training becomes unrealistic and less effective since the officers are unable to complete the exercise. Therefore, once all the windows in the vehicle have been destroyed, the vehicle essentially becomes obsolete since it can no longer serve as an effective training unit. Accordingly, during the course of training, multiple vehicles are required in order to stage appropriate drills. Furthermore, once all of the existing windows have been destroyed, the vehicle can no longer be used for any other outdoor training exercises in poor weather conditions since the interior of the vehicle cannot be protected from the elements as there are no windows left to roll-up. Therefore, once the windows have been destroyed, the vehicle becomes unsuitable for training purposes rendering the training process costly wasteful and inefficient.
[0004] In view of the foregoing, it is desirable to develop a technology that enables ERT officers to be able to repeatedly practice vehicle take-downs that involve the breaking of vehicle windows, without destroying the original windows on the vehicle rendering the vehicle obsolete.
[0005] U.S. Pat. No. 5,820,119 to Chacon, Sr. discloses a window retaining apparatus used to hold the rear window of a truck in place in the window frame while the urethane seal therebetween is curing. The apparatus disclosed comprises a telescoping body portion made up of inner and outer tubular sections so that the unit can be adjusted to suit various sizes of windows. Suction cups are used to engage the glass window panel, while tie-down clamps, located at opposite ends of the unit are used to engage the window frame. In use, the apparatus allows for the glass window panel to be held in place and to be pressed against the window frame while the urethane seal therebetween cures. The apparatus is advantageous in that the glass window panel no longer needs to be held in place manually during the curing process.
[0006] While Chacon, Sr. discloses a type of clamping unit that is adjustable to suit different sized windows and employs suction cups and hook-type fasteners to secure the clamping unit to the automobile when in use, the unit is not suitable or easily adaptable for use as a training unit. The clamping unit disclosed by Chacon, Sr. holds the window panel in the actual opening of the doorframe; therefore the original window panel would have to be removed and the vehicle would not remain in a usable condition. Accordingly, the unit disclosed by Chacon Sr. does not meet the needs that are addressed by the present invention.
SUMMARY OF THE INVENTION
[0007] The present invention provides a clamping system for securing a sheet of automotive glass over an existing window opening in a vehicle door. The system provides first and second clamping units adapted for securely supporting the sheet of automotive glass therebetween. First means associated with the first clamping unit supports the first clamping unit from a frame of a vehicle door and second means associated with the second clamping unit supports the second clamping unit on an outside panel of the door. Each clamping unit includes inner and outer clamping bars which adjustably hold the sheet of automotive glass therebetween, the first clamping unit being adapted to hold an upper portion of the sheet adjacent an upper edge thereof and the second clamping unit being adapted to hold a lower portion of the sheet adjacent a lower edge thereof. Once the sheet of automotive glass has been broken as part of a training exercise the broken remnants of the sheet are removed from the clamping units and replaced with a new sheet of glass so that training can continue.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The present invention will be better understood with reference to the detailed description taken in combination with the drawings in which:
[0009] FIG. 1 is a perspective view of a vehicle showing the clamping system of the present invention in use thereon;
[0010] FIG. 2 is a perspective view of the upper clamping unit of the clamping system according to a preferred embodiment;
[0011] FIG. 3 is a perspective view of the lower clamping unit of the clamping system according to a preferred embodiment.
[0012] FIG. 4 is a cross-sectional view illustrating the manner in which the upper clamping unit is suspended on a vehicle door frame; and
[0013] FIG. 5 is a view similar to FIG. 3 showing an alternate means for securing the suction cups to the lower clamping unit.
DETAILED DESCRIPTION OF THE INVENTION
[0014] Referring to the drawings, there is shown in FIG. 1 the clamping system 10 according to a preferred embodiment of the invention in use on a vehicle 1 . The clamping system 10 comprises an upper clamping unit 12 adapted to engage the upper portion of the doorframe 2 of the vehicle 1 , and a lower clamping unit 14 adapted to be secured to the outer surface of the door 3 of the vehicle 1 below the lower portion of the window opening. The clamping system 10 serves to hold a sheet W of automotive window glass in place over where the original window is located in the vehicle door. Therefore, the glass sheet W can easily be replaced multiple times during training exercises without damaging the original vehicle windows.
[0015] The upper or first clamping unit 12 , as shown in FIG. 2 , comprises first (inner) and second (outer) clamping bars 12 a , 12 b which cooperate in order to engage an upper portion W! of the sheet W of automotive window glass. The first clamping bar 12 a comprises an elongated body 16 having an inner surface 18 and an outer surface 20 which is most proximal to the vehicle doorframe 2 when the clamping system 10 is in use. The second clamping bar 12 b also comprises an elongated body 22 having an inner surface 24 , which is opposite to the inner surface 18 of the first clamping bar 12 a . The outer surface 26 of the second clamping bar 12 b is located most distal to the vehicle doorframe 2 when the clamping system 10 is in use. Each of he inner surfaces 18 , 24 of the first and second clamping bars 12 a , 12 b is preferably equipped with a strip of cushioning material 27 along the length of the respective elongated bodies 16 , 22 so as to protect the glass window panel W when the upper clamping unit 12 is secured thereto. The cushioning material 27 prevents premature cracking of the glass window panel W from the hard surface of the bodies 16 , 22 of the first and second clamping bars 12 a , 12 b.
[0016] The upper clamping unit 12 includes an adjustable locking means 28 for bringing the first and second clamping bars 12 a , 12 b into engagement with the upper portion W 1 of the glass window panel W adjacent the upper edge thereof. Preferably, the locking means 28 comprises an elongated threaded member (or bolt) 30 which is inserted into corresponding annular receiving brackets or bosses 32 , 33 each of which is mounted on the respective upper surface 34 , 35 of the first and second clamping bars 12 a , 12 b . The receiving boss 32 located on the first clamping bar 12 a is threaded internally for receiving and engaging with the threads on the elongated threaded member 30 . The receiving boss 33 located on the second clamping bar 12 b does not require internal threading as the elongated threaded member 30 is intended to rotate freely within the receiving boss 33 . Once the elongated threaded member 30 engages with the threads on the inside surface of the receiving boss 32 , rotation of the elongated threaded member 30 draws the first and second clamping bars 12 a , 12 b towards each other and eventually into contact with the glass window panel W.
[0017] In order to prevent the first and second clamping bars 12 a , 12 b from twisting with respect to each other as the threaded member 30 is screwed into the receiving boss 32 , aligning means 36 are provided which serve to both align and stabilize the clamping bars 12 a , 12 b with respect to each other. The aligning means 36 are located on either side of the locking means 28 and are disposed towards the ends of the clamping bars 12 a , 12 b . The aligning means 36 preferably comprise corresponding first and second bracket elements or annular bosses 38 , 39 positioned on the respective upper surfaces 34 , 35 of the first and second clamping bars 12 a , 12 b . An aperture 40 , 41 extends through each of the first and second bosses 38 , 39 , the aperture 40 , 41 being sized to receive an aligning rod 42 . The aligning rod 42 is inserted through the apertures 40 , 41 in the first and second bosses 38 , 39 , thereby ensuring that the first and second clamping bars 12 a , 12 b remain in a substantially parallel relationship when in use. The aligning rod 42 can be formed from any suitable means such as a wooden dowel, or a metal or plastic rod.
[0018] The upper clamping unit 12 is preferably affixed to the door frame by means of tether straps 44 positioned on either side of the centrally located locking means 28 . The straps 44 are attached at a first end 45 to the first clamping bar 12 a between the adjustable locking means and aligning means by means of screws that are hidden behind the strip of cushioning material 27 . As shown in FIG. 4 , the second end 46 of said straps wrap or loop around the upper portion of the doorframe D, and are secured in place by means of snaps 47 or any other suitable means thereby attaching the upper clamping unit 12 to the vehicle. The straps 44 can be made of nylon or any other suitable materials, and are of a standard width. The straps 44 also have sufficient length to allow for vertical adjustment by means of a plastic clip system (not shown), similar to the straps found on conventional backpacks. In use, the snaps 47 (or other locking means) at the second end 46 of the straps 44 are opened and the second end 46 is looped around the upper portion of the doorframe. The second end 46 is then snapped shut and the length of the straps 44 is adjusted using the plastic clips. The glass window panels that are used in conjunction with the clamping system 10 are not very heavy; therefore additional reinforcing means are not required. The maximum weight that has been used for the glass window panel has been about 5 lbs.
[0019] The lower clamping unit 14 , shown in FIG. 3 , is similar in structure to the upper clamping unit 12 in that it too comprises first (inner) and second (outer) clamping bars 14 a , 14 b . Each of the first and second clamping bars 14 a , 14 b comprises an elongated body 48 , 50 , and is adapted to cooperate in order to engage a lower portion W 2 of the automobile glass window panel W adjacent a lower edge thereof. Similar to the upper clamping unit 12 , the elongated body 48 of the first clamping bar 14 a of the lower clamping unit 14 has an inner surface 52 adapted for receiving the lower portion W 2 of the window panel W, and an outer surface 54 which is most proximal to the vehicle door 3 when the clamping system 10 is in use. The elongated body 50 of the second clamping bar 14 b of the lower clamping unit 14 also has an inner surface 56 , which corresponds to the inner surface 52 of the first clamping bar 14 a for receiving the lower portion of the window panel. The outer surface 58 of the second clamping bar 14 b is located most distal to the vehicle door 3 when the clamping system 10 is in use.
[0020] As with the upper clamping unit 12 , the lower clamping unit 14 also includes adjustable locking means 60 comprising a pair of annular receiving brackets or bosses 62 , 63 , and an elongated threaded member 64 (or bolt). The receiving bosses 62 , 63 , however, are instead mounted on the bottom surface 65 , 66 of each of the first and second clamping bars 14 a , 14 b . The receiving boss 62 that is mounted on the first clamping bar 14 a is threaded internally for engaging with the threads on the elongated threaded member 64 as it is inserted into the receiving bosses 62 , 63 . Once the elongated threaded member 64 engages with the threads on the inside surface of the receiving boss 62 , rotation of the elongated threaded member 64 draws the first and second clamping bars 14 a , 14 b towards each other and eventually into contact with the glass window panel W. The lower clamping unit 14 also include aligning means 67 identical to the aligning means 36 provided on the upper clamping unit 12 . Accordingly, the aligning means 67 comprises corresponding first and second bracket elements or bosses 68 , 70 positioned on the bottom surfaces 65 , 66 of the clamping bars 14 a , 14 b . An aperture 72 , 73 extends through each of the first and second bracket elements 68 , 70 , the apertures 72 , 73 being sized to receive an aligning rod 74 . The aligning rod 74 is inserted through the apertures 72 , 73 in the first and second bracket elements 68 , 70 , thereby ensuring that the first and second clamping bars 14 a , 14 b remain in a substantially parallel relationship when the lower clamping unit 14 is in use.
[0021] The lower clamping unit 14 differs from the upper claming unit 12 in that it is preferably secured to the door of the vehicle by means of suction cups 76 . The suction cups 76 are positioned on either side of the centrally located locking means 60 equidistant from locking means 60 and the aligning means 67 . The suction cups 76 are attached to the outer surface 54 of the first clamping bar 14 a with a hinge mechanism (not visible in FIG. 3 ) so that the suction cups 76 can be angled to ensure a proper seal with the surface of the vehicle door 3 . The size of the automobile glass window panel W used will determine the exact position of the lower clamping unit 14 on the surface of the door; therefore the hinge mechanism is desirable in order to ensure that the suction cups 76 can be adjusted to accommodate variations in door panel structures.
[0022] According to another embodiment of the invention, as seen in FIG. 5 , the lower clamping unit 14 is designed so that the suction cups 76 are secured to the bottom surface 65 of the first clamping bar 14 a . In this embodiment, the suction cups 76 each include a mounting bracket 78 that incorporates the hinge mechanism 80 . A screw is used to secure the mounting bracket 78 to the bottom surface 65 of the first clamping bar 14 a.
[0023] As mentioned above, the glass window panel W used with the clamping system 10 is not very heavy. Nevertheless, it is preferable to design the lower clamping unit 14 to be able to carry additional weight to ensure that the clamping system 10 is secure. Accordingly, the suction cups 76 used on the lower clamping unit 14 are adapted to be able to support a load of up to 25 lbs, even although the glass window panel does not usually exceed 5 lbs.
[0024] When the clamping system 10 is in use, the automobile glass window panel W is first secured in the upper and lower clamping units 12 , 14 . The clamped window panel is then lifted towards the vehicle door where the original window has been rolled downwards into its retracted position, exposing the vehicle interior via the window opening. With the door 3 of the vehicle in the open position, the straps 44 are then affixed to the upper portion D of the doorframe 2 thereby positioning the upper clamping unit 12 and the glass window panel W in place over the original window opening in the door. The lower clamping unit 14 is then secured to the outer surface of the vehicle door panel by applying pressure to the suction cups 76 which then adhere to the door panel surface. Once the clamping system 10 and the glass window panel W are in place over the original window opening in the vehicle door, the training exercise can begin and the glass window panel can be broken without damaging the original window. Once the training exercise is complete, a new automobile glass window panel can be inserted into the clamping system 10 and the training exercise can be repeated. Once training has been completed, the vehicle remains completely usable as the clamping system 10 can easily be removed from the vehicle 1 and the original windows can be raised or rolled-up into their closed position.
[0025] While the present invention has been described with respect to certain preferred embodiments, it will be understood by persons skilled in the art that variations or modifications can be made without departing from the scope of the invention as described herein.
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A clamping system for securing a sheet of automotive glass exterior to a window opening in a vehicle door includes first and second clamping units adapted for, respectively, securely supporting therebetween the sheet of automotive glass. The first clamping unit is supporting from a frame of the vehicle door and the second clamping unit is supported on an outside panel of the door. Each of the clamping units includes inner and outer clamping bars adjustably holding the sheet of automotive glass therebetween, the first clamping unit being adapted to hold the sheet adjacent an upper edge thereof and the second clamping unit being adapted to hold the sheet adjacent a lower edge thereof. The system is used in training exercises for emergency measures personnel who need to be able to break automotive glass to gain entrance to a vehicle.
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The present application claims benefit of priority from U.S. Provisional Patent Application Ser. No. 60/466,929 filed Apr. 30, 2003.
BACKGROUND
Storm Water Management
The most effective, and possibly the only device for simply reducing or controlling storm water peak flow, is the storage basin—commonly known as a retention or detention basin. The term detention basin has come to be distinguished from a retention basin in that the latter is a storage device that has a normal pool of water such as a lake, pond or reservoir, while the detention basin is considered dedicated to its task and is normally empty. Both of these operate by the natural accumulation of storm water when a restriction, such as a weir or orifice, is placed on the flow.
These storage basins are typically used to mitigate storm water increases due to land development and are very effective when designed properly. For example, in a small watershed of 5 acres, for a shopping center that converts an existing wooded site to a land use consisting of pavement, the peak storm water flows can rise from 10 cfs to 20 cfs rather easily. In larger watersheds, proportional increases such as these could cause serious flooding and environmental damage.
The key criterion in storm water management is the limitation of after-development peak flows to rates equal to or less than the peak flows prior to development. In the example above, the developer of the shopping center would need to provide a storage basin to limit the after-development peak flows to 10 cfs. The developer may then need to provide substantial water quality treatment storage. Of course, the storage basin would occupy a significant portion of the site, typically ranging from five (5) to fifteen (15) percent or more of the development land area.
Many state and local municipalities normally require either control of storm water through written codes or insist on peak flow controls during the approval process. Whether or not storm water control is required, it is usually prudent to control storm water flows that are destined for off-site areas, merely to reduce the liability for damages in case of downstream flooding.
Storm Water Treatment
The treatment of storm water to improve water quality has gained considerable interest. Federal and state regulations now require storm water treatment for large sites and new Federal NPDES rules will require treatment from small sites. Further, some local municipal codes or environmental concerns mandate some form of storm water treatment for all sites.
A key criterion of storm water treatment is the capture of the first one-half (½) inch of runoff from newly disturbed areas within the watershed. The great majority of pollutants from runoff are contained in the first-flush. To treat the first-flush, the flows must be conveyed to specially designed water quality treatment basins where a variety of treatment processes take place, culminating with infiltration to the soil and/or evaporation. The water quality basins are designed particularly to capture only the first-flush of runoff, and to avoid the later segments of the runoff that would mix with and wash out the captured flow.
Our firm developed a simple design for a first-flush control device in 1990 that we have been using since on various engineering projects. Essentially, the control works on a hydraulic balancing principle—diverting the low flows to a water quality basin and then directing flows back to the drainage system when the water quality basin is full. The water quality basin is designed to store water for just a few days since an empty basin is necessary at the time of rainfall to fulfill the goal of water quality treatment.
Storm Water Storage Basin Theory
The method of computation used to design storm water storage systems is the straightforward and familiar application of conservation of mass principles—the volume flowing out is equal to the volume flowing into a system. This is known as the reservoir routing method, and a wide range of information is available on the subject in engineering and hydrology texts. A brief summation of the method is given here, as follows:
It is assumed for the numerical solution, that we are given the flow “Q” at every time interval “t”, being the series, Qin(t).
Given: Vol(out)=Vol(in):
If a volume is allowed to accumulate (S), the modified mass equation accounts for this as follows:
Vol(out)=Vol(in)− S
In a time interval t:
Vol(out)/Δt = Vol(in)/Δt − ΔS/Δt
Since:
Vol(out)/Δt = Qout(t)
And, since:
Vol(in)/Δt = Qin(t) and
ΔS = S(t)
Substituting
Qout(t) = Qin(t) − ΔS/Δt
Rearranging:
S(t) = (Qin(t) − Qout(t)) × Δt
(Eq. 1)
As described in words, the change in volume of storage within any time interval is equal to the rate of inflow in minus the rate of outflow, multiplied by the interval of time.
The outflow of a storage basin can be modeled by a non-linear hydraulic function, “g” relating head, or height (stage) “H” in the basin, and various physical characteristics of the control device; e.g., length of a weir or diameter of a pipe, referred to as the set “n”, and generally a constant “C”.
For example:
Qout = C × g(n, H)
(Eq. 2)
If the outflow of a storm water storage basin is restricted by a weir, the outflow function is as follows:
Q=C×L×H^ 3/2 or Q out( t )= C×L×H ( t )^3/2
Where:
C is a factor (3.337)
H is the flood stage in the basin in
L is the weir length (ft)
feet and H(t) is the height at any time
Further, there is a natural geometric relationship, or function “f” between height “H” and the volume “S” in the storage basin. This is often a tabular relationship between contour elevation and surface area that can readily be interpolated for storage volume at any height.
For example:
H = f(S) or H(t) = f(S(t))
(Eq. 3)
Equations 1, 2 and 3, above fully define the mathematics of the storage process that occurs in a detention or retention basin. The equations are easily solved by iterative techniques. The mathematical method is generally referred to by the generic term, reservoir routing, and it describes a relationship between inflow and outflow that can be seen graphically in FIG. 1 .
It is important to note that the area between the inflow and outflow hydrograph is the exact equivalent of the storage volume reached in the storm water basin. Further, in the descending phase of the inflow, the area representing the outflow volume leaving the storage system is the 1 same as the inflow volume, unless some volume is captured within the system.
It is therefore an object of the invention to provide a system for reducing environmental impact of storm water flows, comprising a feed conduit, receiving storm water runoff; a bypass conduit; a detention basin; for reducing a net peak flow of storm water run off; a treatment basin, for removing pollutants from the storm water runoff; and a control system, receiving storm water runoff flow from the feed conduit, and splitting the flow between at least the detention basin, the treatment basin, and the bypass conduit, wherein a flow to the treatment basin is sensitive to a water level therein, a managed quantity of water flowing to the treatment basin until filled, and a remainder of the flow is split in a flow rate sensitive proportion to the bypass conduit and detention basin.
This system may operate in an environmental region, having a natural hydrograph, a development, situated within the environmental region, having a development hydrograph characterized by a higher and earlier peak flow than the natural hydrograph, wherein the system for reducing environmental impact of storm water flows delays the time of peak flow and reduces the level of peak flow of the development hydrograph, resulting in a mitigated hydrograph corresponding to the natural hydrograph.
It is also an object of the present invention to provide an environmental system, subject to storm water flows, comprising an environmental region, having a natural hydrograph, a development, situated within the environmental region, having a development hydrograph characterized by a higher and earlier peak flow than the natural hydrograph, a storm water runoff mitigation system, receiving storm water runoff from the development according to the development hydrograph, having a mitigated hydrograph, comprising:
(1) a bypass conduit,
(2) a detention basin, for reducing a net peak flow of storm water runoff;
(3) a treatment basin, for removing pollutants from the storm water runoff; and
(4) a control system, receiving storm water runoff flow, and splitting the flow between at least the detention basin, the treatment basin, and the bypass conduit, wherein a flow to the treatment basin is sensitive to a water level therein, a managed quantity of water flowing to the treatment basin until filled, and a remainder of the flow is split in a flow rate sensitive proportion to the bypass conduit and detention basin,
wherein the mitigated hydrograph has a peak flow rate at or below the natural hydrograph.
It is a further object of the invention to provide a method for reducing environmental impact of storm water flows, comprising receiving storm water runoff flow, and splitting the flow between at least a detention basin, a treatment basin, and a bypass conduit wherein a flow to the treatment basin is sensitive to a water level therein, a managed quantity of water flowing to the treatment basin until filled, and a remainder of the flow is split in a flow rate sensitive proportion to the bypass conduit and detention basin, the detention basin reducing a net peak flow of storm water runoff and the treatment basin removing pollutants from the storm water runoff.
The system may further comprise an outlet conduit, receiving flow from the detention basin and the bypass conduit. The control system may, for example, operate passively. A flow splitting may therefore occur passively. A partition of flows between the bypass conduit and the detention basin may be based on one or more of a respective pipe diameter, and a respective pipe height within a chamber. A partition of flows between the bypass conduit and the detention basin may be based on characteristics selected from the group consisting of one or more of a pipe diameter, a pipe height, orifice structure, and a weir structure. Under peak flow conditions, a water efflux rate from the bypass conduit and detention basin is preferably reduced by this system. A first flush runoff may be selectively shunted to the treatment basin. A treatment basin capacity may be established at level sufficient to hold a first flush volume plus an amount sufficient to minimize the aggregate volume of the detention basin and treatment basin, constrained by a predetermined peak flow efflux rate from an optimized combination of detention basin and bypass conduit characteristics; wherein the characteristic of the treatment basin, detention basin, and control system may be optimized through an iterative process. The control system is preferably optimized to reduce peak flows from the detention basin and bypass conduit according to the Army Corps of Engineers HEC-1 computer program. Preferably, the mitigated hydrograph models the natural hydrograph.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a relationship between inflow and outflow of a typical reservoir.
FIG. 2 shows the flow path of the reservoir represented in FIG. 1 .
FIG. 3 shows a theoretically efficient storage basin, in which outflow follows the inflow hydrograph.
FIG. 4 shows a flow schematic of simple extention basin operation.
FIG. 5A schematically shows a system in which a water quality feature is added to the flow path by simply permitting the first low flows, up to the volume of inflow equal to the first-flush.
FIG. 5B schematically shows an advanced layout which places an additional control structure on the low flow bypass of the system shown in FIG. 5A .
FIG. 6 shows hydrologic flows in such a detention basin.
FIGS. 7 and 8 shows respectively, the flow path, and flow rates, in a system which attempts to control peak flows and provide the required water quality storage volume, in which the water quality basin is fed by a diversion of the main watershed flow until the value of 5.33 acre-feet is reached, and thereafter, the remaining flow is detained in a conventional storage basin.
FIG. 9 shows the inflow and outflow routing of the simple extention basin when receiving 4 in. of rainfall.
FIG. 10 shows the results of the existing flows as compared to the final flows from an extention basin, when receiving 4 in. of rainfall.
FIG. 11 shows a comparison of a comparison of existing flows, proposed flows, and extension basin flows.
DESCRIPTION OF THE INVENTION
The hydrographs in FIG. 1 represent the flow in and out of a typical storage basin whose flow paths are represented by FIG. 2 .
To absolutely minimize the amount of storage volume needed, one must allow the outflow hydrograph to closely track the rise in the inflow hydrograph until a pre-determined flow is reached. In theory, the most efficient storage basin—one with the least storage for the same flow reduction, is one whose outflow follows this non-continuous route, as shown in FIG. 3 .
Such an outflow function is difficult to replicate using standard reservoir routing, though it can be provided by using mechanical intervention. For example, to restrict outflows to, say 100 cfs, an operator can be stationed at a valve in the system. The operator would know when to open the valve and divert flows away or towards the design point.
This mechanical system is not acceptable in practice for a variety of reasons, least of which is the reliance on mechanical means in perpetuity as well as the monitoring of rainfall and runoff rates. Clearly, a fully non-mechanical method of performing the same task is our goal.
The extention basin provides such an automatic function. It operates hydraulically and non-mechanically, by allowing the storm flow to bypass the storage basin during the ascending part of the storm then diverts flow into the storage basin only during the period of peak inflow. The extention basin provides flow reductions through external control structures and external piping, and extends the functionality of the storage basin by adding water quality treatment, hence the given name.
A flow schematic of a simple extention basin operation is shown in FIG. 4 .
A simple extention basin will control peak flows over a narrow range of storm frequencies. The following is a narrative of the operation and components of the simple extention basin.
1. Inflows are directed to the external control structure that is comprised of a low-level pipe outlet and a high level, diverting weir. The low flows bypass the storage basin in the bypass piping and are conveyed to a junction point. 2. At a calculated high-level flow, the diverting weir develops enough head to discharge to the storage basin. Generally, the diverting weir is long to allow a rapid flooding into the storage basin. 3. At mid-level to high-level flows, the storage basin takes the bulk of the main flow with some limited bypass continuing in the low flow piping. 4. The outflow of the storage basin, as controlled by the internal control structure, a weir, pipe or combinations, joins with the low flow bypass to produce a combined total outflow at the design point.
Operation of the Extention Basin with Storm Water Treatment
A water quality feature is added to the flow path by simply permitting the first low flows, up to the volume of inflow equal to the first-flush, to enter the water quality basin, as shown in FIG. 5A . When the desired level in the water quality basin is reached, further flow is inhibited due to the backwater effect from the developed head in the water quality basin. Hence, the operation is similar to the simple extention basin noted above, except additional storage is added for water quality treatment.
An advanced layout places an additional control structure on the low flow bypass, as illustrated in FIG. 5B .
Sample Computations for the Extention Basin
A numerical proof of the improved operation of the extention basin can be provided based on the earlier equations or by a simple inspection of the nature of the inflow and ideal outflow hydrograph. A practical proof is easily provided by modeling the extention basin using a variety of sample cases and computing the results using readily available software.
While there are a number of software products that can be used to model the flows through the extention basin system, we have used the Army Corps of Engineers HEC-1 program here. The HEC-1 software allows a number of the necessary and detailed hydraulic techniques.
For example, the development of separate hydrographs is needed for the low flow bypass and the inflow to the storage basin. HEC-1 can create these hydrographs using the diversion card (HEC-1 was written in FORTRAN and uses card style input). Further, in the plan with storm water treatment, the diversion cards can also be used to track the filling of the water quality basin and the subsequent re-diversion to the low flow bypass.
Of course, HEC-1 provides hydrograph creation based on watershed characteristics of curve number, lag time and area, as well as hydrograph summation and basic graphing functions.
Since the design of the extention basin is most practical by trial and error or iteration, we have developed a new Windows™ interface to HEC-1 that greatly improves the program functionality and allows numerous trial runs to fine-tune the proposed hydraulic system design. It is necessary to adjust the diversion ratios; internal control structure dimensions and storage basin until the desired final design flows are met.
Description of the Sample Cases
To test our theory that the extention basin requires minimal storage while providing the required capture of the first-flush runoff, we have created a sample watershed system that undergoes development.
We assume the watershed is mildly developed in the present state with a composite SCS runoff curve number of 70.75.
We further assume that a large, new development site of about 0.20 square mile (125 acres) is contemplated, which would convert a portion of the wooded land use to essentially, all impervious areas, resulting in a new, composite curve number of 73.75.
The breakdown of existing and proposed land uses that comprise the SCS curve number is shown in Table A below:
TABLE A Computation of Composite SCS Curve Number Land Use Curve Number Area Product Existing Condition Woods 70 0.950 66.500 Industrial 85 0.050 4.250 Total 70.75 1.000 70.750 Proposed Condition Woods 70 0.750 52.500 Industrial 85 0.050 4.250 New Industrial 85 0.200 17.000 Total 73.75 1.000 73.750
First-Flush of Runoff:
Since the base criterion for storm water treatment is the capture of the first-flush of runoff from the newly disturbed area, the volume of capture is computed to be 5.33 acre feet from 0.200 square miles, (0.5″/12×0.200×640 ac/sm).
The first-flush flow does not directly re-enter the drainage system—it is infiltrated to the soil, evaporated, or slowly drained back to the drainage system over a period of days at rates well below design storm frequencies.
First-flush capture for storm water treatment is generally additive to any storage required by the peak flow control system. In other words, if 9 acre-feet are required for storm water management, one must add the additional 5.33 acre-feet regardless of the method of storm water storage. In a conventional storage system it is impossible to use the storage required for water quality to offset the storage required for peak flow control without greatly over sizing the system, because the first-flush volume accumulates well before the time of peak runoff. In some limited applications, it is possible to offset the storage required for peak flow reduction in very small storms, when runoff is near to one-half (½) inch.
We seek a solution where the storage required for water quality can be credited fully in the process of storm water management and peak flow reductions.
Watershed Lag:
For simplicity, we have assumed that the watershed lag is 1.0 hour. This is certainly in the order of magnitude of the watershed size of 1 square mile. In general, the analysis herein can be done with any assumed value of lag. To simplify comparisons, we further assume that the lag time remains the same in both the existing and proposed case, and is possible when the new development is not on the flow path where lag time might be measured. If a new situation develops where the lag changes in the proposed condition, adjustment to the model can be made easily.
Rainfall:
For simplicity, we have chosen 4.0 inches of rainfall as the design storm. This is a mid-range value since design storms range from 3.2 inches up to 7.2 inches, depending on the application. The analysis herein can be run with any design storm. To be consistent, the same rainfall is assumed in both the existing and proposed condition.
The rainfall distribution is assumed as the SCS 24 hour, with Type 3 rainfall distribution and Type 2 antecedent moisture conditions. We have provided the synthetic rainfall ordinates in the computer input card file based on values commonly in use in our local area.
Control Structures:
The control structures are necessary to either divert or retard flow. In the storage basin, they are composed of a low-level pipe or orifice, a mid-level spillway weir and a high level weir to control overtopping. All elevations used are relative, and it assumed the designer would use proper techniques to design individual components.
Diversion control structures are devices that split flows according to certain, desired proportions. This is accomplished with weirs or notches that direct flows to different directions.
Peak Flow Reduction:
Each sample case assumes that the watershed flow must be reduced to 278 cfs for the design storm. This is the peak flow of the watershed at existing conditions. To compare methods, the storage volume necessary to produce this reduction is compiled for each case.
The following sample watershed characteristics are used to determine the inflow hydrographs.
TABLE B
Sample Watershed Characteristics
Existing
Proposed
Item
Condition
Condition
Units
Watershed Area
1.0
1.0
square miles
Watershed Lag Time
1.0
1.0
hours
SCS Runoff Curve Number
70.75
73.75
(no units)
Rainfall
4.0
4.0
inches
Rainfall Hydrograph
SCS Type
SCS Type
0.1 hour inc.
3–24 hr.
3–24 hr.
Initial Abstraction
Computed
Computed
inches
Internally
Internally
Base Flow
0
0
cfs
Sample Case 1A—Existing Conditions
This case assumes a watershed without development. It is provided to illustrate actual conditions in a typical situation, with nominal values that may be encountered by design engineers.
Based on the sample input data, the following are the results of the computations:
TABLE 1-A Results of Sample Case 1A - Existing Conditions Peak Flow 278 c.f.s Time of Peak Flow 13.17 hours
Sample Case 1B—Proposed Conditions without Control in Storage Basins
In this case, we model the peak flows after development, where flows are left uncontrolled. The change in development is modeled by simply increasing the SCS runoff curve number of the undeveloped case, based on the addition of 125 acres of impervious area in the watershed. The remaining watershed characteristics are assumed to be unchanged by the development.
TABLE 2-A Results of Sample Case 1B - Proposed Conditions Peak Flow 328 cfs Time of Peak Flow 13.00 hours
Sample Case 2A—Control of Flows using the Conventional Detention Basin without Water Quality Storage
In this case, the after development flows are routed through a conventional detention basin system using reservoir routing techniques. The flows in such a conventional detention basin are shown in FIG. 6 . The characteristics of the detention basin are as follows:
TABLE 2-C
Storage Volume versus Elevation/Surface Area -
Conventional Detention Basin
Elevation
Surface Area
Volume
(feet)
(acres)
(acre-feet)
340
0
0.000
342
0.87
0.553
344
2.17
3.448
346
2.45
8.065
348
2.74
13.253
350
3.04
19.030
352
3.36
25.427
TABLE 2-D Results of Sample Case 2A Proposed Conditions/Conventional Detention Basin without Water Quality Storage Peak Inflow 328 cfs Peak Outflow 278 cfs Time of Peak Flow 13.50 hours Peak Height in Basin 349.43 feet Volume of Storage 17 acre-feet
Sample Case 2B—Control of Flows using the Conventional Detention Basin and Water Quality Storage
In this case, we attempt to control peak flows and provide the required water quality storage volume. The water quality basin is fed by a diversion of the main watershed flow until the value of 5.33 acre-feet is reached, thereafter, the remaining flow is detained in a conventional storage basin.
The flow path, and flow rates, respectively, of this case is illustrated in FIGS. 7 and 8 .
TABLE 2E Results of Sample Case 2B Proposed Conditions - Conventional Peak Flow Storage and Water Quality Storage Peak Inflow 328 cfs Peak Outflow 278 cfs Time of Peak Flow 13.50 Peak Height in Basin 348.85 Volume of Storage 16.0 acre-feet Volume of WQ Storage 5.33 acre-feet
Sample Case 3—Control of Flows using the Simple Extention Basin
In this case, the after development flows are routed through the simple extention basin system with a portion of the flow diverted to a water quality basin. The diversions are set according to the following relationships:
TABLE 3-A
Diversion Schedules for Case 3
Inflow (cfs)
0
10
20
50
80
100
180
300
Divert to Design Point (cfs)
0
10
20
40
55
65
120
230
Remaining Flow to Storage
0
0
0
10
25
35
60
70
Basin (cfs)
The volume characteristics of the storage basin are as follows:
TABLE 3-B
Storage Volume versus Surface Area/Elevation - Simple Extention Basin
Elevation
Surface Area
Volume
(feet)
(acres)
(acre-feet)
340
0
0.000
342
0.87
0.553
344
2.17
3.448
346
2.45
8.065
348
2.74
13.253
350
3.04
19.030
352
3.36
25.427
TABLE 3-B
Results of Sample Case 3 Proposed Conditions/Simple Extention Basin
Peak Inflow
328 cfs
Peak Flow
278 cfs
Time of Peak Flow
13.00
Peak Height in Basin
346.19
Volume of Storage
9.0 acre-feet
Volume of Water Quality Storage
5.33 acre-feet
The inflow and outflow routing of the simple extention basin (4 in. of rainfall) in this case is shown in FIG. 9 .
Discussion: Simple Extention Basin
In sample case 2A, we used a conventional detention basin computation that brought the peak flow from 328 cfs to 278 cfs and required 17 acre-feet of storage. In contrast, sample cases 3 and 4 provide clear proof that the simple extention basin can provide the same reduction in peak flows with about one-half the storage (9.0 acre-feet).
In a variation of Sample Case 2. Sample Case 2B adds 5.33 acre-feet of water quality storage to the required peak flow storage requirement of 16 acre-feet, totaling 21.33 acre-feet. This variation in Case 2 was provided here, to assess if simply adding first-flush storage alone is effective in reducing peak flows. The results indicate it was only slightly effective, reducing the net required storage by about 5 percent (22.33 to 21.33 ac-ft). For comparison purposes, the simple extention basin in Case 3 required only 9 acre-feet of storage plus the required 5.33 acre-feet, for 14.33 acre-feet, total.
This remarkable result is evident graphically (FIG. 9 )—the outflow hydrograph follows the rising limb of the inflow hydrograph and the need for storage is minimized accordingly.
However, the practical need of storm water management is to control flows over a range of storms, say, from the 2 year to the 100-year storm event. The simple extention basin would not be able to control flows much lower than its design because its inherent bypass system allows low flows out to the design point without control. It is, however, the most effective system to control a small, well-defined range of storm frequencies.
Given the need to capture the first flush, and remembering that the first-flush capture basin is really only effective in reducing peak flows when the main flows are small, we can integrate the storm water control and water quality control in our highly effective, extention basin. This is illustrated in Sample Case 4, below:
Sample Case 4—Control of Flows using the Extention Basin and Storm Water Treatment
In our final Sample Case 4, a water quality basin is added to the extention basin system and we attempt to control a wide range of storm frequencies. Flows are diverted to the water quality basin until the pre-computed first-flush volume of ½ inch of runoff over the newly developed portion of the watershed is reached.
A portion of the flow is conveyed to the water quality basin by imposing a new diversion control structure on the low flow bypass of the simple extention basin. The lowest flows are directed to the water quality basin, thereafter, when the basin is full, flows are naturally re-directed to the final design point by the principle of hydraulic balancing.
Our sample case requires that 5.33 acre-feet of first-flush runoff be stored in the water quality basin. This value is placed in field 2 of the DT input card file of our HEC-1 model.
Most importantly, this case examines a range of flows from 1.84 inches of rainfall, to 4.0 inches of rainfall. This is accomplished in HEC-1 by creating 6 plans as evidenced by the JR multiratio card. The ratios of each plan range from 0.46 to 1.00 and operate in HEC-1 by re-computing the entire model for each ratio times the design rainfall of 4.0 inches on the PB card.
For Case 4, we have assumed that the 100-year storm is 4.0 inches of rainfall in 24 hours, and have provided rainfalls for the 2, 5, 10, 25 and 50-year storms by the multiratio plans. In fact, 100-year storms are closer to 7 inches of rainfall in the northeast; however, we use the lower value to maintain consistency with our goal of using mid-range flows whenever possible in the sample cases. Any reasonable value of rainfall can be used to compare the effectiveness of the extention basin to the detention basin since the computations are always relative.
The following are the steps in the final computation over a range of flows:
TABLE 4-A
Storage Volume versus Elevation - Extention Basin
Elevation
Surface Area
Volume
(feet)
(acres)
(acre-feet)
340
0
0.000
342
0.87
0.553
344
2.17
3.448
346
2.45
8.065
348
2.74
13.253
350
3.04
19.030
352
3.36
25.427
TABLE 4-B
Storage Volume versus Elevation - Water Quality Basin
Elevation
Surface Area
Volume
(feet)
(acres)
(acre-feet)
340
0.00
0.00
342
0.20
0.13
344
0.53
0.83
346
1.06
2.39
348
1.93
5.33
TABLE 4-C
Diversion Schedules for Case 4
Inflow (cfs)
0
10
20
50
80
100
180
300
Divert to Design Point (cfs)
0
10
20
40
55
65
120
237
Remaining Flow to Storage
0
0
0
10
25
35
60
63
Basin (cfs)
TABLE 4-D
Computation of First Flush Volume Required:
New Impervious -- Disturbed Area
125
acres
Rainfall to be Captured
0.5
inches
Computed Volume to be Captured
5.33
acre-feet
TABLE 4-E Sample Case 4 - Summary of Peak Flows by Storm Frequency Storm Frequency Existing Flow Proposed Inflow Extention Basin (year) (cfs) (cfs) Outflow (cfs) 100 278 328 278 50 209 251 203 25 161 198 151 10 111 144 107 5 72 99 72 2 27 42 24
Discussion of the Extention Basin:
It is clear from the summary Table 4-E, that the extention basin system has reduced peak flows to almost match the original flows, and more importantly, it has done this over a wide range of flows.
For example, the 100-year storm runoff is 278 cfs both in the existing and proposed cases, even though the development in the watershed has increased to flows 328 cfs. The 2-year storm has been reduced from the proposed flow of 42 to 24 cfs—slightly below the existing peak flow of 27 cfs.
The graph of the results of the existing flows as compared to the final flows is shown in FIG. 10 .
A close-up comparison of the final results along with the proposed, after-development inflows for the 100-year storm is shown on the graph in FIG. 11 .
In FIG. 11 , the existing hydrograph is nearly identical to the extention basin outflows when comparing both peak time and hydrograph shape. It is immediately apparent from the graphs that the extention basin accomplishes an additional task of limiting the lag in the peak outflow.
The reduction of outflow lag is an added, environmental benefit of the extention basin since any natural drainage system is less likely to be affected by the change in timing. Further, we have eliminated unknown flooding affects associated with timing of peak flows from other watersheds.
Sample Case Summary:
Each sample case performed the task of reducing the after development peak flow from 328 cfs to the design peak flow of 278 cfs using a storage basin. The conventional storage basin system using standard reservoir routing techniques computed the storage at 17 acre-feet (16 acre-feet for case 2B), to these values we must add 5.33 acre feet required for first-flush storage.
The extention basin performed very much better, requiring only 9 acre feet of storage to control peak flows and 5.33 acre feet for storm water treatment for a total storage of 14.33 acre-feet.
The Table below summarizes the storage required for each sample case.
TABLE 5
Comparison of Storage Requirements for the Sample Cases
Storage
Storage
Volume
Volume for
Total
for Peak
Water Quality
Storage
Sample
Flow
Treatment
Volume
Case
Description
Control
(acre-feet)
Required
1-A
Existing Conditions
n.a.
n.a.
n.a.
1-B
After Development
n.a.
n.a.
n.a.
Conditions
2-A
Conventional Detention
17
n.a.
n a
Basin - No Water Quality
Treatment
2-B
Conventional Detention
16
5.33
21.33
Basin w/ Water Quality
Treatment
3 and 4
Extention Basin w/
9.0
5.33
14.33
Water Quality Treatment
TABLE 6
Summary of Peak Flows and Peak Time versus Storm Frequency for each
Sample Case
Storm Frequency (years)
Sample
100
50
25
10
5
2
Case
Peak Flows (cfs)/ Peak Time (hrs) (increased flows are red light shaded)
1-A
278/13.17
209/13.17
161/13.17
111/13.17
72/13.17
27/13.33
1-B
328/13.00
251/13.00
198/13.17
144/13.17
99/13.17
42/13.33
2-A
278/13.00
208/13.17
158/13.17
114/13.17
81/13.17
42/13.33
2-B
278/13.50
197/13.67
139/13.83
80/14.33
36/15.50
22/15.50
3
278/13.00
208/13.17
158/13.17
114/13.17
81/13.17
42/13.33
4
278/13.00
203/13.17
151/13.17
107/13.17
72/13.50
24/14.83
CONCLUSION
The extention basin provides the control of peak flows using less storage than a conventional retention or detention basin. This phenomenon occurs because we have found a method to “tune” the system to minimize the storage requirement.
The extention basin described in our sample case requires only about 67% of the storage of a conventional storage basin where water quality treatment is also required (Case 3 vs. Case 2-B), and controls flows over a very wide range of storm frequencies.
Similarly, when control is required over only a small range of storm frequencies and water quality treatment is not needed, the simple extention basin requires only about 50% of the storage of a conventional storage basin (Case 2A—100, 50, 25 year storm).
When the capture of the first-flush of storm water is required for water quality treatment and control of peak flows is required over a wide range of storm frequencies, the storage volume can be minimized by the use of an extention basin that uses storage volumes close to the theoretical minimum storage volume (Case 4).
Based on the theory involved, much greater savings in storage volume can be achieved than we have reported here. The actual savings would be dependent on the shape of the inflow hydrograph and the designer's ability to shape the outflow hydrograph using strategic diversions.
The technique for computing these detailed volumes is straightforward—and can be computed by trial and error methods. Since the expected savings of up to 50% in storage is so great, the additional design time required to fine-tune the computations using successive iteration is well worth the effort.
REFERENCES
1. U.S. Army Corps of Engineers HEC-1 Flood Hydrograph Package, Users Manual, September 1981, The Hydrologic Engineering Center, 609 Second Street, Davis, Calif. 95616
2. U.S. Army Corps of Engineers HEC-1 Computer Program
3. Urban Hydrology for Small Watersheds, USDA, Soil Conservation Service, Technical Release 55 Jun. 1986
4. RGM HEC 2000 Computer Program
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This paper proposes an integrated approach to storm water management and storm water treatment. Today's requirements for capturing and treating the first-flush of storm water can be met with a new device that also controls peak flows over a wide range of storms and uses a net storage volume that is substantially lower than the storage computed by traditional reservoir routing methods.
The extention basin debuts here as the most efficient method of reducing peak storm water flows—being far more effective than the retention or detention basins in common use today.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Pursuant to 35 U.S.C. §119(a), this application claims the benefit of earlier filing date and right of priority to Korean Application No. 10-2005-0047653, filed on Jun. 3, 2005, the contents of which are hereby incorporated by reference herein in their entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to digital multimedia broadcasting (DMB), and in particular to managing digital broadcasting channels in a DMB system.
2. Discussion of the Related Art
High-quality digital audio devices, such as compact discs (CDs) and digital versatile discs (DVDs), have increased in acceptance and popularity throughout the world. Consequently, listeners of digital broadcasts have demanded that such broadcasts provide audio at quality that equals that of CDs and DVDs. Digital audio broadcasting (DAB) systems have been widely used to obviate limitations in the quality of audio available from typical amplitude modulation (AM) and frequency modulation (FM) broadcast services.
DAB is a technology that is currently implemented in various countries such as Europe, Canada, and the United States. A DAB system implements technology which differs from that of conventional AM and FM broadcasting systems, and is able to provide robust, high-quality, signals which are readily received by both stationary and mobile receivers.
In recent times, a variety of multimedia services include both audio and video data using a digital multimedia broadcasting (DMB) service. A typical DMB service can provide users with high-quality audio and video data. The Eureka-147 system has been developed for the above-mentioned DAB service, and has been utilized to provide content using DMB.
A single ensemble, which is one of the many types of broadcast signals in the DAB system, is composed of one or more services. A single service is composed of one or more service components. Individual sub-channels or fast information data channels (FIDCs) may be used for each of these service components.
Multiplex configuration information (MCI) identifies services multiplexed into the ensemble, service components contained in individual services, and position information of the service components. The MCI forms part of the main service channel (MSC), which is repeatedly broadcast and subsequently received by a receiving device, such as a terminal. The terminal utilizes the received MCI to interpret the MSC.
The term reconfiguration will be used herein to refer to a change in an ensemble structure of a received broadcast signal. Typically, the receiving terminal is readied for a change to a new ensemble prior to the actual reconfiguration process. This may be accomplished by transmitting new MCI (i.e., information regarding the reconfiguration) to the receiving terminal at a point of time prior to the actual occurrence of the reconfiguration process. As an example, the MCI may be broadcast to the receiving terminal about six seconds before the reconfiguration actually occurs.
During reconfiguration, one or more changes may occur. For instance, the reconfiguration may change the number of services that make up the ensemble, the structure of the service components, the configuration within an ensemble structure, and combinations thereof.
FIG. 1 depicts a reconfiguration in which the number of services within an ensemble structure is increased from three to four services. The original services include sports, movies, and radio. The reconfiguration provides for the addition of the news service.
FIG. 2 depicts a reconfiguration in which the number of services within an ensemble structure is decreased from three to two services. Another reconfiguration possibility would be for the number of services to remain the same, but the sub-channel which belongs to a particular service may be changed to another sub-channel. This channel switching may be performed for one or more of the services of the ensemble structure.
A user is typically unaware of changes to the ensemble structure until they are notified of the reconfiguration. The user therefore only realizes the addition or deletion of a service, resulting from received channel information, after changes in the structure of the ensemble has occurred. In addition, conventional techniques usually permit obtaining the relevant ensemble change information only when actively displaying a particular service. There is currently no viable technique for obtaining the relevant information when changing non-active configurations of the ensemble. Periodically performing fast information channel (FIC) decoding has previously been proposed to solve the problem. However, this solution requires performing FIC decoding in fade areas.
SUMMARY OF THE INVENTION
Features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof, as well as the appended drawings.
In accordance with an embodiment, a method for managing a digital multimedia broadcasting channel includes receiving a broadcast data frame that includes an occurrence change field, and performing a service update responsive to reconfiguration version data defined within the occurrence change field.
In one aspect, the broadcast data frame is implemented as a fast information group (FIG) type 0 field for extension 0 frame, and the occurrence change field is 8 bits. If desired, the broadcast data frame further includes a change flag, and the method further includes initiating the performing of the service update whenever a value of the reconfiguration version data is different than a previous value of the reconfiguration version data, and a value of the change flag is zero.
In another aspect, the method further includes initiating the performing of the service update whenever a value of the reconfiguration version data is different than a previous value of the reconfiguration version data.
In yet another aspect, the method further includes extracting the reconfiguration version data from the occurrence change field.
In still yet another aspect, the method further includes storing the new channel in memory.
In accordance with an alternative embodiment, a method for managing a digital multimedia broadcasting channel includes transmitting a broadcast data frame that includes an occurrence change field and causing a receiving terminal to perform a service update responsive to reconfiguration version data defined within the occurrence change field.
In accordance with yet another alternative embodiment, a digital multimedia broadcast terminal includes a receiver for receiving a broadcast data frame that includes an occurrence change field, and a controller configured to generate a control signal causing a service update responsive to reconfiguration version data defined within the occurrence change field.
In one embodiment, a digital multimedia broadcasting system includes a data generator for selectively storing reconfiguration version data within an occurrence change field of a broadcast data frame, such that a value of the reconfiguration version data is varied to cause a receiving terminal to perform a service update. The system further includes a transmitter for transmitting the broadcast data frame to the receiving terminal.
Another embodiment is directed toward a method for generating a broadcast data frame for a terminal operating within a digital multimedia broadcast system. The method includes defining an occurrence change field in the broadcast data frame and varying values of reconfiguration version data defined within the occurrence change field to cause the terminal to perform a service update.
These and other embodiments will also become readily apparent to those skilled in the art from the following detailed description of the embodiments having reference to the attached figures, the invention not being limited to any particular embodiment disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention. Features, elements, and aspects of the invention that are referenced by the same numerals in different figures represent the same, equivalent, or similar features, elements, or aspects in accordance with one or more embodiments. In the drawings:
FIG. 1 depicts a reconfiguration in which the number of services within an ensemble structure is increased from three to four services;
FIG. 2 depicts a reconfiguration in which the number of services within an ensemble structure is decreased from three to two services;
FIG. 3 depicts a broadcast data frame of a fast information group (FIG) type 0 field extension 0 (also referred to herein as FIG 0/0) in accordance with the Eureka-147 standard;
FIG. 4 is a flowchart depicting a method for providing digital multimedia broadcast channel management in accordance with an embodiment of the present invention; and
FIG. 5 is a schematic block diagram depicting relevant components of a typical terminal configured in accordance with an embodiment of the present invention to function in cooperation with a digital multimedia broadcasting system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or similar parts.
FIG. 3 depicts a broadcast data frame of a fast information group (FIG) type 0 field extension 0 (also referred to herein as FIG 0/0) in accordance with the Eureka-147 standard. By way of example only, ensemble information is coded at FIG 0/0, each field being described as follows.
EId (Ensemble Identifier): Includes a total of 16 bits, with 4 bits representing country ID), and 12 bits representing an ensemble reference.
Change flag: Includes 2 bits which provide notice of changes in the sub-channel and/or service configuration. Possible change flags are set forth in Table 1 below.
TABLE 1
b15
b14
Remarks
0
0
no change, no occurrence change field present
0
1
sub-channel organization only
1
0
service organization only
1
1
sub-channel organization and service organization
A1 flag: Includes a 1 bit flag which is used to indicate an accessible alarming message, along with an ensemble. A value “0” indicates an inaccessible alarming message and a value “1” indicates an accessible alarming message.
CIF count: The higher order portion of the CIF count field includes a modulo-20 counter (0 to 19) and the lower order portion of the CIF count includes a modulo-250 counter (0 to 249).
Occurrence change: Includes an 8 bit field which is for an occurrence change, and represents the lower part of the CIF counter. This particular field is implemented in accordance the present invention to indicate a service update. The occurrence change field is often used in conjunction with the change flag field (e.g., setting the change flag to 0). The reason that the occurrence change field is used to transmit the reconfiguration version data is because the occurrence change filed is not otherwise used in many instances.
Reconfiguration is a method by which the broadcast station provides notice of configuration changes to receiving terminals, for example. As will be described in more detail below, reconfiguration notification may be accomplished by increasing the value of the reconfiguration version data, which may be transmitted in the occurrence change field in accordance with an embodiment. More specifically, the broadcast station may incrementally increase an 8 bit value of the reconfiguration version data from 0-255 using a modular-256 operation whenever a reconfiguration occurs. If desired, reconfiguration version data within the occurrence change field may be sent to the terminal prior to the time (e.g., six seconds) that the actual reconfiguration process occurs. This aspect provides advance notice to the terminal of the reconfiguration of the ensemble.
In accordance with an embodiment, the broadcast station transmits reconfiguration version data using the change flag and the occurrence change field. A terminal receives and then compares the value of the transmitted version data with a previous value of the version data. A service update may be performed if the previous and current values of the reconfiguration version data has changed, and the change flag has a value of 0. The terminal does not conduct a service update (e.g., a channel search) when the transmitted version data is identical to a previous value of the version data. The terminal typically performs a new channel configuration by searching for a service within an ensemble.
FIG. 4 is a flowchart depicting a method for providing digital multimedia broadcast channel management in accordance with an embodiment of the present invention. By way of nonlimiting example only, this method will be described with reference to the broadcast data frame depicted in FIG. 3 .
First of all, it is to be understood that a terminal is located within the coverage area of a digital multimedia broadcast system. At some point, the broadcast system transmits a broadcast data frame which includes reconfiguration version data. In an embodiment, the reconfiguration version data is implemented using the 8 bit occurrence change field. As an additional parameter, a value of the change flag of the broadcast data frame may also be set to 0.
At block S 11 , the terminal receives the broadcast data frame and included reconfiguration version data. At block S 12 , the value of the reconfiguration version data is extracted or otherwise determined. The value of the extracted reconfiguration version data may then be compared with the value of previously received reconfiguration version data. Whether or not a service update is necessary may be determined responsive to the relative differences between the current and previous values of the reconfiguration version data. For instance, if the current and previous values of the version data are the same, this indicates that a service update is not required. On the other hand, if these values are different, this indicates that a service update is desired. In an embodiment, a service update is indicated only if there is a change in the reconfiguration version data and the value of the change flag is set to a particular value (e.g., zero).
According to decision block S 13 , if the current and previous values are equal, no service update is required and operations are terminated. On the other hand, if these values are not equal, a service update or change is desired and control flows to block S 14 .
At block S 14 , a service update process is performed during which a search for the new channel, for example, is performed. Once the channel is located, the channel information may be stored in memory (block S 15 ). The various operations depicted in FIG. 4 may be repeated on a continuous, periodic, or other basis.
FIG. 5 is a schematic block diagram depicting relevant components of terminal 10 configured in accordance with an embodiment of the present invention to function in cooperation with digital multimedia broadcast system 20 .
Broadcast system 20 includes a transmitting component configured to transmit a broadcast data frame, such as that depicted in FIG. 3 . The broadcast system may be implemented using satellites, terrestrial stations, and the like, to transmit the broadcast data frame. Terminal 10 is an example of a receiving component configured to operate in cooperation with the broadcast system. The terminal may be implemented using a mobile, portable, or fixed digital broadcast terminal configured to receive TV, radio, digital multimedia data, and combinations thereof.
In accordance with an embodiment of the present invention, broadcast system 20 may transmit a broadcast data frame (e.g., FIG type 0/0) which includes reconfiguration version data within the occurrence change field. This reconfiguration version data is often implemented in conjunction with the change flag field being assigned a “0” value.
Terminal 10 is shown having DMB receiver 30 , controller 40 , and memory 50 . The DMB receiver may be configured to receive signaling from broadcast system 20 , such signaling including the broadcast data frame of FIG. 3 . Memory 30 supports the memory requirements of the terminal, and may be configured to store data relating to current and previous values of the reconfiguration version data. Controller 20 is configured to provide the necessary processing and control signal generation (e.g., channel searching) to support any of the operations discussed above in conjunction with FIG. 4 .
Advantages provided by various embodiments include providing notification to the user of a change in ensemble configuration even though the ensemble configuration is not currently being displayed or otherwise presented to the user.
The foregoing embodiments and advantages are merely exemplary and are not to be construed as limiting the present invention. The present teaching can be readily applied to other types of apparatuses and processes. The description of the present invention is intended to be illustrative, and not to limit the scope of the claims. Many alternatives, modifications, and variations will be apparent to those skilled in the art.
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A method for managing a digital multimedia broadcasting channel includes receiving a broadcast data frame that includes an occurrence change field, and performing a service update responsive to reconfiguration version data defined within the occurrence change field. Alternatively, the method includes transmitting a broadcast data frame that includes an occurrence change field, and causing a receiving terminal to perform a service update for a new channel responsive to reconfiguration version data defined within the occurrence change field. A digital multimedia broadcast terminal includes a receiver for receiving a broadcast data frame that includes an occurrence change field, and a controller configured to generate a control signal causing a service update responsive to reconfiguration version data defined within the occurrence change field.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
Embodiments described herein are directed toward artificial lift systems used to produce fluids from wellbores, such as crude oil and natural gas wells. More particularly, embodiments described herein are directed toward an improved anchor for use with a downhole pump. More particularly, the embodiments described herein are directed to a resettable anchor configured to prevent longitudinal and rotational movement of the pump relative to a tubular.
2. Description of the Related Art
Modern oil and gas wells are typically drilled with a rotary drill bit and a circulating drilling fluid or “mud” system. The mud system (a) removes drill bit cuttings from the wellbore during drilling, (b) lubricates and cools the rotating drill bit, and (c) provides pressure within the borehole to balance internal pressures of formations penetrated by the borehole. Rotary motion is imparted to the drill bit by rotation of a drill string to which the bit is attached. Alternately, the bit is rotated by a mud motor which is attached to the drill string just above the drill bit. The mud motor is powered by the circulating mud system. Subsequent to the drilling of a well, or alternately at intermediate periods during the drilling process, the borehole is cased typically with steel casing, and the annulus between the borehole and the outer surface of the casing is filled with cement. The casing preserves the integrity of the borehole by preventing collapse or cave-in. The cement annulus hydraulically isolates formation zones penetrated by the borehole that are at different internal formation pressures.
Numerous operations occur in the well borehole after casing is “set”. All operations require the insertion of some type of instrumentation or hardware within the borehole. Examples of typical borehole operations include: (a) setting packers and plugs to isolate producing zones; (b) inserting tubing within the casing and extending the tubing to the prospective producing zone; and (c) inserting, operating and removing pumping systems from the borehole.
Fluids can be produced from oil and gas wells by utilizing internal pressure within a producing zone to lift the fluid through the well borehole to the surface of the Earth. If internal formation pressure is insufficient, artificial fluid lift devices and methods may be used to transfer fluids from the producing zone and through the borehole to the surface of the Earth.
One common artificial lift technology utilized in the domestic oil industry is the sucker rod pumping system. A sucker rod pumping system consists of a pumping unit that converts a rotary motion of a drive motor to a reciprocating motion of an artificial lift pump. A pump unit is connected to a polish rod and a sucker rod “string” which, in turn, operationally connects to a rod pump in the borehole. The string can consist of a group of connected, essentially rigid, steel sucker rod sections (commonly referred to as “joints”) in lengths, such as twenty-five or thirty feet (ft), and in diameters, such as ranging from five-eighths inch (in.) to one and one-quarter in. Joints are sequentially connected or disconnected as the string is inserted or removed from the borehole, respectively. Alternately, a continuous sucker rod (hereafter referred to as COROD) string can be used to operationally connect the pump unit at the surface of the Earth to the rod pump positioned within the borehole. A delivery mechanism rig (hereafter CORIG) is used to convey the COROD string into and out of the borehole.
Prior art borehole pump assemblies of sucker rod operated artificial lift systems typically utilize a progressing cavity (PC) pump positioned within wellbore tubing. FIG. 1A is a sectional view of a prior art PC pump 100 . A pump housing 110 contains an elastomeric stator 130 a having multiple lobes 125 formed in an inner surface thereof. The pump housing 110 is usually made from metal, preferably steel. The stator 130 a has five lobes. Although, the stator 130 a may have two or more lobes. Inside the stator 130 a is a rotor 118 . The rotor 118 having one lobe fewer than the stator 130 a formed in an outer surface thereof. The inner surface of the stator 130 a and the outer surface of the rotor 118 also twist along respective longitudinal axes, thereby each forming a substantially helical-hypocycloid shape. The rotor 118 is usually made from metal, preferably steel. The rotor 118 and stator 130 a interengage at the helical lobes to form a plurality of sealing surfaces 160 . Sealed chambers 147 between the rotor 118 and stator 130 a are also formed. In operation, rotation of the sucker rod or COROD string causes the rotor 118 to nutate or process within the stator 130 a as a planetary gear would nutate within an internal ring gear, thereby pumping production fluid through the chambers 147 . The centerline of the rotor 118 travels in a circular path around the centerline of the stator 120 .
One drawback in such prior art motors is the stress and heat generated by the movement of the rotor 118 within the stator 130 a . There are several mechanisms by which heat is generated. The first is the compression of the elastomeric stator 130 a by the rotor 118 , known as interference. Radial interference, such as five-thousandths of an inch to thirty-thousandths of an inch, is provided to seal the chambers to prevent leakage. The sliding or rubbing movement of the rotor 118 combined with the forces of interference generates friction. In addition, with each cycle of compression and release of the elastomeric stator 130 a , heat is generated due to internal viscous friction among the elastomer molecules. This phenomenon is known as hysteresis. Cyclic deformation of the elastomer occurs due to three effects: interference, centrifugal force, and reactive forces from pumping. The centrifugal force results from the mass of the rotor moving in the nutational path previously described. Reactive forces from torque generation are similar to those found in gears that are transmitting torque. Additional heat input may also be present from the high temperatures downhole.
Because elastomers are poor conductors of heat, the heat from these various sources builds up in the thick sections 135 a - e of the stator lobes. In these areas the temperature rises higher than the temperature of the circulating fluid or the formation. This increased temperature causes rapid degradation of the elastomeric stator 130 a . Also, the elevated temperature changes the mechanical properties of the elastomeric stator 130 a , weakening each of the stator lobes as a structural member and leading to cracking and tearing of sections 135 a - e , as well as portions 145 a - e of the elastomer at the lobe crests. This design can also produce uneven rubber strain between the major and minor diameters of the pumping section. The flexing of the lobes 125 also limits the pressure capability of each stage of the pumping section by allowing more fluid slippage from one stage to the subsequent stages below.
Advances in manufacturing techniques have led to the introduction of even wall PC pumps 150 as shown in FIG. 1B . A thin tubular elastomer layer 170 is bonded to an inner surface of the stator 130 b or an outer surface of the rotor 118 (layer 170 bonded on stator 130 b as shown). The stator 130 b is typically made from metal, preferably steel. These pumps 150 provide more power output than the traditional designs above due to the more rigid structure and the ability to transfer heat away from the elastomer 170 to the stator 130 b . With improved heat transfer and a more rigid structure, the new even wall designs operate more efficiently and can tolerate higher environmental extremes. Although the outer surface of the stator 130 b is shown as round, the outer surface may also resemble the inner surface of the stator. Further, the rotor 118 may be hollow.
FIG. 2 illustrates a prior art insertable PC pump assembly 200 . The PC pump assembly 200 includes a rotor sub-assembly, a stator sub-assembly, and a special production tubing sub-assembly. The special production tubing sub-assembly is assembled and run-in with the production tubing. The production tubing sub-assembly includes a pump seating nipple 236 , a collar 238 , and a locking tubing joint 240 . The pump seating nipple 236 is connected to the collar 238 by a threaded connection. The nipple 236 includes a profile formed on an inner surface thereof for seating a profile formed on an outer surface of a seating mandrel 220 . The collar 238 is connected to the locking tubing 240 by a threaded connection. The locking tubing joint 240 includes a pin 242 protruding into the interior thereof. The pin 242 will receive a fork 234 of a tag bar 232 , thereby forming a rotational connection. Before the PC pump assembly 200 is positioned and operated down hole, the special production tubing sub-assembly is installed as part of the production tubing string so that the pump will be positioned to lift from a particular producing zone of interest. If the PC pump assembly 200 is subsequently positioned at a shallower or at a deeper zone of interest within the well, this can be accomplished by removing the tubing string, or by adding or subtracting joints of tubing. This repositions the special joint of tubing as required.
The rotor sub-assembly includes a pony rod 212 , a rod coupling 216 , and a rotor 218 . The top of the pony rod 212 is connected to a COROD string (not shown) or to a conventional sucker rod string (not shown) by the connector 214 , thereby forming a threaded connection. The pony rod 212 is connected to the top of the rotor 218 by the rod coupling 216 , thereby forming a threaded connection. The rotor 218 may resemble the rotor 118 . An outer surface of the rod coupling 216 is configured to abut an inner surface of the cloverleaf insert 222 , thereby longitudinally coupling the cloverleaf insert 222 and the rod coupling 216 in one direction. The rotor 218 is connected to the rod coupling 216 with a threaded connection.
The stator sub-assembly includes a seating mandrel 220 , a cloverleaf insert 222 , upper and lower flush tubes 224 , 226 , a barrel connector 228 , a stator 230 , and the tag bar 232 . The seating mandrel 220 is coupled to the upper flush tube 224 by a threaded connection and includes the profile formed on the outer surface thereof for seating in the nipple 236 . The profile is formed by disposing elastomer sealing rings around the seating mandrel 220 . The cloverleaf insert 222 is disposed in a bore defined by the seating mandrel 220 and the upper flush tube 224 and longitudinally held in place between a shoulder formed in each of the seating mandrel 220 and the upper flush tube 224 . The inner surface of the cloverleaf insert 222 is configured to shoulder against the outer surface of the rod coupling 216 . The lower flush tube 226 is coupled to the upper flush tube 224 by a threaded connection. Alternatively, the flush tube 224 , 226 may be formed as one integral piece. The barrel connector 228 is coupled to the lower flush tube 226 by a threaded connection. The stator 230 is coupled to the barrel connector 228 by a threaded connection. The stator 230 may be either the conventional stator 130 a or the recently developed even-walled stator 130 b . The tag bar 232 is connected to the stator 230 with a threaded connection. A fork 234 is formed at a longitudinal end of the tag bar 232 for mating with the pin 242 , thereby forming a rotational connection between the tag bar 232 and the locking tubing 240 . The tag bar 232 further includes a tag bar pin 235 (see FIG. 3 ) for seating a longitudinal end of the rotor 218 .
FIG. 3A illustrates the rotor and stator sub-assemblies of the prior art PC pump assembly 200 being inserted into a borehole. The production tubing sub-assembly is installed as part of the production tubing string so that the PC pump assembly 200 , when installed downhole, will be positioned to lift from a particular producing zone of interest. Once the production tubing sub-assembly is installed down hole as part of the tubing string, the rotor and stator sub-assemblies are assembled and run down hole inside of the production tubing using a COROD or conventional sucker rod system.
FIG. 3B illustrates the rotor and stator sub-assemblies being seated within the borehole. When reaching the special locking joint 240 , the forked slot 234 at the lower end of the assembly tag bar 232 aligns with the pin 242 as shown in FIG. 3B . Once the fork slot 234 aligns with and engages the pin 242 , the stator sub-assembly is locked radially within the locking joint 240 and can not rotate within the locking joint 240 when the PC pump assembly 200 is operated. After the fork 234 and pin 242 have aligned and engaged, the seating mandrel 220 will then slide into, seat with, and form a seal with the seating nipple 236 . The prior art insertable PC pump assembly 200 is now completely installed down hole.
FIG. 3C illustrates the prior art PC pump assembly 200 in operation, where the rotor 218 is moved up and down within the stator 230 by the action of the pony rod 212 and connected sucker rod string (not shown). After compensating for sucker rod stretch, the sucker rod string is slowly lifted a distance 252 , off of the tag bar pin 235 of the tag bar 232 . This positions the rotor 218 in a proper operating position with respect to the stator 230 .
FIG. 3D shows the system configured for flushing. During operation, it is possible that the insertable PC pump assembly 200 may need to be flushed to remove sand and other debris from the stator 230 and the rotor 218 . To perform this flushing operation, the rotor 218 is pulled upward from the stator by the sucker rod string by a distance 254 . In order to avoid disengaging the entire pump assembly 200 from the seating nipple 236 , the rotor 218 is moved upward only until it is located in the flush tubes 224 , 226 . The PC pump assembly 200 may now be flushed, and then the rotor 218 reinstalled without completely reseating the entire PC pump assembly 200 . Since the prior art insertable PC pump assembly 200 is picked up from the top of the rotor 218 , the flush tubes 224 , 226 are required. Furthermore, the length of the flush tubes 224 , 226 must be at least as long as the rotor 218 . The entire PC pump assembly 200 will then be at least twice as long as the stator 230 . This presents a problem in optimizing stator length within the operation and clearly illustrates a major deficiency in prior art insertable PC pump systems.
FIG. 3E illustrates the rotor and stator sub-assemblies being removed from the locking joint 240 and seating nipple 236 . The sucker rod string is lifted until the rod coupling 216 on the top of the rotor 218 engages with the cloverleaf insert 222 . The seating mandrel 220 is then extracted from the seating nipple 236 by further upward movement of the sucker rod string, and the rotor and stator subassemblies are conveyed to the surface as the sucker rod string is withdrawn from the borehole.
The operating envelope of an insertable PC pump is dependent upon pump length, pump outside diameter, and the rotational operating speed. In the prior art PC pump assembly 200 , the pump length is essentially fixed by the distance between the seating nipple 236 and the pin 242 of the locking joint 240 . Pump diameter is essentially fixed by the seating nipple size. Stated another way, these factors define the operating envelope of the pump. For a given operating speed, production volume can be gained by lengthening stator pitch and decreasing the total number of pitches inside the fixed operating envelope. Volume is gained at the expense of decreasing lift capacity. On the other hand, lift capacity can be gained within the fixed operating envelope by shortening stator pitch and increasing the total number of pitches. Production volume can only be gained, at a given lift capacity, by increasing operating speed. This in turn increases pump wear and decreases pump life. For a given operating speed and a given seating nipple size, the operating envelope of the prior art system can only be changed by pulling the entire tubing string and adjusting the operating envelope by changing the distance between the seating nipple 236 and the pin 242 . Alternately, the tubing can be pulled and the seating nipple 236 can be changed thereby allowing the operating envelope to be changed by varying pump diameter. Either approach requires that the production tubing string be pulled at significant monetary and operating expense.
In summary, the prior art insertable PC pump system described above requires a special joint of tubing containing a welded, inwardly protruding pin for radial locking and a seating nipple. The seating nipple places some restrictions upon the inside diameter of the tubing in which the pump assembly can be operated. This directly constrains the outside diameter of the insertable pump assembly. The overall distance between the pin and the seating nipple constrains the length of the pump assembly. In order to change the length of the pump assembly to increase lift capacity (by adding stator pitches) or to change production volume (by lengthening stator pitches), (1) the entire tubing string must be removed and (2) the distance between the seating nipple 236 and the locking pin 242 must be adjusted accordingly before the production tubing is reinserted into the well. Longitudinal repositioning of the PC pump assembly 200 without changing length can be done by adding or subtracting tubing joints to reposition the seating nipple 236 and the locking pin 242 as a unit. The prior art PC pump assembly 200 requires a flush tube 224 , 226 so that the rotor 218 can be removed from the stator 230 for flushing. This increases the length of the assembly and also adds to the mechanical complexity and the manufacturing cost of the assembly.
Therefore, there exists a need in the art for an insertable PC pump that does not require specialized components to be assembled with a production string.
SUMMARY OF THE INVENTION
Embodiments described herein generally relate to a method of anchoring a PC pump in a tubular located in a wellbore. The method comprises running the PC pump coupled to an anchor assembly to a first longitudinal location inside the tubular and actuating the anchor assembly thereby engaging the tubular with an anchor of the anchor assembly. The engaging of the tubular thereby preventing the rotation and longitudinal movement of the anchor assembly relative to the tubular. The method further comprises setting off a relief valve in the anchor assembly thereby releasing the anchor assembly from the tubular.
Embodiments described herein further relate to an anchoring assembly for anchoring a downhole tool in a tubular in a wellbore. The anchoring assembly comprises an inner mandrel, and an anchor actuable by the manipulation of the inner mandrel. The anchoring assembly further comprises an engagement member configured to engage an inner wall of the tubular and resist longitudinal forces applied to the anchoring assembly. The anchoring assembly further comprises an actuation assembly having one or more one way valves configured to allow fluid to flow from a first piston chamber to a second piston chamber and a relief valve configured to release fluid pressure in the second piston chamber, wherein the relief valve allows the release of the anchor when a predetermined fluid pressure is applied to the second piston chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1A is a sectional view of a prior art progressing cavity (PC) pump. FIG. 1B is a sectional view of a prior art even wall PC pump.
FIG. 2 illustrates a prior art insertable PC pump system.
FIG. 3A illustrates rotor and stator sub-assemblies of a prior art PC pump system being inserted into a borehole. FIG. 3B illustrates the rotor and stator sub-assemblies being seated within the borehole. FIG. 3C illustrates the prior art PC pump system being operated within the borehole. FIG. 3D illustrates the prior art PC pump system being flushed. FIG. 3E illustrates the rotor and stator sub-assemblies being removed from the borehole.
FIG. 4A is an isometric sectional view of a PC pump assembly, according to one embodiment of the present invention. FIG. 4B is a partial half-sectional view of an anchor of the PC pump system of FIG. 4A . FIG. 4C is a schematic showing various operational positions of a J-pin and slotted path of the PC pump system of FIG. 4A . FIG. 4D is a sectional view taken along lines 4 D- 4 D of FIG. 4B .
FIGS. 5A-G illustrate various positions of the PC pump system of FIG. 4A . FIG. 5A illustrates the PC pump system being run-into a wellbore. FIG. 5B illustrates the PC pump system in a preset position. FIG. 5C illustrates the PC pump system in a set position. FIG. 5D illustrates the PC pump system in a pre-operational position. FIG. 5E illustrates the PC pump system in an operational position. FIG. 5F illustrates the improved PC pump system in a flushing position. FIG. 5G illustrates the improved PC pump system being removed from the borehole.
FIG. 6 is a cross sectional view of an anchor assembly according to one embodiment described herein.
FIG. 7A is a side view of an anchor assembly according to one embodiment described herein.
FIG. 7B is a detail of a slotted path according to one embodiment described herein.
FIG. 8 is a cross sectional view of a valve assembly according to one embodiment described herein.
FIGS. 9A and 9B are cross sectional views of a sealing member for the valve assembly according to one embodiment described herein.
DETAILED DESCRIPTION
FIG. 4A is an isometric sectional view of a PC pump assembly 400 , according to one embodiment of the present invention. Unlike the prior art PC pump assembly 200 , the PC pump assembly 400 does not require a special production tubing sub-assembly. In other words, the PC pump assembly 400 is capable of longitudinal and rotational coupling to an inner surface of a conventional production tubing string at any longitudinal location along the production tubing string. This feature allows for installation of the PC pump assembly 400 at a first longitudinal location or depth along the production tubing string, operation of the PC pump assembly 400 , and relocation of the PC pump assembly to a second longitudinal location or depth along the production tubing string, which may be closer or farther from the surface relative to the first location, without pulling and reconfiguration of the production tubing string. The PC pump assembly 400 includes a rotor subassembly, a stator subassembly, and an anchor subassembly 450 . Unless otherwise specified, components of the PC pump assembly 400 are made from metal, such as steel or stainless steel.
The rotor subassembly includes a pony rod 412 , a rotor 418 , and a wedge-shaped structure or arrowhead 419 . The pony rod 412 includes a threaded connector at a first longitudinal end for connection with a drive string, such as a conventional sucker rod string, a COROD string, a wireline, a coiled tubing string, or a string of jointed (i.e., threaded joints) tubulars. A wireline may be used for instances where the PC pump assembly 400 is driven by an electric submersible pump (ESP). The coiled tubing string may be used for instances where the PC pump is driven by a downhole hydraulic motor. The pony rod 412 may connect at a second longitudinal end to a first longitudinal end of the rotor 418 by a threaded connection. The rotor 418 may resemble the rotor 118 . The arrowhead 419 may connect to a second longitudinal end of the rotor by a threaded connection. The wedge-shaped outer surface of the arrowhead 419 facilitates insertion and removal of the rotor 418 through the stator 430 . The outer surface of the arrowhead 419 is also configured to interfere with an inner surface of the floating ring 422 to provide longitudinal coupling therebetween in one direction. Alternatively, any type of no-go device, such as one similar to the rod coupling 216 , may be used instead of the arrowhead 419 .
The stator subassembly includes an optional seating mandrel 420 , a floating ring 422 , an optional ring housing 424 , a flush tube 426 , a barrel connector 428 , a stator 430 , and a tag bar 432 . The seating mandrel 420 , the floating ring 422 , the ring housing 424 , the flush tube 426 , the barrel connector 428 , and the tag bar 432 are tubular members each having a central longitudinal bore therethrough. The seating mandrel 420 is coupled to the upper flush tube 426 by a threaded connection and includes an optional profile formed on the outer surface thereof for seating in the nipple 236 . The profile may be provided in cases where the nipple 236 has already been installed in the production tubing. The profile is formed by disposing one or more sealing rings 421 around the seating mandrel 420 . The sealing rings 421 are longitudinally coupled to the seating mandrel 420 at a first end by a shoulder formed in an outer surface of the seating mandrel 420 and at a second end by abutment with a first longitudinal end of a gage ring 423 . The gage ring 423 has a threaded inner surface and is disposed on a threaded end of the seating mandrel 420 .
The ring housing 424 has a threaded inner surface at a first longitudinal end and is disposed on the threaded end of the seating mandrel 420 . The first longitudinal end of the ring housing 424 abuts a second longitudinal end of the gage ring 423 and is connected to the threaded end of the seating mandrel 420 with a threaded connection. The threaded end of the seating mandrel 420 has an o-ring and a back-up ring disposed therein (in an unthreaded portion). An inner surface of the ring housing 424 forms a shoulder and the floating ring 422 is disposed, with some clearance, between the shoulder of the ring housing 424 and the threaded end of the seating mandrel 420 , thereby allowing limited longitudinal movement of the floating ring 422 . Clearance is also provided between an outer surface of the floating ring 422 and the inner surface of the ring housing 424 , thereby allowing limited radial movement of the floating ring 422 . The inner surface of the floating ring 422 is configured to interfere with the outer surface of the arrowhead 419 , thereby providing longitudinal coupling therebetween in one direction. Preferably, this configuration is accomplished by ensuring that a minimum inner diameter of the floating ring 422 is less than a maximum outer diameter of the arrowhead 419 . The floating action of the floating ring 422 , provided by the longitudinal and radial clearances, allows the rotor 418 to travel therethrough. Alternatively, any no-go ring, such as the cloverleaf insert 222 , may be used instead of the floating ring 422 .
The flush tube 426 is coupled to the ring housing 424 by a threaded connection. Alternatively, the flush tube 426 and the ring housing 424 may be formed as one integral piece. The barrel connector 428 is coupled to the flush tube 426 by a threaded connection. The stator 430 is coupled to the barrel connector 428 by a threaded connection. The stator 430 may be either the conventional stator 130 a or the recently developed even-walled stator 130 b . The tag bar 432 is connected to the stator 430 with a threaded connection. The tag bar 432 includes a tag bar pin 435 for seating the arrowhead 419 . A cap 452 (see FIG. 4B ) of the anchor subassembly 450 is connected to the tag bar 432 with a threaded connection.
FIG. 4B is a partial half-sectional view of the anchor subassembly 450 of the PC pump assembly 400 . The anchor includes the cap 452 , a J-mandrel 454 , a sealing element 458 , a slip mandrel 460 , and a J-runner/slip retainer 468 . The J-runner 468 includes two or more slips 464 , two or more cantilever springs 466 , upper 468 a and lower 468 c spring retainers, a J-pin retainer 468 b , two or more bow springs 472 , and a J-pin 470 .
The cap 452 , the gage ring 456 , the sealing element 458 , the slip mandrel 460 , and the J-mandrel 454 are tubular members each having a central longitudinal bore therethrough. The cap 452 is connected to the J-mandrel 454 with a threaded connection. A longitudinal end of the cap 452 forms a tapered shoulder which abuts a tapered shoulder formed at a first longitudinal end of a gage ring 456 . The gage ring 456 has a threaded inner surface which engages a threaded portion of an outer surface of the J-mandrel 454 . The gage ring 456 may be made from metal or a hard plastic, such as PEEK. The gage ring 456 also has a curved shoulder formed at a second longitudinal end which abuts a curved shoulder formed at a first longitudinal end of the sealing element 458 . Preferably, a portion of an inner surface of the sealing element 458 is bonded to an outer surface of the gage ring 456 . The remaining portion of the inner surface of the sealing element 458 is disposed along the outer surface of the J-mandrel 454 . The sealing element 458 is made from a polymer, preferably an elastomer. Alternatively, the sealing element 458 may be made from a urethane (urethane may or may not be considered an elastomer depending on the degree of cross-linking). During setting of the slips 464 , the sealing element 458 is longitudinally compressed between the gage ring 456 and the slip mandrel 460 in order to radially expand into sealing engagement with the production tubing 500 (see FIG. 5 ). The sealing element 458 has a shoulder formed at a second longitudinal end which abuts a shoulder formed at a first longitudinal end of the slip mandrel 460 .
The slip mandrel 460 may include a base portion 460 a and a plurality of finger portions 460 b longitudinally extending from the base portion. A flat actuations surface 460 c is formed in a portion of an outer surface of each of the finger portions 460 b . Two adjacent flat surfaces cooperatively engage to form an actuation surface 460 c for each of the slips 464 . The discontinuity between the flat surfaces 460 c and the remaining tubular outer surfaces of the finger portions 460 b , when engaged with corresponding inner surfaces of the slips 464 , provides rotational coupling between the slips 464 and the slip mandrel 460 . Referring to FIG. 4D , rotational coupling between the slip mandrel 460 and the J-mandrel 454 is provided by a key 461 disposed in a slot formed in the outer surface of the J-mandrel 454 and a corresponding slot formed in an inner surface of the slip mandrel 460 . Returning to FIG. 4B , the outer surface of the finger portions 460 b is inclined at a second longitudinal end of the slip mandrel 460 . The second longitudinal end of the slip mandrel 460 abuts a slip mandrel retainer 462 . The slip mandrel retainer 462 abuts a shoulder formed in the outer surface of the J-mandrel 454 . Attached to a second longitudinal end of the J-mandrel 454 by a threaded connection is an optional thread adapter 474 . The thread adapter allows other tools (not shown) to be attached to the J-mandrel 454 if desired.
Referring also to FIG. 4C , the J-runner 468 is disposed along the outer surface of the J-mandrel 454 . The J-runner 468 includes the J-pin 470 which extends into a slotted path 454 j,r,s formed in the outer surface of the J-mandrel 454 . Alternatively, the slotted path 454 j,r,s may be formed in an inner surface of the J-mandrel 454 or through the J-mandrel 454 . The slotted path 454 j,r,s may include three portions: a J-slot portion 454 j formed proximate to a second longitudinal end of the J-mandrel 454 , a first longitudinal or setting portion 454 s extending from the J-slot 454 j toward a first longitudinal end of the J-mandrel 454 , and a second longitudinal or run-in portion 454 r extending from the J-slot 454 j toward the first longitudinal end of the J-mandrel 454 . The slotted path 454 j,r,s includes one or more ends or pockets at which the J-pin 470 is longitudinally coupled to the J-mandrel in one direction. Movement of the J-mandrel 454 in the opposite direction will move the J-pin to the next pocket (with the exception of the setting portion 454 s which may not have a pocket). Inclined faces formed in the outer surface of the J-mandrel 454 bounding the slotted path 454 j,r,s guide the J-pin 470 to a particular pocket in a particular sequence. Each of the pockets correspond to one or more operating positions of the anchor 450 : a make-up position MUP, a run-in position RIP, a preset position PSP, a setting position SP, and a pull out of hole position POOH. Reference is made to movement of the J-mandrel 454 instead of movement of the J-runner 468 because, for the most part, the J-runner 468 will be held stationary by engagement of the bow springs 472 with the production tubing 500 .
The J-pin 470 is disposed through an opening through a wall of the J-pin retainer 468 b and attached thereto with a fastener. The spring retainers 468 a,c and J-pin retainer 468 b are tubular members each having a central longitudinal bore therethrough. The J-pin retainer 468 b is disposed longitudinally between the spring retainers 468 a,c with some clearance to allow for rotation of the J-pin retainer 468 b relative to the spring retainers 468 a,c . A retainer pin 473 is attached to the upper spring retainer 468 a with a fastener and radially extends into the first longitudinal portion 454 s , thereby rotationally coupling the upper spring retainer 468 a to the J-mandrel 454 and maintaining rotational alignment of the slips 464 with the actuation surfaces 460 c . Unlike the J-pin 470 , the retainer pin 473 preferably remains in the first longitudinal setting portion 454 s of the slotted path 454 j,r,s during actuation of the anchor 450 through the various positions. Alternatively, the J-pin retainer 468 b and the upper spring retainer 468 a may be configured for the alternative where the slotted path 454 j,r,s is formed on an inner surface of the J-mandrel 454 or therethrough. Attached to the upper 468 a and lower 468 c spring retainers with fasteners are two or more bow springs 472 . As discussed above, the bow springs 472 are configured to compress radially inward when the anchor 450 is inserted into the production tubing 500 , thereby frictionally engaging an inner surface of the production tubing 500 to support the weight of the J-runner 468 . Alternatively, the bow springs 472 may be replaced by longitudinal spring-loaded drag blocks.
Also attached to the upper spring retainer 468 a by fasteners are two or more cantilever springs 466 . Attached to each of the cantilever springs 466 by fasteners is a slip 464 . The cantilever springs 466 longitudinally couple the slips 464 to the J-runner 468 while allowing limited radial movement of the slips so that the slips may be set. Alternatively, the slips 464 may be pivotally coupled to the upper spring retainer 468 a instead of using the cantilever springs 466 . The slips 464 are tubular segments having circumferentially flat inner surfaces and arcuate outer surfaces. As discussed above, the flat inner surfaces of the slips 464 engage with the actuation surfaces 460 c of the slip mandrel 460 to form a rotational coupling. Alternatively, the rotational coupling between the inner surfaces of the slips 464 and the actuation surfaces 460 c of the slip mandrel 460 may be provided by straight splines, convex-concave surfaces, or key-keyways. Disposed on the outer surfaces of the slips 464 are teeth or wickers made from a hard material, such as tungsten carbide. When set, the teeth penetrate an inner surface of the production tubing 500 to longitudinally and rotationally couple the slips 464 to the production tubing 500 . The teeth may be disposed on the slips 464 as inserts by welding or by weld deposition. Each slip 464 is longitudinally inclined so that when the slip is slid along the actuation surface 460 c of the slip mandrel 460 , the teeth of the slip 464 will be wedged into the inner surface of the production tubing 500 .
FIG. 5A illustrates the PC pump assembly 400 being run-into a wellbore. Referring also to FIG. 4C , at the surface, when the PC pump assembly 400 is being assembled or made-up, the J-pin 470 is in the make-up position MUP. The PC pump assembly 400 is then inserted into the production tubing 500 . Alternatively, the anchor 450 may be configured to secure the PC pump assembly 400 to casing of a wellbore that does not have production tubing installed therein, or any other tubular located in a wellbore. The bow springs 472 engage the inner surface of the production tubing 500 and longitudinally and rotationally restrain the J-runner 468 (only longitudinally restrain the J-pin retainer 468 b ). The arrowhead 419 is engaged with the floating ring 422 , thereby supporting the weight of the stator subassembly. The drive string is then lowered into the wellbore. The J-mandrel 454 moves down while the J-runner 468 is stationary. The J-pin 470 contacts the inclined boundary of the J-slot 454 j at which point the J-pin retainer 468 b will rotate until the J-pin 470 is longitudinally aligned with the run-in portion 454 r of the slotted path 454 j,r,s . The J-mandrel 454 continues to move down the wellbore. The run-in pocket RIP reaches the J-pin 470 . The J-mandrel 454 then exerts a downward force on the J-runner 468 via the J-pin 470 which overcomes the frictional restraining force exerted by the bow springs 472 . The J-runner 468 then begins to slide down the production tubing 500 with the stator subassembly and the rest of the anchor subassembly 450 .
FIG. 5B illustrates the improved PC pump system in a preset position. Once the PC pump assembly 400 is lowered to the desired setting depth, the drive string is raised. The J-mandrel 454 moves upward while the J-runner 468 remains stationary. The J-pin 470 contacts another inclined boundary and rotates the J-pin retainer 468 b until the preset pocket PSP engages the J-pin 470 .
FIG. 5C illustrates the PC pump assembly 400 in a set position. The drive string is then lowered. The J-slot 454 j travels downward and then the J-pin 470 contacts another inclined boundary and rotates the J-pin retainer 468 b until the J-pin 470 is longitudinally aligned with the setting portion 454 s of the slotted path 454 j,r,s . The setting portion 454 s moves downward until the slips 464 engage the actuation surfaces 460 c . The slips 464 are moved radially outward into engagement with the production tubing 500 by engagement with the actuation surfaces 460 c . The slip mandrel 460 is held stationary by engagement with the slips 464 and the J-mandrel 454 continues a downward movement. The gage ring 456 compresses the sealing element 458 against the stationary slip mandrel 460 . The sealing element 458 radially expands into engagement with the production tubing 500 . At this point, the anchor 450 is set, thereby longitudinally and rotationally coupling the stator subassembly to the production tubing 500 .
FIG. 5D illustrates the PC pump system in a pre-operational position. The drive string continues to be lowered. The arrowhead 419 unseats from the floating ring 422 and the rotor subassembly moves downward. The floating ring 422 floats as the rotor 418 moves through the floating ring 422 . The rotor subassembly is lowered until the arrowhead 419 rests on the tag bar pin 435 .
FIG. 5E illustrates the PC pump assembly 400 in an operational position. After compensating for rod stretch, the drive string is slowly lifted until the arrowhead 419 is at a predetermined distance 505 , for example about 1 foot, above the tag bar pin 435 . The PC pump assembly 400 is now in the operational position and pumping of production fluid from the wellbore to the surface may commence.
FIG. 5F illustrates the PC pump assembly 400 in a flushing position. The rotor 418 is lifted by a second predetermined distance 510 , for example, the length of the rotor 418 . Preferably, the second distance 510 should be sufficient so that the rotor 418 is lifted out of the stator 430 and less than that which would cause the arrowhead 419 to engage with the floating ring 422 . The rotor 418 and the stator 430 may now be flushed of debris.
FIG. 5G illustrates the PC pump assembly 400 being removed from the wellbore. The drive string is lifted so that the arrowhead 419 engages with the floating ring 422 . Lifting is continued. The gage ring 456 moves upward allowing the sealing element 458 to longitudinally expand and disengage from the production tubing 500 . The slip mandrel retainer 462 engages the slip mandrel 460 and pushes the slip mandrel upward with the J-mandrel 454 , thereby disengaging the actuating surfaces 460 c from the slips 464 . The cantilever springs 466 push the slips 464 radially inward to disengage the slips 464 from the production tubing 500 . The setting portion 454 s of the slotted path 454 j,r,s moves upward relative to the stationary J-runner 468 . The J-pin 470 then engages an inclined boundary and rotates the J-pin retainer 468 b until the J-pin 470 is aligned and seats in the pull out of hole pocket POOH. The J-mandrel 454 exerts an upward force on the J-runner 468 which overcomes the frictional force of the bow springs 472 . The J-runner 468 then slides up the production tubing 500 with the stator subassembly. The PC pump assembly 400 may be raised to the surface where it may be serviced and/or replaced. Alternatively, and as discussed above, the PC pump assembly 400 may be raised or lowered to a second location along the production tubing 500 , re-installed, and further operated.
FIG. 6 shows an anchor assembly 600 for anchoring downhole tools to a tubular, in the wellbore according to an alternative embodiment. The anchor assembly 600 comprises a cap 602 , an inner mandrel 604 , a sealing element 606 , an anchor 608 , an engagement member 610 , an actuation assembly 612 , and an outer mandrel 614 . The actuation assembly 612 is adapted to selectively set and release the anchor 608 thereby engaging and disengaging the anchor assembly 600 with the tubular in a wellbore, as will be described in more detail below. The anchor assembly 600 may be coupled to any downhole tool including, but not limited to, any of the pumps described herein, packers, acidizing tools, whipstocks, whipstock packers, production packers and bridge plugs. Further, the anchor assembly 600 may be run into a tubular on any conveyance (not shown) including, but not limited to, a wire line, a slick line, a coiled tubing, a corod, a jointed tubular, or any conveyance described herein.
The anchor assembly 600 may include the cap 602 configured to couple the anchor assembly 600 to a downhole tool and/or a conveyance, not shown. The cap 602 , as shown, includes a threaded male end adapted to couple to a female end of the downhole tool and/or conveyance. It should be appreciated that any connection may be used so long as the cap 602 is capable of coupling to the downhole tool and/or conveyance. The cap 602 is coupled to the inner mandrel 604 with a threaded connection thereby preventing relative movement between the cap 602 and the inner mandrel 604 during operation of the anchor 608 . The cap 602 may have a lower shoulder 616 adapted to engage a gage ring 618 during the actuation of the anchor assembly, as will be discussed in more detail below.
The inner mandrel 604 is configured to move relative to the engagement member 610 , and the outer mandrel 614 in order to set and release the anchor 608 , as will be described in more detail below. As shown in FIGS. 7A and 7B , the inner mandrel 604 includes a slotted path 700 . The slotted path 700 may be adapted to engage and manipulate a J-pin 620 in order to set and release the anchor 608 . The inner mandrel 604 supports the sealing element 606 , the anchor 608 , the engagement member 610 , and the actuation assembly 612 . The inner mandrel 604 is manipulated by the conveyance, not shown, in order to operate the anchor 608 and the sealing element 606 .
The engagement member 610 may be any member adapted to engage the inner wall of a tubular, not shown, that the anchor assembly 600 is operating in. The engagement member 610 , as shown, is two or more bow springs 626 . The bow springs 626 are configured to compress radially inward when the anchor assembly 600 is inserted into the tubular, thereby frictionally engaging an inner surface of the tubular. The engagement member 610 is adapted to engage the inner wall of the tubular with enough force to prevent the engagement member from moving relative to the inner mandrel 604 during setting and unsetting operations of the anchor assembly 600 . The engagement member 610 , however, does not provide enough force to prevent the anchor assembly 600 from moving in the tubular during run, run out, and relocation in the tubular. The two or more bow springs 626 may be coupled on each end by an upper 628 a and a lower 628 b spring retainer. Further, the two or more bow springs 626 couple to the J-pin 620 , via the J-pin retainer 630 . The upper spring retainer 628 a engages a lower end of the actuation assembly 612 . This enables the engagement member 610 to manipulate the actuation assembly 612 . The actuation assembly in turn operates the anchor assembly 600 as the inner mandrel 604 manipulates the J-pin 620 in the slotted path 700 .
FIG. 7B shows the slotted path 700 with the J-pin 620 in the run in position. The operation of the J-pin 620 in the slotted path may be the same as described above. As the anchoring assembly 600 is being run in, or moved in the tubular, the J-pin 620 is in the run in position. The J-pin 620 remains in the run-in position as a downward force, such as gravity or force from the conveyance, is applied to the inner mandrel 604 in order to move the anchoring assembly 600 down the tubular. In the run in position the J-pin 620 is against an upper end of the slotted path 700 thereby preventing relative movement between the inner mandrel 604 and the engagement member 610 . Once the anchoring assembly 600 arrives at a desired setting position, the inner mandrel 604 is lifted up from the surface of the wellbore. As the inner mandrel 604 moves up, the engagement member 610 holds the J-pin 620 stationary due to the friction force between the two or more bow springs 626 and the tubular. The continued upward movement of the inner mandrel 604 and the slotted path 700 move the J-pin 620 into the preset position PSP. With the J-pin 620 in the preset position PSP, further upward pulling on the inner mandrel 604 causes the entire anchoring assembly 600 , including the engagement member 610 , to move up due to the J-pin being engaged with the lower end of the slotted path 700 . Thus, the upward movement of the inner mandrel 604 is typically stopped once the J-pin is in the preset position PSP.
The inner mandrel 604 may then be released or forced down from the surface. As the inner mandrel 604 moves down the engagement member 610 maintains the J-pin 620 stationary in the same manner as described above. As the inner mandrel 604 moves down relative to the J-pin 620 , the J-pin moves to the set position SP. The movement of the J-pin 620 between the preset position PSP and the set position SP causes the anchor assembly to set as will be described in more detail below. The J-pin will remain in the set position SP until it is desired to relocate the anchor assembly 600 . To release the anchor assembly 600 , the inner mandrel 604 is pulled up from the surface until a predetermined force is reached in the actuation assembly 612 . Once the predetermined force is reached, further pulling on the mandrel causes the J-pin 620 to move from the set position to the pull out of hole POOH position. In the pull out of hole POOH position, the J-pin 620 prevents relative movement between the engagement member 610 and the inner mandrel 604 with continued upward pulling on the inner mandrel 604 . If desired, the inner mandrel 604 may be released and the J-pin 620 is allowed to move back to the run in position RIP in order to move the anchoring assembly down and/or reset the anchoring assembly in the tubular without the need to remove the anchoring assembly from the tubular. In one embodiment, the predetermined force is greater than 5000 pounds of tensile force in the inner mandrel 604 . Although the predetermined force is described as being greater than 5000 pounds, it should be appreciated that the predetermined force may be set to any number, and may be as low as 100 lbs and as high as 50,000 lbs.
The sealing element 606 and the anchor 608 are set in a similar manner as described above. As the inner mandrel 604 moves down, the engagement member 610 maintains the outer mandrel 614 in a stationary position. The inner mandrel 604 moves the cap 602 against the gage ring 618 which in turn puts a force on the sealing element 606 and a floating slip block 642 . As the floating slip block 642 moves down, it engages one or more slips 644 and forces the one or more slips 644 radially outward. The one or more slips 644 continue to move outward between the floating slip block 648 and a stationary slip block 646 . The stationary slip block 646 may be coupled to the outer mandrel 614 and in turn the engagement member 610 thereby ensuring that the stationary slip block 646 remains stationary relative to the inner mandrel 604 and the floating slip block 642 as the J-pin 620 travels between the preset position PSP and the set position SP. When the J-pin 620 reaches the set position SP, the slips 644 are immovably fixed to the inner wall of the tubular as described above. Further, the sealing element 606 is engaged against the tubular thereby preventing flow past an annulus between the anchoring assembly 600 and the tubular.
The actuation assembly 612 may include two or more valves 632 , a first piston 634 , a second piston 636 , and a fluid located in a first piston chamber 638 and a second piston chamber 640 . The first piston 634 and the second piston 636 are fixed to the inner mandrel 604 . Further, the first piston 634 and the second piston 636 have a fluid seal, for example an o-ring, which seals the annulus between the inner mandrel 604 and the outer mandrel 614 .
The first piston chamber 638 , as shown in FIG. 6 , is defined by the space between the inner mandrel 604 , the outer mandrel 614 , the first piston and the two or more valves 632 . The second piston chamber 640 , as shown in FIG. 6 , is defined by the space between the inner mandrel 604 , the outer mandrel 614 , the second piston 636 and the two or more valves 632 . The two or more valves 632 control the flow of the fluid between the first piston chamber 638 and the second piston chamber 640 as the inner mandrel 604 is manipulated relative to the J-pin as will be described in more detail below.
FIG. 8 shows a cross sectional view of the two or more valves 632 . The two or more valves 632 include one or more one way valves 800 and at least one relief valve 802 , located in an annular body 804 . The annular body 804 may be located between the inner mandrel 604 and the outer mandrel 614 . In one embodiment, the annular body 804 is fixed to the outer mandrel 614 , while the inner mandrel 604 is allowed to move relative to the annular body 804 . It should be appreciated that in another embodiment the annular body 804 may be fixed to the inner mandrel 604 , while the outer mandrel 614 is allowed to move relative to the annular body 804 . Further, it should be appreciated that the general location and arrangement of the piston chambers, the valves, actuation assembly and the anchor may be moved so long as the actuation assembly can set and release the anchor.
The one or more one way valves 800 allow fluid from the first piston chamber 638 to flow into the second piston chamber 640 as the inner mandrel 604 moves down relative to the outer mandrel 614 . Once the fluid flows into the second piston chamber, the one or more one way valves prevent fluid flow back into the first piston chamber 638 . Thus, as the inner mandrel moves down from the preset position PSP to the set position SP, the one or more one way valves 800 allow the inner mandrel 604 to move down while preventing the inner mandrel 604 from moving up relative to the outer mandrel 614 . This ensures that the sealing element 606 and the anchor 608 are set and not released as the inner mandrel is moved down.
FIG. 6 shows the inner mandrel 604 and the J-pin 620 in the run in position RIP. In order to move the inner mandrel 604 and thereby the J-pin 620 to the preset position PSP, the inner mandrel 604 , the first piston 634 , and the second piston 636 must move up relative to the J-pin 620 and the outer mandrel 614 . The upward movement of the inner mandrel 604 causes the second piston chamber 640 to lose volume and the first piston chamber 638 to gain volume. However, one or more one way valves 800 and at least one relief valve 802 will not allow fluid to flow through the one or more valves 632 without increasing the pressure to the predetermined pressure to activate the relief valve 802 . Therefore, a fluid path 900 , shown in FIG. 9A , provides a bypass of the two or more valves 632 . The fluid path 900 is open when the J-pin 620 is in the run in position RIP. Therefore, as the J-pin 620 moves down relative to the inner mandrel 604 from the run in position RIP to the preset position PSP, fluid freely bypasses the two or more valves 612 . This allows the volume in the first piston chamber 638 to increase as the J-pin 620 moves to the preset position. The movement of the inner mandrel 604 and the J-pin 620 to the preset position closes the fluid path 900 . Thus, when the inner mandrel 604 begins to move from the preset position PSP to the set position SP, the fluid may only move between the first piston chamber 638 and the second piston chamber 640 through the two or more valves 632 .
In one embodiment, the fluid path 900 is opened and closed by a moveable seal 902 moving from an unsealed to a sealed position. The moveable seal 902 is not seated in a groove 904 when the J-pin is in the run in position RIP. When the inner mandrel 604 begins to move down toward the preset position PSP, the inner mandrel 604 pushes the moveable seal 902 into the groove 904 thereby sealing the two or more valves 632 between the inner mandrel 604 and the outer mandrel 614 . The moveable seal 902 remains in this position until the anchor is ready to be removed from the tubular. The movement of the J-pin 620 between the pull out of hole position POOH and the run in position RIP moves the moveable seal 902 from the sealed position to the unsealed position thereby opening the fluid path 900 .
In an alternative embodiment, the seal is not moved and a fluid resistor (not shown) is used in addition to or as an alternative to the relief valve 802 . The fluid resistor allows fluid to flow slowly past the two or more valves 632 if a continuous force and fluid pressure is applied to it. The fluid resistor will not allow fluid past it in the event of quick impact loads. Therefore, as the inner mandrel 604 moves from the run in position RIP to the preset position PSP, the fluid resistor slowly allows the fluid to move from the second piston chamber 640 to the first piston chamber 638 . Once the J-pin is in the preset position PSP, the one way valves 800 allow the inner mandrel 604 to operate in the manner described above.
To release the anchor 608 , the inner mandrel must be moved from the set position SP to the pull out of hole position POOH. A tensile or upward force is applied to the conveyance thereby causing the inner mandrel 604 to attempt to move up relative to the J-pin 620 , the two or more valves 632 , and the outer mandrel 614 . This upward force puts the fluid in the second piston chamber 640 into compression. The one way valves 800 prevent the fluid from flowing past the two or more valves 632 . The increased pulling on the inner mandrel 604 increases the pressure in the second piston chamber 640 until the predetermined pressure of the relief valve 802 is reached. The predetermined pressure causes the relief valve 802 to go off thereby allowing the fluid in the second chamber 640 to freely flow into the first chamber 638 . This allows the inner mandrel 604 to move up thereby releasing the anchor 608 and the sealing element 606 . When the J-pin 620 has reached the pull out of hole position POOH, the anchor 608 is no longer engaged with the tubular. The relief valve 802 may automatically reset once the fluid pressure in the second piston chamber 640 is relieved.
Thus, in the alternative embodiment the anchor assembly 600 is run into the hole with the J-pin 620 in the run in position RIP. The engagement member 610 engages the inner wall of the tubular. The anchor assembly 600 travels in the tubular until a desired location is reached. The inner mandrel 604 is then lift up and the engagement member 610 maintains the J-pin 620 , the outer mandrel 614 , the two or more valves 632 , and the stationary slip block 646 in a stationary position. The upward movement of the inner mandrel 604 causes the second fluid chamber 640 to lose volume thereby pushing fluid past the fluid path 900 into the first fluid chamber. The continued movement of the inner mandrel 604 moves the J-pin 620 from the run in position RIP to the preset position PSP. As the inner mandrel 604 moves from the run in position RIP to the preset position PSP the moveable seal 902 is set thereby sealing the two or more valves 632 between the outer mandrel 614 and the inner mandrel 604 . The sealing element 606 and the anchor 608 may then be set by removing the upward force from the inner mandrel 604 and allowing the inner mandrel to move down thereby moving the J-pin 620 to the set position SP. The downward movement of the inner mandrel 604 causes the cap 602 to engage the gage ring 618 . The gage ring 618 applies force to the sealing element 606 and the floating slip blocks 642 . The floating slip block 642 wedges the slips 644 against the stationary slip blocks 646 thereby moving the slips 644 radially outward and into engagement with the inner wall of the tubular. The compression of the sealing element 606 causes the sealing element to sealing engage the inner wall of the tubular. As the inner mandrel 604 moves from the preset position PSP to the set position SP, the fluid path 900 is closed. With the anchor assembly 600 set in the tubular, a downhole operation may be performed. In one example a progressive cavity pump, as described above, is used to pump production fluid from the tubular.
The downhole operation is performed until it is desired to move or remove the anchor assembly 600 from the tubular. To disengage the anchor assembly 600 , the inner mandrel 604 is pulled up. This causes the pressure in the second piston chamber 640 to increase due to the one way valves 800 not allowing flow past the two or more valves 632 . The pressure is increased in the second piston chamber 640 until the relief valve 802 is set off. The fluid is then free to flow to the first piston chamber 638 thereby allowing the inner mandrel 604 to move up relative to the slips 644 and the outer mandrel 614 . The upward movement of the inner mandrel 604 causes the slips 644 and the sealing element 606 to disengage the tubular. The inner mandrel 604 now has the J-pin in the pull out of hole position. If desired, continued pulling on the conveyance will remove the anchor assembly 600 from the wellbore. If it is desired to relocate and/or reset the tool downhole, the inner mandrel 604 is allowed to move down relative to the engagement member 610 . This allows the inner mandrel 604 and the J-pin 620 to move back to the run in position RIP. As the inner mandrel 604 moves toward the run in position RIP, the fluid path 900 is reopened. The anchor assembly is now free to move to a second location in the tubular and perform another downhole operation.
While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
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Embodiments of the present invention generally relate to methods and apparatuses for anchoring progressing cavity (PC) pumps. In one embodiment, a method of anchoring a PC pump to a string of tubulars disposed in a wellbore which includes acts of inserting the PC pump and anchor assembly into the tubular. Running the PC pump and anchor assembly through the tubular to any first longitudinal location along the tubular string. Longitudinally and rotationally coupling the PC pump and the anchor assembly to the tubular and forming a seal between the PC pump and the tubular string at the first location and performing a downhole operation in the tubular.
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BACKGROUND OF THE INVENTION
[0001] I. Field of the Invention
[0002] The present invention is directed primarily to truck bodies designed specifically for refuse hauling trucks and, more particularly, to an improved packing and ejection mechanism control system for rear loading, rear discharging refuse truck bodies which enables the front-to-rear packing density of packed material to be varied within a load to thereby shift more of the refuse weight forward in the storage compartment of the refuse truck body to achieve improved load balance.
[0003] II. Related Art
[0004] Refuse collection trucks commonly include a truck chassis fitted with a distinctly configured body specifically designed for receiving, compacting, hauling and discharging refuse materials and including all of the associated operated mechanisms. One very successful design of refuse hauling truck bodies is known as a “rear loader” and includes a refuse hauling reservoir accessible for loading and discharging from the rear of the vehicle. This system includes a hydraulic compacting mechanism which repeatedly compacts the refuse after each loading. In this manner refuse eventually fills the available or useable reservoir volume extending from the front end back toward the rear of the body until no more material can be compacted. The forward wall against which the refuse is compacted in a typical rear loading refuse truck body also is the packing/ejection panel of a cylinder-operated ejection mechanism which, in effect, during an ejection cycle moves the panel aft on a horizontal plane in the manner, of a plow to expel the entire contents of the refuse volume during ejection. Typically, the bottom portion of the ejection mechanism is supported on a plurality of load bearing sliders carried by rails and adapted to slidably support the ejector system just above the truck body floor. The ejector system is operated by a hydraulic cylinder which typically mounts in the front of the truck body and is connected to the rear portion of the ejector panel, i.e., behind the face of the panel. By way of definition, this cylinder is referred to as the packing cylinder, ejection cylinder and packing/ejection cylinder. Likewise, the ejector panel may be referred to as the packing panel. These names arise from the fact that refuse is packed against the packing or ejector panel and the resistance of the packing or ejector panel to being pushed back is controlled by the packing/ejection cylinder.
[0005] The operation of the cylinder to position the ejector system is two-fold. When the cylinder is fully retracted the ejector is in the fully forward position as when the truck is fully loaded with refuse. When the cylinder is fully extended the ejector mechanism if moved fully aft to the truck body to a position where refuse will be completely expelled. At the beginning of the packing operation with the reservoir empty, the ejection mechanism and panel are positioned in the rearward portion of the truck body with the ejector mechanism exhibiting a preset resistance to retreating toward the forward end of the body. This is accomplished by controls which adjust the pressure in the ejection cylinder to a predetermined fixed amount. As this is exceeded, fluid is expelled from the cylinder and the piston rod retracts. This causes the ejection mechanism to retreat toward the front of the truck body as it is pushed ahead of the packed refuse against a constant resistance until the truck body is fully filled which, more or less, produces a load of substantially uniform packing density.
[0006] A rear loading, rear-discharging refuse body packing density control typically is one in which the hydraulic system is provided with a tailgate/ejector spool valve assembly which is typically located on the left or right front of the rear loader body and which has a dedicated open center sensing hydraulic cartridge in the ejector valve work section to control the ejector cylinder pressure. Other rear loader hydraulic systems use separate manifold assemblies to sense pressures within the packing cylinder. As previously indicated, all of these systems attempt to maintain a constant density in the refuse throughout the entire load.
[0007] A common problem with rear loading, rear discharging refuse packers of the class involves the weight distribution of the load. The packing process is designed to pack the load to a substantially uniform density from front to rear. However, rear loaders have a heavy tailgate assembly and large hopper for loading refuse that are located aft of the rear wheels of the chassis. The rear loader tailgate typically also contains large hydraulic spool valves, controls, slide and sweep assemblies and four large hydraulic cylinders to operate slide and sweep functions of the packing sequence. The rear loader tailgate may also carry optional devices such as cart tippers, tipper bars, winches and other accessories installed requiring yet more additional hydraulics and controls thereby adding still more weight aft. All of these components add to the weight of the rear loader tailgate and can cause the total tailgate weight to approach 10,000 lbs. (4,535 kg.) on some models. The added weight behind the chassis rear wheels makes it difficult for the front axle to reach or come close to its legally allowed gross front axle weight limit when the packer is loaded by the time the rear axles reach their gross weight rating. At that time, the rear loader has packed its maximum allowable payload even though the front axle may not be fully loaded or the body reservoir completely full. When the rear axles of the rear loader are at the maximum legal payload, the rear loader driver must leave the route and travel to the transfer station or landfill to unload.
[0008] Thus, there has existed a definite need to shift additional weight forward in the packer body storage reservoir so that more of the load is carried by the front axle so that the front axle will approach the gross weight limit when the rear axles are at the gross weight limit thus permitting trucks of the rear loader class to legally transport a greater total payload.
SUMMARY OF THE INVENTION
[0009] By means of the present invention there is provided a packing control system for a rear loading, rear discharge refuse packing body that enables adjustability in the overall weight distribution of the packed refuse. The packing density control system of the invention involves controlling the resistance of the packing/ejection panel against which refuse is packed in a rear loading refuse collection truck body so that the force necessary to cause the panel to retreat toward the front of the truck as refuse is packed in front of it can be varied in accordance with the desired density of the load as it is packed.
[0010] The variable packing density control system of the invention uses a detection system to sense the position of the packer/ejection panel within the vehicle and uses this information to control the pressure in the ejection cylinder which determines the resistance of the packing/ejection panel to the material being packed against it. Preferably, the system is controlled such that refuse material packed closest to the packing/ejection panel is subjected to higher packing force and thereby achieves a higher packing density. This translates to a higher packing density in the forward portion of the load when the packing/ejection panel retreats to its fully loaded position at the front of the refuse collection body.
[0011] In one preferred embodiment, the system utilizes one or more proximity or mechanical switches to sense angular position of the ejection cylinder which is normally attached between the forward portion of the refuse container body and the packing/ejection panel in a top-to-bottom relation which angle increases as the packing/ejection panel retreats toward the front of the refuse container body before the mass of packed refuse. When this angle reaches certain predetermined value, the packing density is switched usually from a higher to a lower amount in accordance with hydraulic control valve settings. It is also possible to use a system which modulates the pressure as the packing/ejection panel retreats to gradually change the packing density.
[0012] In this manner, the densest part of the load is shifted to the front of the refuse container body and therefore additional weight is transferred from the rear axles to the front axle thereby increasing the nominal capacity of the refuse vehicle by as much as about a ton.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] In the drawings wherein like reference characters refer to like parts throughout the same:
[0014] FIG. 1 is a side elevational view of a rear loading, rear discharging refuse vehicle of the class suitable for using the load density control system of the invention;
[0015] FIG. 2 is a schematic diagram of a hydraulic load density control system in accordance with one embodiment of the invention;
[0016] FIG. 3 is a schematic diagram of a hydraulic load density control system in accordance with another embodiment of the invention; and
[0017] FIG. 4 is a side elevational view of a refuse reservoir of a rear loading, refuse collection body with the sidewall removed showing the ejector panel in a plurality of positions.
DETAILED DESCRIPTION
[0018] It will be understood that the invention may be embodied in different forms and that various uses may be made of the principles explained, pray the invention will be described with reference to an embodiment to illustrate these principles but that embodiment is meant as an example of the invention only and not as a limitation on the scope in any manner.
[0019] FIG. 1 of the drawings is a side elevational view of a rear loading/rear discharge refuse vehicle of the class suitable to be equipped with the variable packing density system of the present invention and includes a tailgate 10 attached to a storage body 12 and a cabin chassis portion 14 . The tailgate 10 includes an open loading hopper 16 which has a curvilinear bottom wall 18 and a large receiving opening generally designated 20 for receiving refuse which may be from containers tipped over a sill, or the like, as at 22 . The cab and chassis unit further includes a pair of dual wheel rear axles 24 and 26 and a front axle is shown at 28 . As seen in the figure, the entire weight of the tailgate 10 is carried behind the rear axles 24 and 26 . The tailgate unit carries the well known hydraulic sweeping and packing equipment (not shown) and possibly cart tipping or other such devices attach thereto at the sill 22 as are commonplace (also not shown) As can be seen from the figure, even when the truck is fully loaded, the great majority of the weight is carried by the rear axles which may well reach their legal axle weight capacity prior to the front axle loading being near capacity, as was previously indicated.
[0020] FIG. 4 depicts a truck body with the tailgate removed and the side cut away so that the packing/ejector blade operating system can more readily be viewed. It includes a hollow truck body generally at 40 including longitudinal and transverse structural support members 42 and 44 which support a metal floor plate 46 . The body further includes top structural members as at 50 and a far side wall 52 , also of metal plate. The packing/ejection panel extends essentially from near the top to near the bottom of the interior of the truck body storage reservoir and also extends substantially from side to side. It includes a top angled segment 54 , a substantially vertical segment 56 and a second angled segment 58 which together form the panel structure. The packing/ejection panel which may generally be referred to as 60 is operated by a telescoping fluid-operated (normally hydraulic) cylinder, generally at 62 , having telescoping segments 64 , 66 and 68 . The cylinder is preferably mounted at an angle with the rod end pivotally mounted in the lower front portion of the collector body reservoir as at 70 and the blind or cylinder end pivotally mounted to the upper portion of the structure 60 in segment 54 as at 72 . Of course, the rod end and the cylinder end of the cylinder 62 may be reversed, however, the mounting is depicted in FIG. 3 as preferred inasmuch as the fluid connection to the cylinder 62 is preferably through the rod end in segment 68 .
[0021] The system is shown in three locations, namely, in the far forward or fully packed location, in a midway location and at the full eject location with the cylinder 62 fully extended. The latter position fully expels the contents of the refuse container reservoir and is the position utilized at the beginning of the packing cycle where refuse is again packed into the hollow container reservoir. Thus, as refuse is packed against the packing/ejection panel 60 , as the packing force exceeds the force exerted by the cylinder 62 , the cylinder begins to retract and the system moves toward the front end of the container reservoir.
[0022] FIG. 2 depicts a schematic diagram of one variable packing density hydraulic system for a rear loading refuse truck configured in accordance with one embodiment of the invention. The system illustrated in FIG. 2 , as shown generally at 100 , is designed to pack refuse in three different controlled segments which may be at three different densities based on three different packing pressure operating control settings which can be adjusted as desired. This system includes a tailgate/ejector spool valve assembly 102 and a manifold assembly generally within the broken line 138 and which includes a pair of pressure-biased valves in the form of variable density or adjustable auxiliary packing cartridges including a first variable density adjustable auxiliary packing cartridge 104 and a second variable density or adjustable auxiliary packing cartridge 106 . Each auxiliary packing cartridge is associated with a respective control valve which, when open, connects the adjustable auxiliary packing cartridge with the barrel end of the cylinder 62 . These access valves are preferably two-way, two-position (2W2P) normally closed (NC) cartridge valves as at 108 and 110 . Likewise, however, other known valve systems such as three-way, three position (3W3P) valves, etc., could also be used in this application. A return line metering outlet orifice is shown at 112 .
[0023] Rearward and forward position sensing devices 114 and 116 are provided which may be proximity detecting devices, mechanical switches or any other such devices that are capable of sensing the extension position of the cylinder 62 as will be explained. The sensing devices 114 , 116 also act as signaling devices to open respective (2W2P) NC cartridges 108 and 110 . Thus, proximity-detecting the device 114 is connected to cartridge valve 108 via electrical signal line 118 to valve operating coil 120 and proximity detecting device 116 is likewise connected to cartridge valve 110 via electric signal control line 122 to valve operating coil 124 . The normally closed cartridge valve 108 together with the first adjustable auxiliary packing cartridge 104 are used to control a second packing pressure in the rear loader and the second adjustable auxiliary packing cartridge 106 operating in conjunction with the control cartridge valve 110 controls the packing at a third predetermined packing pressure utilizing signals from the respective position detecting devices 114 and 116 in conjunction with packing system pressure as will be discussed.
[0024] The first and second auxiliary packing cartridge assemblies 104 and 106 are designed to operate exclusive of each other and can be set to open at any pressure below that of the ejector spool valve (below). A hydraulic fluid supply/drain line 126 is connected between spool valve assembly 102 and the barrel end of cylinder 62 . The line 126 further connects to cartridge 108 via line 128 and cartridge 110 via line 130 . Lines 128 and 130 are used for drainage from the barrel end of cylinder 62 . Separate outlet or drain lines are provided at 132 and 134 with regard to the auxiliary packing cartridges 104 and 106 , respectively, which join into a common line 136 above the metering orifice 112 . The broken line 138 depicts the manifold assembly containing the auxiliary control assembly.
[0025] The tailgate/ejector spool valve assembly 102 includes an ejector work valve 140 , including a packing cartridge 142 , a tailgate work valve 144 , an inlet which may have an unloader spool 146 , which also includes a main relief valve, and the inlet for the oil line for the pump connected to an associated flow controller (not shown). An outlet is shown at 148 with return or drain line 150 . The packing devices and equipment themselves may be conventional and are generally known and need no further explanation here. An open center pilot pressure line is connected to both auxiliary packing cartridges 104 and 106 as shown as 152 .
[0026] The general packing operation also is quite well known and is accomplished by sweeping refuse from the charging hopper using a pair of sweep cylinders and using a pair of slide cylinders to move a slide and pack the refuse against the ejector panel which retreats incrementally as the associated packing cartridge valve opens and closes based on system pressure. The hydraulic pressure required to open the associated packing cartridge valve is preset at a pressure somewhat below the maximum operating or kick out pressure of the slide cylinder, the amount being dependent on the desired packed refuse density. The initial packing pressure will be determined by the setting of the ejector work valve packing cartridge 142 .
[0027] If the slide cylinder kick out pressure is 2450 psi, for example, the valve packing cartridge 140 / 142 may be set at 2250 psi. The pressure in the packing or slide cylinders also appears in the open center pilot pressure line 152 . The auxiliary sequential packing cartridges 104 and 106 are normally set to open at different, lesser values x and y to modulate packing density toward the rear of the load as desired, or at the same value. As previously stated, the control system provides for independent operation of the auxiliary packing cartridges 104 and 106 , however, they are both subject to the maximum setting in the spool valve packing/ejection cartridge 138 which remains in a control mode.
[0028] In operation, at the beginning of the packing cycle the container reservoir body 40 is empty and the ejector panel is in the far rearward position (cylinder 62 fully extended). Refuse is loaded into the receiving hopper, it is packed into the rear loader body against the packing panel 60 using the slide cylinders thereby applying forces against the packing panel 60 . The pressure in the slide cylinders increases as the slide moves up to pack refuse in the truck body as does the resisting pressure in the packing/ejection cylinder 62 . At this time, the maximum pressure in the packing/ejection cylinder 62 is set to the maximum desired pressure so that the material packed against the packing panel 60 will be at maximum density.
[0029] When the necessary maximum packing force is achieved based on open center pressure of the ejector work valve 140 or the pressure in the slide cylinders, the packing cartridge valve is opened for a fraction of a second allowing a small amount of hydraulic fluid to be released from the barrel end of the packing/ejection cylinder 62 which will allow the cylinder to incrementally retract and allow the next refuse to be packed. The controlled level of the hydraulic pressure in the packing/ejection cylinder in the time of each incremental release, of course, will determine the density of the refuse packed at that point.
[0030] In accordance with one aspect of the invention, as indicated, the ejector work valve 140 is designed to control the density of the initial portion of the packed refuse at a very high density in accordance with the need for shifting cargo weight toward the front of the vehicle. As the packing/ejection cylinder 62 retracts, the sensor 114 will be able to identify the angle of the packing/ejection cylinder or otherwise determine the packing/ejection panel position and electrically signal the operator coil 120 which energizes opening 2W2P NC cartridge 108 . This is at the point where it is indicated that the high or first density portion of the load should end. This switches the normally closed cartridge 108 to the open position which switches control of fluid release switches to packing cartridge 104 . This allows hydraulic fluid to meter from the barrel end of the packing/ejection cylinder through and based on the operation of the variable density packing cartridge 104 and the orifice 112 based on the pressure as determined by the setting (x) of variable density cartridge 104 as it is equaled by the pressure in open center pilot pressure line 152 . This changes (normally lowers) the density of the refuse packed in accordance with the setting (x).
[0031] Likewise, as the packing/ejection cylinder 62 continues to retreat, it will move beyond sensor 114 and control will be switched to the second sensor 116 which will cause cartridge 110 to open and allow the system to change or maintain the density of the load in a like manner based on the setting (y) of the auxiliary packing cartridge 106 . Thus, the electrical signal from the sensor 116 will travel on line 122 to operator coil which will be energized to open the normally closed 2W2P cartridge 110 and allow the auxiliary packing cartridge 106 to control the draining of fluid utilizing the open center pilot pressure in line 152 . The setting (y) may be different, usually lower, than the setting (x) or may be the same depending on the desired loading density profile.
[0032] Generally, in accordance with an aspect of the present invention, it is desirable to have the highest packing density near the front of the loaded vehicle and the lowest packing density at the rear to compensate for the heavy tailgate. Thus, generally the initial setting of ejector work valve >x>y.
[0033] The sensors 114 , 116 , of course, can be adjusted to sense the varying angles of the packing/ejection cylinder and base control on the deserved legal weight distribution of the packer/chassis combination. As indicated, the sensors 114 , 116 may be any type of suitable proximity detection device or any kind of a tripable mechanical limit switch or the like in addition to being one which senses the angle of the cylinder rod or senses the linear position of the packing/ejection panel as the packing/ejection panel retreats toward the front of the rear-loading vehicle.
[0034] The system has been illustrated in FIG. 2 as a 3-position, 3-density (high/lower/low) system; however, a simpler 2-density (high/low) system can be provided, for example, that will allow any desired high/low density profile to be implemented along the load. Such a system is illustrated in FIG. 3 which depicts a schematic hydraulic system diagram of another embodiment of a variable packing density system which is otherwise similar to that of FIG. 2 , but which is designed to pack refuse at two different densities based on two different packing pressure controls. This system, generally at 200 , also includes a tailgate/ejector spool valve assembly 202 and a single auxiliary packing cartridge 204 , shown within a manifold assembly designated by broken line 206 . Variable density auxiliary packing cartridge 204 with adjustable operating pressure (z) is associated with (2W2P) normally closed (NC) cartridge 208 with operating coil 210 which is connected by a signal line 212 to a single position sensing device 214 .
[0035] The tailgate/ejector spool valve assembly 202 includes an ejector work valve 216 with packing cartridge 218 , a tailgate work valve 220 , an inlet which may have an unloader spool 222 which also includes the main relief valve and the inlet for the oil line for the pump connected to an associated flow control (not shown) and an outlet 223 with return or drain line 224 . This assembly may be the same as that shown and discussed in conjunction with FIG. 2 .
[0036] An open center pilot pressure line 226 is connected to a variable density auxiliary packing cartridge 204 . A hydraulic fluid supply/drain line connecting to the barrel end of cylinder 62 is shown at 228 . A line 230 connects line 228 with the normally closed cartridge 208 which also is provided with an outlet drain 232 , orifice 234 and drain 236 . The operation of this system is similar to the operation of the system described in conjunction with FIG. 2 except that only a single sensor is used and packing density continues to be controlled by the variable density auxiliary packing cartridge 204 for the rest of the load.
[0037] Both systems are quite useful; a certain packer, for example, may require the front half of the load to be very dense and the last half to be less dense. Another packer and chassis combination may require the first third of the load to be very dense and the middle third lighter and the last third of the load to be lighter still. The correct combination should be determined by initially weighing the packer and chassis to achieve the best legal axle weights. In this manner, more weight can be safely shifted forward in the loaded packer while maintaining operation of the vehicle well within the GVW weight limits or axle capacity weight limits as determined by local, state and Federal laws.
[0038] It should be noted that the telescoping packing/ejection cylinder is shown mounted with the rod end of the cylinder in the lower forward position of the packer body reservoir and the barrel end elevated against the packer panel upper section 54 . As with other exemplary illustrations, other mounting positions such as mounting the rod end at the top of the forward portion of the truck body container refuse reservoir with the barrel end against the lower panel portion 58 are contemplated.
[0039] This invention has been described herein in considerable detail in order to comply with the patent statutes and to provide those skilled in the art with the information needed to apply the novel principles and to construct and use such specialized components as are required. However, it is to be understood that the invention can be carried out by specifically different equipment and devices, and that various modifications, both as to the equipment and operating procedures, can be accomplished without departing from the scope of the invention itself.
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The disclosure describes a packing control system for a rear loading, rear discharge refuse packing body that enables adjustability in the overall weight distribution of the packed refuse. The packing density control system involves controlling the resistance of the packing/ejection panel against which refuse is packed in a rear loading refuse collection truck body so that the force necessary to cause the panel to retreat toward the front of the truck as refuse is packed in front of it can be varied in accordance with the desired density profile of the load as it is packed.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is related to U.S. patent application Ser. No. 09/887,939 filed Jun. 22, 2001, incorporated by reference herein.
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] The receiver of a hearing instrument, the component that generates the sound heard by the instrument's user, contains an electromechanical transducer similar to a loudspeaker held within an enclosure. If the receiver comes into physical contact with the inside of the hearing instrument or perhaps another component, vibration generated by the action of the receiver may be transferred to the housing and then to the microphone which would be amplified and provided to the input of the receiver, thus resulting in feedback. A resilient and compliant mount for the receiver can help prevent the creation of such a feedback path.
[0003] In one arrangement, the receiver is supported on one side by a semi-rigid receiver tube. A flexible tether having resilient qualities, made from a material such as rubber or an elastomer, supports and anchors the other side of the receiver. Alternatively, studs fashioned from a material such as rubber or an elastomer and projecting outwardly from opposite faces of the receiver and positioned in a cradle on the inside wall of the housing may also be employed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] [0004]FIG. 1 is a partial cross-sectional view of a hearing instrument housing;
[0005] [0005]FIGS. 2 and 3 are exterior and cross-sectional views, respectively, of a receiver tube;
[0006] [0006]FIGS. 4 and 5 are two orthogonal views of a receiver with a tether;
[0007] [0007]FIGS. 6-8 are orthogonal views of the tether of FIGS. 4 and 5;
[0008] [0008]FIGS. 9 and 10 are drawings of alternative tether sections for the tether of FIGS. 6-8;
[0009] [0009]FIGS. 11-13 are orthogonal views of a tether having two anchor points;
[0010] [0010]FIG. 14 is a cross-sectional view of a receptacle in a hearing instrument housing for a receiver tube;
[0011] [0011]FIG. 15 is a partial cross-sectional view of another arrangement of a hearing instrument housing;
[0012] [0012]FIG. 16 is a flow chart of a procedure for designing a tether and assembling the hearing instrument; and
[0013] [0013]FIGS. 17 and 18 are two orthogonal views of a combined receiver boot with a tether; FIG. 19 illustrates the receiver boot positioned in a hearing instrument shell.
DESCRIPTION OF THE INVENTION
[0014] [0014]FIG. 1 is a partial cross-sectional view of a hearing instrument housing 10 and a receiver assembly 100 (enclosing the receiver mechanism) positioned therein. A flexible receiver tube 200 having some degree of resilience and compliance, also shown in FIGS. 2 and 3, is attached to the receiver assembly 100 to convey sound to the outside of the instrument housing 10 .
[0015] The tube 200 may be fabricated from a synthetic material such as an elastomer or any other suitable material. One such elastomer is marketed by DuPont Dow Elastomers, L.L.C. under the trademark Viton. A receptacle 20 within the instrument housing 10 accepts the receiver tube 200 and, in conjunction with the tube 200 , provides support for the receiver assembly 100 . The flexible receiver tube 200 reduces the vibration that would otherwise be induced in the housing 10 when the transducer mechanism within the receiver assembly 100 operates. Further, should the hearing instrument be dropped, the tube 200 would absorb some of the stress induced by the impact and prevent the receiver assembly 100 from shifting its position within the hearing instrument housing 10 .
[0016] If supported solely by the receiver tube 200 , given sufficient force, the receiver assembly 100 could shift within the housing 10 , making contact with the wall 12 of the housing or perhaps another component within the housing 10 , and providing a path for feedback. To prevent this from happening, the receiver assembly 100 may be secured within the instrument housing 10 .
[0017] In FIG. 1, a tether 300 attached to the receiver assembly 100 functions as an anchor and may also provide support to the receiver assembly 100 . The tether 300 exhibits the properties of resilience and compliance, and may be fabricated from a flexible material such as the previously-mentioned Viton elastomer or another similar material, and may be affixed to the receiver assembly 100 with a glue such as a cyanoacrylate or by some other means. The tether 300 has a ball 310 held in a socket 410 fabricated in the wall 12 of the housing 10 (assuming the necessary degree of thickness) or in an optional platform 420 extending out from the wall 12 , or in some other suitable fixture. To further secure the tether 300 , glue may be applied to the ball 310 to insure that it remains in the socket 410 .
[0018] Alternatively, another shape and securing mechanism could be substituted for the ball 310 and the socket 410 , such as a wedge, a hook, or a ring that mates with a post. Alternatively, a slot provided in the housing 10 could receive the tether 300 and then secured with glue.
[0019] The tether 300 is shown attached to the receiver assembly 100 in the orthogonal view of FIGS. 4 and 5 and then by itself in the orthogonal views of FIGS. 6-8. As can more easily be seen in FIGS. 6 and 7, the ball 310 is at the end of a tether section or member 302 (the region to the left of the dashed line in FIG. 7). The tether section 302 is roughly triangular in shape, narrowing down where it meets the ball 310 . If greater flexibility is desired, the tether section 302 could assume a more rectangular shape by decreasing the width of the tether section 302 , i.e., the length of the dashed line 304 , as illustrated in FIG. 9. Alternatively, the tether section 302 could have a parabolic taper, as shown in FIG. 10.
[0020] Optionally, a strain relief tab 320 may be provided for anchoring the wiring 110 connected to the receiver assembly 100 (see FIG. 4). The wiring 110 is soldered to terminals 120 on the receiver assembly 100 and affixed to the strain relief tab 320 with glue 330 or any other suitable means.
[0021] As can be seen in FIG. 8, the tether 300 may have a lengthwise right-angle cross-section, although other structures such as a U-shaped channel or a flat rectangular shape may be utilized. The angle cross-section aids in the attachment of the tether 300 to the receiver assembly 100 and also provides a surface for the strain relief 320 .
[0022] If the receiver 100 is sufficiently large, a tether having two attachment points may be desired. FIGS. 11-13 illustrate such a configuration.
[0023] To assist with the assembly and registration of the receiver assembly 100 and the receiver tube 200 , a spline 210 , visible in FIGS. 2 and 3, is provided along a portion of the tube 200 and mates with a keyway 22 in the receptacle 20 in the housing 10 (see FIG. 14). The spline 210 assures that the receiver assembly 100 is oriented (radially about the receiver tube 200 ) in the desired position. A flange 220 limits the travel of the tube 200 within the receptacle 20 where it butts up against the inside wall 24 at the entrance to the receptacle 20 .
[0024] In the orientation of the receiver assembly 100 shown in FIG. 1, the primary component of vibration generated by the action of the receiver mechanism would be perpendicular to the page, emanating from the face 130 of the receiver assembly 100 . The receiver tube 200 and the tether 300 minimize the amount of vibration coupled to the housing given such an orientation.
[0025] An alternative support arrangement for the receiver assembly 100 is shown in FIG. 15. There, a cradle 500 has two slots 510 in side plates 520 that accepts an axle-assembly 150 comprising rubber studs 160 projecting outwardly from opposite faces of the receiver assembly 100 . The receiver assembly 100 is held in place in part by tips 530 of the side plates 520 and allowed to rotate about the studs 150 .
[0026] A procedure for positioning the components within an instrument housing 10 and creating the tether 300 is shown in the flow chart of FIG. 16. Initially, a three-dimensional description of the largest volume that the hearing instrument housing 10 could occupy is required, based on the geometry of the user's ear canal and adjoining ear structure if the hearing instrument extends to the outer ear.
[0027] The components of the instrument are then determined and three-dimensional models or representations of those components are pre-positioned within the housing volume determined above. The representations are positioned in a manner that minimizes the internal volume of the housing 10 required to house the items. A test for collision detection is then performed to insure that the placement of any given component does not interfere with another component, and any necessary adjustments are performed. This is an iterative process, performed until a satisfactory configuration is achieved. In turn, the outer dimensions of the housing 10 are determined, i.e., the minimum size required to house the pre-positioned components. Since the cross-section at any given point in the ear canal is fixed, the size of the housing 10 can be adjusted by varying its length.
[0028] The tip 30 of the hearing instrument housing 10 is then filled creating a filled-in volume or tip fill 32 to provide the surrounding structure for the receiver tube receptacle 20 and a surface 24 for the receiver tube flange 220 (see FIGS. 1 and 14). The depth of the tip fill 30 may be set to allow for the desired length of the receiver tube 200 between the flange 220 and the receiver assembly 100 . This length is selected based in part on the flexibility of the receiver tube 200 and the desired stiffness and resilience.
[0029] Since the position of the receiver assembly 100 within the housing 10 is now known, the dimensions of the tether 300 can be determined. If the configuration of FIG. 1 is used, the optional platform 420 is located on the wall 12 and the socket 410 is positioned therein. Alternatively, the socket 410 may be located in the wall 12 given a sufficiently thick outer wall 12 .
[0030] The information resulting from the foregoing process may be provided to the fabrication process, be it manual or automated. For example, the housing 10 may be fabricated using the rapid prototyping process described in U.S. patent application Ser. No. 09/887,939.
[0031] To assemble the hearing instrument, the receiver assembly 100 is inserted into the housing 10 , and the receiver tube 200 is inserted into the receptacle 20 . The spline 210 on the tube 200 is oriented according to the keyway 22 , until the flange 220 on the tube 200 butts up against the inside wall 24 at the entrance of the receptacle 20 . The tether 300 or the axle assembly 150 , on the receiver assembly 100 , is then anchored on the housing 10 , either at the socket 410 or the cradle 500 , respectively. In either case, the receiver tube 200 is bent slightly, creating a degree of spring tension that helps to stabilize the receiver assembly 100 in the housing 10 . Where the tether 300 is employed, the bending also results in spring tension therein. To achieve the tension in the receiver tube 200 , the length of the tube 200 may be selected such that section from the flange 220 to the receiver assembly 100 forms an arc when the receiver assembly is anchored by either the tether 300 and ball 310 or the axle assembly 150 in the cradle 500 .
[0032] The dimensions of the receiver tube 200 , and the location of the flange 220 thereon, and of the tether 300 and its components depend in part on the dimensions of the particular hearing instrument and the receiver assembly 100 employed. The dimensions can be determined empirically or using finite element analysis. In various prototypes, a receiver tube 200 having an outside diameter of 2.4 mm and an inside diameter of 1.4 mm, where the flange 220 is located a distance approximately 5.0 mm from the receiver assembly 100 has been found to work satisfactorily. That distance may vary from approximately 0.5-6.0 mm. Similarly, a tether 300 having a thickness of 0.4-0.5 mm, a width varying from 1 mm to 6 mm at the widest to 1 mm at the ball 310 (see FIG. 7), and a length of 2.0 mm (in a range of 0.5-5.0 mm, depending on the desired degree of resilience and stiffness), and having a ball 310 having a diameter of 1.0-1.5 mm has also been found to work satisfactorily.
[0033] In certain applications, such as smaller hearing instruments where the entire device resides in the ear canal, the receiver assembly is considerably smaller and may be enclosed in a receiver boot fabricated from a material such as the Viton elastomer. One such an arrangement is shown in FIGS. 17-19. As shown in the figures, an outer receiver boot 600 holds the receiver assembly 100 ; the receiver tube 610 may be an integral part of the boot or it may be a separate component. The receiver assembly 100 is inserted into an opening 602 in the boot 600 and oriented such that its output port (not shown) is positioned adjacent the receiver tube 610 . In the case where the receiver tube 610 is a separate component, a protrusion or spout may be provided on the receiver assembly 100 (not shown) to attach and support the receiver tube 610 . The receiver tube 610 also has a spline 612 to aid in orientation of the receiver assembly 100 during assembly.
[0034] The boot 600 also has a tether 620 and ball 620 . The tether 620 may have a length of 1-3 mm and thickness of 0.5 mm; the ball 630 may have a diameter of 1 mm. The receiver tube portion 610 may have a length of 1-5 mm, a diameter of 2 mm, and wall thickness of 0.4 mm. As shown in FIG. 19, a drawing of a hearing instrument employing a receiver boot 600 , the ball 630 resides in a socket 640 in the wall 650 of the hearing instrument.
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A flexible support for a hearing instrument receiver suspended on a receiver tube in a hearing instrument housing will lessen the feedback that could be generated if the housing is jostled. A tether affixed to the receiver and anchored to the housing functions in this manner, and also improves the stability of the receiver inside the housing. Alternatively, a floating arrangement, where the receiver rotatably resides in a cradle may also offer feedback reduction and isolation for the receiver.
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TECHNICAL FIELD OF THE INVENTION
[0001] The present invention relates in general to an apparatus for marketing a brand, and more specifically, to an apparatus or hanging device used to secure and transport a plurality of hangers, which serves as a promotional tool for marketing a brand.
BACKGROUND OF THE INVENTION
[0002] Promotional items are a known marketing tool utilized throughout various industries. Promotional items are either sold or given away to customers or clients with the purpose of promoting a particular brand of products or services. For example, items such as pens, pencils, and notepads, are often used in the hospitality industry to promote hotel brands. Often, promotional items can be decorative items, but typically, promotional items are functional so as to increase the promotional value of the item. However, the commonality of these items (i.e. the fact that virtually every hotel offers pens or notepads displaying the hotel brand), and the fact that a user often fails to take these items with them, is an undesirable result of many promotional items known in the prior art. Users of these common promotional items become so accustomed to receiving them that the items lose promotional value. Thus, there is always a need for new and unique promotional items that offer unique opportunities to market, advertise, or promote a particular brand.
[0003] Hangers in general are useful tools for hanging garments. They help to organize garments as well as to keep their shape, for example, to prevent wrinkles from forming. Many people utilize a wide array of hangers for these very purposes. In the hospitality industry, for example the hotel-casino industry or the cruise-ship industry, hangers are typically provided in guestrooms. Additionally, hangers are widely used in high-end or luxury hotels that provide special services to their guest such as laundry and dry cleaning services.
[0004] Whether an individual privately sends their garments to a dry cleaning service, or a hospitality service provider offers a dry cleaning service to their guests, it is often necessary to transport multiple hangers and articles of clothing from one location to another. For example, when a person picks up their newly cleaned garments from a dry cleaner, it is typically necessary to take multiple cleaned garments placed upon multiple separate hangers, and transport the lot back to another location. Similarly, luxury hotels that offer premium services, such as dry cleaning services, must provide their guests with multiple hangers every time a guest requires cleaning of multiple articles of clothing. Often, the guest will desire to take their dry cleaned articles of clothing either from the reception's desk to their guestroom, or from their guestroom to their vehicle, for example, when leaving the hotel after a vacation or business trip. Thus, it is desirable to offer these service providers with a useful promotional item that addresses this issue, and allows for the promotion and marketing of their brand.
[0005] For example, when transporting newly dry-cleaned clothes in a vehicle, having multiple articles of clothing is particularly problematic. Placing multiple hangers on a hook provided in a typical car is burdensome, and often impossible, as multiple hangers may not fit on the typically small hook. It is also often the case that there is only a single hook for hanging garments in the car. Whatever the case, when transporting multiple garments in a vehicle, some of the hangers may need to be transferred to another hook in the car, or placed on the back seat, or transferred to a trunk space; all of these options are undesirable, as the garments may become wrinkled, dirtied, or both. Furthermore, because the dry cleaner typically bundles all of the clothes together in a nice neat package, it is more desirable to keep all the garments held together rather than have to separate them in order to transport them to another location. Thus, while there are several other options to transporting multiple garments, neither is ideal.
[0006] Therefore, in light of the problems presented by the prior art, there is a need in the art for a hanging device that is capable of efficiently securing hangers for transportation, and serves as a promotional item by offering functionality to users and a marketing opportunity to distributors. It is to these ends that the present invention has been developed.
BRIEF SUMMARY OF THE INVENTION
[0007] To minimize the limitations in the prior art, and to minimize other limitations that will be apparent upon reading and understanding the present specification, the present invention describes an apparatus, or hanging device, used to secure and transport a plurality of hangers, which serves as a promotional tool for marketing a brand.
[0008] In one embodiment of the present invention, a device for marketing a brand, comprises: a first coupling member configured to attach to a vehicle hanging member; a second coupling member coupled to or integral with the first coupling member, wherein the second coupling member is configured to support thereupon one or more clothing hangers; and an advertising member coupled between the first and second coupling members, wherein the advertising member comprises indicia for promoting one or more goods or services.
[0009] In another embodiment of the present invention, a device used for promotional purposes, comprises: a first coupling member configured to attach to a vehicle hanging member; a second coupling member comprising at least a portion of a cord; and an advertising member coupled between the first and second coupling members, wherein the advertising member comprises indicia for promoting one or more goods or services.
[0010] In yet another embodiment of the present invention, a hanger accessory for promoting a brand, comprises a first coupling member configured to attach to a vehicle hanging member; a second coupling member coupled to or integral with the first coupling member, wherein the second coupling member is configured to support thereupon one or more clothing hangers; and an advertising member coupled to the first and second coupling members, wherein the advertising member comprises indicia for promoting one or more goods or services.
[0011] It is an objective of the present invention to provide a means of advertising or marketing a brand for businesses, nonprofits, individuals, and others, via a promotional item that is functional to users.
[0012] It is another objective of the present invention to provide businesses, nonprofits, individuals, and others with a brand marketing opportunity for distribution via dry-cleaning services.
[0013] It is yet another objective of the present invention to provide hospitality service providers, such as hotel-casinos or cruise-ship operators, with a brand marketing opportunity by means of providing their guests with a promotional item associated with their hospitality services.
[0014] It is yet another objective of the present invention to provide users with a means to easily and safely transport their articles of clothing from one location to another.
[0015] It is yet another objective of the present invention to provide hospitality service providers, such as hotel-casinos or cruise-ship operators, with a promotional item that can be distributed to their patrons in a manner that will guarantee the item's use and thus exploit a marketing opportunity.
[0016] It is yet another objective of the present invention to provide hospitality service providers, such as hotel-casinos or cruise-ship operators, with a hanger apparatus used to secure and transport a plurality of hangers, which serves as a promotional tool for marketing a brand.
[0017] These and other advantages and features of the present invention are described herein with specificity so as to make the present invention understandable to one of ordinary skill in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Elements in the figures have not necessarily been drawn to scale in order to enhance their clarity and improve understanding of the various embodiments of the invention. Furthermore, elements that are known to be common and well understood to those in the industry are not depicted in order to provide a clear view of the various embodiments of the invention. The drawings that accompany the detailed description can be briefly described as follows:
[0019] FIG. 1 is a three dimensional schematic view of an apparatus for marketing a brand, or hanging device, in accordance with one embodiment of the present invention.
[0020] FIG. 2 is a front elevation schematic view depicting the upper portion, or coupling member, of the connector, which is detached from the hanging device shown in FIG. 1 .
[0021] FIG. 3 is a front elevation schematic view depicting the upper portion, or coupling member shown in FIG. 2 , with an adjustor for securing a hook or multiple hangers, to the hanging device.
[0022] FIG. 4 is a front elevation schematic view of the upper portion of the connector, or first coupling member and adjustor depicted in FIG. 3 , showing how the upper portion of the connector or coupling member can be coupled to a back component of a body or advertising member using an adhesive, in accordance with one embodiment of the present invention.
[0023] FIG. 5 is a front elevation schematic view of the upper portion of the connector, or coupling member, and adjustor depicted in FIG. 4 , in addition to the lower portion of the connector, or second coupling member (also including a second adjustor), coupled to the back component of the advertising member using an adhesive.
[0024] FIG. 6 is a front elevation schematic view of the hanging device depicted in FIG. 5 , with the addition of a front component of the advertising member coupled to the first and second coupling members in a manner so that the connector is sandwiched securely between the front component and back component of the advertising member.
[0025] FIG. 7 is a side elevation schematic view of the hanging device depicted in FIG. 6 , which shows the first and second coupling members joint together and sandwiched between the two components of the advertising member.
[0026] FIG. 8 is a front elevation schematic view of adjustors coupled to a single cord and forming a single loop, which makes up the first and second couplers of the device, in accordance with another embodiment of the present invention. Here, the cord is shown in a disjunctive state, facilitating the coupling of the adjustors.
[0027] FIG. 9 is a front elevation schematic view of the adjustors and cord in FIG. 8 , the cord shown in a merged state, after the adjustors have been coupled to the cord.
[0028] FIG. 10 is a three dimensional schematic view of a hanging device in accordance with another embodiment of the present invention, comprising a single-piece and cylindrically shaped advertising member.
[0029] FIG. 11 is a three dimensional schematic view of a hanging device, in accordance with yet another embodiment of the present invention, having the first coupling member comprising a hook and the second coupling member comprising a cord and adjustor.
[0030] FIG. 12 is a three dimensional close-up schematic view of the second coupling member, in accordance with one embodiment of the present invention, wherein the second coupling member comprises a cord. An adjustor is coupled to the cord, which is shown retaining the hooks of several hangers placed in the small loop created by the adjustor.
[0031] FIG. 13 is a close-up schematic view of the interior of a vehicle, wherein a typical vehicle hanging member, or car hook, is being used to hang several hangers securely held together with a hanging device, in accordance with one embodiment of the present invention.
[0032] FIG. 14 is a three dimensional close-up schematic view of one embodiment of the present invention, being used to carry or transport a plurality of hangers, wherein a user has coupled multiple hangers to both first and second coupling members, thereby being able to carry the hangers using the advertising member or body as a handle or support.
[0033] FIG. 15 is a three dimensional close-up schematic view of one embodiment of the present invention, being used to carry or transport a plurality of hangers, wherein a user has coupled multiple hangers to both first and second coupling members by joining the coupling members together, thereby being able to carry the hangers using the advertising member or body as a handle or support.
DETAILED DESCRIPTION OF THE INVENTION
[0034] In the following discussion that addresses a number of embodiments and applications of the present invention, reference is made to the accompanying figures that forms a part thereof, where depictions are made, by way of illustration, of specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and changes may be made without departing from the scope of the present invention.
[0035] FIGS. 1-7 depict one embodiment of the present invention. FIG. 1 is a three dimensional schematic view of a device for marketing the brand of a business. Very generally, it is a promotional item, but more specifically, a hanger apparatus used to secure and transport a plurality of hangers, which serves as a promotional tool for marketing a brand. FIG. 1 shows hanging device 101 . Hanging device 101 comprises of marketing member 102 , connector 103 , and adjustors 104 , each of which, include button 105 for the adjustors 104 to be adjusted when securing hanging device 101 to, for example, a car hook and plurality of hangers.
[0036] Advertising member 102 serves as a marketing component for offering an opportunity for a business to promote their brand by placing marketing indicia 106 , which displays a business name, on hanging device 101 . For example, and without departing from the scope of the present invention, marketing indicia 106 may contain a slogan, a brand name, a logo, a design, or a business name as shown in FIG. 1 . The manner in which marketing indicia 106 may be displayed is not to be limited. Marketing indicia 106 may, for example, be engraved on both sides of advertising member 102 . Other means that may be employed to convey a marketing message may include, without departing from the scope of the present invention, the use of stickers, acid etchings, paintings, prints, lithographs, hand drawings, pencil markings, pen markings, photographs, digital displays, either on one side, the front, the back, or all around advertising member 102 , and or any other means or combination of means of conveying any particular marketing message.
[0037] In the embodiment shown in FIG. 1 , advertising member 102 comprises two components, front component 108 and back component 109 , which sandwich connector 103 in place. Components 108 and 109 may be made of any material that is durable and suitable for either displaying a brand, such as marketing indicia 106 , or made to look like objects representative of a business or brand. For example, and without departing from the scope of the present invention, front component 108 and back component 109 may be made of a durable plastic, constructed to look like two casino chips that each identify a particular hotel-casino. Alternatively, advertising member 102 may comprise a single component, or a plurality of components, constructed of wood, clay, glass, metals, ceramics, plastics, or any combination of any natural or synthetic material, without deviating from the scope of the present invention. Additionally, it is understood that marketing indicia 106 may be placed on any part of advertising member 102 such as either front component 108 , or back component 109 , or both.
[0038] In another embodiment, other means may be employed to convey a marketing message, and for example, advertising member 102 may comprise of a single elongated cylinder with two openings on either flat surface, or a cavity, through which connector 103 may pass and be secured. This shape may be used to place a marketing indicia such as a label, all around a circumference of advertising member 102 (see, e.g. FIGS. 10 , 11 and 14 ). Furthermore, other shapes such as cubical, spherical, or any other geometric or non-geometric shapes that help represent a brand may be employed without departing from the scope of the present invention.
[0039] In addition to shapes, as stated above, advertising member 102 may comprise objects representative of the brand being advertised or marketed. For example, and in no way limiting the scope of the present invention, advertising member 102 may comprise coasters to be marketed by a restaurant, buttons to be marketed by a clothing company, campaign buttons to be marketed by politicians, coins (or fake coins) to be marketed by banks, corks to be marketed by a vineyard, or other objects representative of the brand being marketed, or any other conceivable device suitable for the purpose of marketing a brand.
[0040] To expound upon the marketing feature of hanging device 101 , a casino, for example, may desire to utilize hanging device 101 where advertising member 102 is comprised of two casino chips, each casino chip displaying the casino's name. The casino may then use hanging device 101 to either sell to its guests in the gift shop or even distribute to guests as a complimentary service during their stay at the casino, for example, as a promotional item distributed every time a guest uses or requests the hotel's dry cleaning or laundry service. Each time that a guest thereafter utilizes hanging device 101 , the guest would naturally see the casino's poker chips, as they may form the central component of hanging device 101 . The guest would thus be exposed and potentially reminded of his positive stay at the casino, thereby allowing for the casino to further penetrate its market and drive return business. Hanging device 101 is also functional for the end user, as will be described below, while providing for a marketing opportunity for an intermediary such as a casino. Hanging device 101 , however, is not limited to distribution by casinos, as other businesses, nonprofits, individuals, or other entities may take advantage of its marketing capabilities.
[0041] Connector 103 can be a single component, or made up of multiple components. For example, and without limiting the scope of the present invention, connector 103 may be a single component of a general cord-like nature. As such, connector 103 may be generally flexible and easily manipulated so as to facilitate hanging the device, for example, from a car hook (See FIG. 13 ). A flexible or cord-like structure and material may be desirable to facilitate receiving a plurality of hangers such that the hangers are tightly secured and not prone to moving about hanging device 101 . However, a rigid and sturdier material could be used for connector 103 without deviating from the scope of the present invention.
[0042] Connector 103 may be constructed of any wire (with a single strand or multiple strands), string, plastic, rope, twine, or any other like material. In one embodiment, connector 103 may comprise of a rigid material, such as a plastic, yet still accomplish a similar result. Although a hardened material may allow for some movement about connector 103 , in one embodiment of the present invention, a generally curved connector 103 may significantly restrict this movement, thus allowing for a hanger to be securely hung about hanging device 101 .
[0043] Connector 103 may comprise a variety of shapes without departing from the scope from the present invention. For example, connector 103 may have a substantially cubically shaped perimeter, as shown in FIG. 1 , or a tubular or substantially cylindrically shaped perimeter, as shown in FIG. 10-14 , or any other shape without deviating from the scope of the present invention. Typically, it is desirable to construct connector 103 of a generally tubular shape so as to provide a smooth flexible surface that is adaptable to a variety of hooks, and so the device itself is flexible and can be transported easily. For example, although connector 103 could be made out of a more rigid material, this may prevent a user from being able to place hanging device 101 in, for example, their pocket.
[0044] Whether a rigid or less flexible material is used to construct connector 103 , or whether a flexible cord-like structure and material is used, or whether connector 103 comprises one or multiple components, connector 103 should be constructed so that connector 103 comprises a first coupling member and a second coupling member. Thus, connector 103 may be constructed as a single component, or multiple components, without deviating from the scope of the present invention.
[0045] In one embodiment, connector 103 comprises a single component with an upper portion and a lower portion or a first coupling member and a second coupling member. The single component may be for example, and without limiting the scope of the present invention, a cord constructed of durable synthetic material, which forms a single closed loop.
[0046] Typically, and without limiting the scope of the present invention, connector 103 comprises an upper portion, or first coupling member 110 , which is adapted to receive a hook, such as a car hook, and a lower portion or second coupling member 111 , which is adapted to receive a plurality of hooks, such as a plurality of hangers (See FIG. 12 and FIG. 13 ).
[0047] To adjust or secure hanging device 101 to a hook such as a car hook, and to secure a plurality of hangers to hanging device 101 , adjustors 104 may be implemented as shown in FIG. 1 , in accordance with one embodiment of the present invention. Adjustors 104 can be typical adjustors common in the art. For example, and without limiting the scope of the present invention, in one embodiment, adjustors 104 are cord adjustors that comprise a spring loaded button, which can be depressed for releasing or securing the adjustor in place. In such embodiment, adjustors 104 are configured to receive a cord, and button 105 on each adjustor is used to adjust the space between the extremities of connector 103 on either first coupling member 110 or second coupling member 111 . In other words, depressing button 105 may allow for an end user to manually adjust adjustors 104 up and down the vertical height of connector 103 . Other similar adjustors known in the art may be employed by hanging device 101 to accomplish similar adjustability, without deviating from the scope of the present invention. To illustrate this feature of hanging device 101 , see FIG. 13 .
[0048] Adjustors 104 may be placed upon connector 103 at two locations as depicted in FIG. 1 , i.e. on first coupling member 110 and on second coupling member 111 of connector 103 . Adjustors 104 may be placed with button 105 facing one side of hanging device 101 , as shown in FIG. 1 , or they may be facing opposite sides, without departing from the scope of the present invention. In other words, adjustors 104 may contain button 105 either on the left side, or the right side, or on alternating sides. Adjustors 104 may allow for further restrictions on the mobility of hanging device 101 . For example, the adjustor on first coupling member 110 of connector 103 may be positioned higher on connector 103 , thus creating loops, such as loop 107 shown in FIG. 1 . Similarly, adjustors 104 may be positioned closer to advertising member 102 , thereby controlling the size of loop 107 . For example, a larger initial loop 107 may be desirable for placing hanging device 101 on a hook in the interior of a car. After hanging device 101 is secured to said car hook, a user may thereafter adjust adjustors 104 in a manner so that an upper adjustor comes to rest near the top of first coupling member 110 of connector 103 and may even touch the hook of the interior of the car, thereby creating a tighter hold.
[0049] One of the adjustors 104 , i.e. on the lower portion of hanging device 101 , may be similarly adjusted to secure any hangers that may be received by hanging device 101 . For example, after a plurality of hangers are placed through loop 107 on second coupling member 111 of connector 103 , the adjustor may be lowered to tightly secure the plurality of hangers. See, e.g. FIG. 12 and FIG. 13 . This adjustability feature of hanging device 101 is desirable such that hangers and the clothes upon said hangers may be secured from the sudden braking and acceleration that drivers are prone to make.
[0050] FIGS. 2-7 depict the process of constructing, or putting together, hanging device 101 , as well as various perspectives of one embodiment of the present invention. FIG. 2 is a front elevation schematic view of connector 103 , and more specifically, it shows first coupling member 110 of connector 103 . As noted above, connector 103 may be constructed of any number of different materials suitable for the purpose of hanging articles of clothing in a plurality of hangers, whether flexible or rigid. Additionally, connector 103 may comprise multiple components or a single component. In the embodiment shown in FIG. 2 , connector 103 comprises an upper portion and a lower portion, with first coupling member 110 shown. In this embodiment of connector 103 , first coupling member 110 is used to secure hanging device 101 from a car hook.
[0051] FIG. 3 is a front elevation schematic view depicting first coupling member 110 of connector 103 , which has been adapted with a first adjustor of adjustors 104 for securing hanging device 101 to a car hook. In one embodiment of the present invention, either end of connector 103 may be fed through two openings on adjustors 104 while depressing button 105 on the adjustor. When button 105 is released, tension may be placed upon connector 103 such that adjustors 104 can be secured in place. Although not shown in FIG. 2-FIG . 4 , in the illustrated embodiment, second coupling member 111 of connector 103 is identical to first coupling member 110 , and can similarly be configured with an adjustor (See FIG. 5 ). In an alternative embodiment however, first coupling member 110 and second coupling member 111 of connector 103 are different. For example, as shown in FIG. 11 , first coupling member 110 of connector 103 may comprise a totally different shape, such as a hook for hanging the device from a vehicle hanger receiving member, or car hook, for hanging clothes inside a vehicle.
[0052] FIG. 4 is a front elevation schematic view of the upper portion of the connector and adjustor depicted in FIG. 3 , showing how the upper portion of the connector can be coupled to a back component of an advertising member using an adhesive, in accordance with one embodiment of the present invention. FIG. 4 shows first coupling member 110 of connector 103 , and the first of adjustors 104 depicted in FIG. 3 , additionally showing back component 109 of advertising member 102 .
[0053] Connector 103 may be secured to advertising member 102 in many different ways, including the use of an adhesive. Alternatively, first coupling member 110 of connector 103 may be coupled to back component 109 of advertising member 102 with a regular or industrial staple, it may be sown into back component 109 , or welded, soldered, or may be securely attached in any other suitable way without departing from the scope of the present invention.
[0054] In the embodiment shown in FIG. 4 , and by no way limiting the scope of the present invention, first coupling member 110 of connector 103 is coupled or attached to back component 109 via the use of adhesive 401 . Said adhesive may consist of, for example, glue, super glue, tape, double sided tape, caulk, or other such adhesives as may be necessary to secure first coupling member 110 to advertising member 102 . In another embodiment, first coupling member 110 may also be secured to advertising member 102 by a method of heat application, i.e. utilizing a heat source to mend and solidly connect the first and second coupling members to advertising member 102 . Again, any way of securely attaching the coupling members to the advertising member may be implemented without deviating from the scope of the present invention.
[0055] FIG. 5 is a front elevation schematic view of the upper portion of the connector and adjustor depicted in FIG. 4 , in addition to the lower portion of the connector (also including a second adjustor), coupled to the back component of the advertising member using an adhesive. FIG. 5 shows first coupling member 110 of connector 103 , a first adjustor of adjustors 104 , advertising member 102 , and adhesive 401 , with the addition of second coupling member 111 of connector 103 , and a second adjustor of adjustors 104 .
[0056] Second coupling member 111 of connector 103 and the second adjustor of adjustors 104 may be similarly attached to back component 109 of advertising member 102 through any means or methods described in the preceding paragraphs. Furthermore, the second adjustor of adjustors 104 , coupled to second coupling member 111 of connector 103 , may also be attached by similar means as described above.
[0057] FIG. 6 is a front elevation schematic view of all the parts and components of the hanging device depicted in FIG. 5 , which has been put together with the addition of a front component of the advertising member, coupled to the first and second coupling members, in a manner so that the coupling members are sandwiched securely between the front component and back component of the advertising member. FIG. 7 is a side elevation schematic view of the hanging device depicted in FIG. 6 , which shows the upper and lower portions of the connector joint together and sandwiched between the two components of the advertising member.
[0058] As may be noted from this perspective, advertising member 102 may be comprised of two components. This should not be construed as a limitation. As noted above, and as depicted in the remainder of the specification, the body, or advertising member, may be a single component, or may be comprised of multiple components. For purposes of clarity and continuity of disclosure, however, FIG. 7 depicts only one particular embodiment of hanging device 101 .
[0059] Specifically, FIG. 6 and FIG. 7 show hanging device 101 , with the addition of front component 108 of advertising member 102 coupled to first and second coupling members 110 and 111 in a manner so that connector 103 is sandwiched securely between front component 108 and back component 109 of advertising member 102 .
[0060] Front component 108 of advertising member 102 may also be attached by any means or methods described in the preceding paragraphs, without limiting or deviating from the scope of the present invention. Once securely constructed, hanging device 101 may be utilized to transport hangers from one location to another. As discussed above, marketing indicia 106 may also be placed on front component 108 or back component 109 , or both components of advertising member 102 (unless advertising member 102 is already a marketing object) such that hanging device 101 may be used to convey marketing information to an end user such as a hotel guest, or a guest on a cruise-ship.
[0061] FIG. 8 is a front elevation schematic view of adjustors coupled to a single cord, which makes up the first and second coupling members of the device, in accordance with another embodiment of the present invention. Here, the cord is shown in a disjunctive state, facilitating the coupling of the adjustors. FIG. 9 is a front elevation schematic view of the embodiment of connector 103 shown in FIG. 8 , depicting adjustors 104 and connector 103 in a merged state. In the embodiment shown in FIG. 8 and FIG. 9 , connector 103 , or first and second coupling members 110 and 111 , comprises a single cord that forms a single loop. In one embodiment, first and second coupling members comprise a single cord made of a synthetic material strong enough to sustain multiple articles of clothing in a plurality of hangers that may be secured by connector 103 .
[0062] FIG. 10 is a three dimensional schematic view of a hanging device in accordance with another embodiment of the present invention, comprising a single-piece and cylindrically shaped body. FIG. 10 shows another embodiment of hanging device 101 , which comprises an alternative embodiment of advertising member 102 constructed as a single component. It may also be noted that this alternative embodiment comprises a flexible connector 103 , as well as alternative rounded adjustors 104 .
[0063] Advertising member 102 may thus be cylindrical in shape with two openings on either end through which connector 103 may pass. Marketing indicia 1001 may also be placed upon the substantially cylindrical advertising member 102 to enable hanging device 101 to convey marketing information of a brand, for example, a hotel's name.
[0064] Without deviating from the scope of the present invention, connectors 103 may be attached to advertising member 102 through similar means and or methods described above, including through the use of various adhesives or heat application methods.
[0065] FIG. 11 is a three dimensional schematic view of a hanging device, in accordance with yet another embodiment of the present invention, having the upper portion of the connector, or first coupling member, comprising a hook. FIG. 11 shows hanging device 101 , in accordance with yet another embodiment of the present invention, wherein the first coupling member comprises hook 1101 . Hook 1101 may be constructed of any material suitable for sustaining the pressures of multiple articles of clothing hanging from the device.
[0066] For example, and without limiting the scope of the present invention, hook 1101 can be constructed of plastic, metal, or wood and may further be curved by any useful measure. Hook 1101 may also be either attached to advertising member 102 via any of the means or methods described above, including the use of adhesives and or heat application. Hook 1101 may be solidly connected to advertising member 102 during the manufacturing process such that hook 1101 and advertising member 102 are united as one component.
[0067] FIG. 12 is a three dimensional close-up schematic view of the lower portion of a connector, or second coupling member, in accordance with an embodiment of the present invention, wherein a second coupling member comprises a cord. An adjustor is coupled to the second coupling member, which is shown retaining a plurality of hooks of several hangers placed in the small loop created by the adjustor, demonstrating how a hanging device in accordance with the present invention can be used to transport clothing from one location to another. FIG. 12 shows second coupling member 111 securely holding multiple hooks 1201 of several hangers placed within loop 107 created by a lower adjustor of adjustors 104 .
[0068] FIG. 13 is a close-up schematic view of the interior of a vehicle, wherein a typical car hook, or vehicle hanging member, is being used to hang several hangers securely held together with a hanging device, in accordance with one embodiment of the present invention. More specifically, FIG. 13 shows how one of the device's adjustors 104 can securely tighten the upper portion of connector 103 to hang the device from car hook 1301 . The lower adjustor 104 is also tightly securing a plurality of hangers 1302 , which hold multiple articles of clothing 1303 .
[0069] FIG. 14 is a three dimensional close-up schematic view of one embodiment of the present invention, being used to carry or transport a plurality of hangers, wherein a user has coupled multiple hangers to both first and second coupling members, thereby being able to carry the hangers using the advertising member or body as a handle.
[0070] The embodiment shown in FIG. 14 is similar to the embodiment shown in FIG. 10 , wherein advertising member 102 comprises a substantially cylindrical shape. First coupling member 110 and second coupling member 111 are coupled securely and held inside a cavity of advertising member 102 . Typically, first coupling member 110 can be placed upon a car hook as shown in FIG. 13 . However, it may be desirable for a user to grasp hanging device 101 from advertising member 102 and utilize both first and second coupling members 110 and 111 to hang and transport a plurality of hangers 1302 on each of the loops 107 within first and second coupling members 110 and 111 .
[0071] Finally, FIG. 15 is a three dimensional close-up schematic view of one embodiment of the present invention, being used to carry or transport a plurality of hangers, wherein a user has coupled multiple hangers to both first and second coupling members by joining the coupling members together, thereby being able to carry the hangers using the advertising member or body as a handle or support.
[0072] The embodiment shown in FIG. 15 is similar to the embodiment shown in FIG. 14 , wherein advertising member 102 comprises a substantially cylindrical shape. A user may take first coupling member 110 and second coupling member 111 and bring them together to form a single support for a plurality of hangers 1302 . Typically, first coupling member 110 can be placed upon a car hook as shown in FIG. 13 . However, it may be desirable for a user to grasp hanging device 101 from advertising member 102 and utilize both first and second coupling members 110 and 111 to hang and transport a plurality of hangers 1302 , for example, when transporting articles of clothing to and from a vehicle. Thus, without deviating from the scope of the present invention, the apparatus for marketing a brand may be utilized in multiple ways depending on the needs of its user.
[0073] A hanging device, or apparatus for marketing a brand, has been described. The foregoing description of the various exemplary embodiments of the invention has been presented for the purposes of illustration and disclosure. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching without departing from the spirit of the invention.
DESCRIPTION OF THE REFERENCE SYMBOLS
[0000]
101 : Hanging device
102 : Advertising member
103 : Connector
104 : Adjustors
105 : Button
106 : Marketing indicia
107 : Loop
108 : Front component
109 : Back component
110 : First coupling member
111 : Second coupling member
401 : Adhesive
1001 : Marketing indicia
1101 : Hook
1201 : Multiple hooks
1301 : Car hook
1302 : Plurality of hangers
1303 : Articles of clothing
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An apparatus for marketing a brand may generally comprise coupling members and an advertising member. The advertising member may serve as a marketing tool upon which a marketer can display information to a potential consumer, thereby making a commercial impression upon an end user. Each coupling member is configured to be placed upon a hook, or to receive a hook from a hanger. For example, a coupling member may be configured to receive a plurality of hooks. Said coupling members may also be equipped with adjustors, such as to allow for the apparatus to be secured to a hook, and for the plurality of hangers to be secured to the apparatus.
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This invention was made under Department of Energy Subcontract No. NREL-ZM-2-11040-3.
FIELD OF THE INVENTION
This invention relates to growing crystalline bodies from a melt and more particularly to an improvement in an apparatus for growing hollow tubular crystals and reducing thermoelastic stress acting on such crystals.
BACKGROUND OF THE INVENTION
A widely used technique for growing tubular crystalline bodies from a melt is the edge-defined, film-fed, crystal growth technique (the EFG process). A customary use of the EFG process is to grow hollow crystalline bodies having a polygonal cross-section, such as "octagons" or "nonagons", for solar cell manufacture. The hollow bodies are grown on a seed from a liquid film of feed material which is transported by capillary action from a crucible containing a quantity of molten material, such as a silicon melt, to the top end of a die having the desired cross-sectional shape. A pulling mechanism is employed for drawing the crystalline body away from the die until a desired length is reached, at which time the crystalline body is removed from the apparatus and a new one drawn. The thus grown hollow tube is then subdivided into a plurality of flat substrates or wafers that are used to form photovoltaic solar cells.
The apparatus used in growing hollow polygonally-shaped crystalline bodies of silicon and the like by the EFG method customarily includes a radiation shield mounted to the crucible inside of the EFG die tip, an inner after-heater that is surrounded by the growing crystalline body and an outer after-heater that surrounds the growing crystalline body, as shown by U.S. Pat. Nos. 4,440,728 issued to R. W. Stormont et al, 4,661,324 issued to N. C. Sink et al, 5,106,763 issued to B. R. Bathey et al, 5,098,229 issued to F. U. Meier et al, and 5,102,494 issued to D. S. Harvey et al.
Residual stresses tend to be present in such hollow bodies as a result of non-uniform changes in temperature of the crystalline body during growth, which can result in or promote buckling, non-flat faces, fracture, plastic flow or creep of the hollow body during growth or during subsequent handling and processing, e.g., during laser cutting into solar blanks.
A number of methods have been proposed to reduce the formation of residual stresses when growing sheet crystals. Annealing the sheet crystal has been suggested. It was expected that annealing at a temperature high enough so that stress relaxation could occur, but lower than its melting point, would relieve residual stresses in grown crystals. However, such a process is not effective in crystals with stresses above 20,000 psi, for example. In any event, annealing means an extra step that is added to the growth process, and thus adds unwanted cost.
U.S. Pat. No. 4,158,038, issued to Jewett, proposed that a crystal temperature profile controller be employed which would provide a substantially linear temperature gradient along the length of a crystalline body as the body is progressively pulled from the growth interface, so as to reduce thermal stresses in the crystalline body. Such a controller consists of a heater which is disposed along the pulling axis of the crystal close to but downstream of the melt/growth interface, with the downstream (higher above the interface) end of the controller being at a substantially lower temperature than the upstream (closer to the interface) end of the controller. The predominant heat flow process along the length of the heater is by conduction and radiation so that it exchanges heat with the moving crystal body. Therefore, the controller induces a thermal distribution lengthwise along the crystal body closely corresponding to its own. However, the Jewett et al device was designed to reduce temperature induced stresses along the length of the growing body and not to lateral stresses. Still other efforts have been made to reduce residual stresses in crystalline bodies grown by the EFG process.
In any event prior efforts have not fully solved the problem of relieving thermoelastic stress along the faces of the polygonally shaped hollow bodies. It has been found that in growing crystalline silicon hollow bodies using prior known apparatus, heat transfer at the corners of the faces is greater than at their center. As a result, uneven heat transfer occurs across the face of the crystal which results in thermal stresses that promote buckling or fracture of the hollow body.
OBJECTS AND SUMMARY OF THE INVENTION
The primary object of the present invention is to provide apparatus for growing hollow tubular crystalline bodies having a polygonal cross-section, wherein the temperature gradient across the faces of said bodies is modified in a desired manner so as to reduce residual stresses in the crystalline bodies.
A still further object of the invention is to produce flatter wafers from hollow tubular crystalline bodies grown by the EFG process.
These and other objects hereinafter described or rendered obvious are achieved by increasing the horizontal separation between (a) portions of the outer edges of the aforementioned radiation shield and (b) the die tip and the growing hollow polygonally-shaped crystalline body, except at the corners of the die tip and said body. Such an arrangement is brought about by providing a cut-back portion or "notch" in the outer edge of the shield opposite the center of each face of the polygonally shaped die. As a result, the center region of each die face will get hotter in relation to the edge regions of those faces, thus causing the meniscus between the die and the growing crystalline body to be at a higher temperature intermediate the corners of the die.
BRIEF DESCRIPTION OF THE DRAWINGS
A complete understanding of the nature and objects of the present invention will become more readily apparent, or will be rendered obvious, upon a reading of the detailed description of a preferred embodiment following hereinafter, and upon an examination of the accompanying drawings, in which like parts are identically numbered, and wherein:
FIG. 1 is a fragmentary sectional elevational view of a conventional furnace employed in practicing the EFG process, with certain parts represented schematically;
FIG. 2 is a plan view of a known (prior art) inner radiation shield usable in the furnace shown in FIG. 1;
FIG. 3 is a plan view, similar to that of FIG. 2, showing an inner radiation shield constituting a preferred embodiment of the present invention; and
FIG. 4 provides two curves illustrating the temperature gradient across the faces of a polygonally shaped crystal using the old and new heat shields shown in FIGS. 2 and 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Although the specific form of apparatus illustrated in the drawings and hereinafter described is designed to grow an octagon shaped hollow tube, it is to be understood that the present invention is adapted for use in growing crystalline bodies of other cross-sectional shapes.
Referring now to FIG. 1, there is shown a typical EFG crystal growing apparatus comprising a furnace enclosure 10, within which is disposed a crucible/die assembly 14 which preferably is made according to U.S. Pat. No. 5,037,622, issued 6 Aug. 1991 to David S. Harvey et al for "Wet-Tip Die For EFG Crystal Growth Apparatus", a heat susceptor 22, outer and inner after-heater assemblies 26 and 30, and seed assembly 34. The seed assembly 34 is supported by a movable stem 40 attached to a pulling mechanism 50 (see U.S. Pat. No. 4,440,728 issued 3 Apr. 1984 to Richard W. Stormont et al for "Apparatus For Growing Tubular Crystalline Bodies" for details of the seed assembly). The crucible portion of crucible/die assembly 14 is normally filled with a charge 54 of the material to be grown. The furnace enclosure 10 is surrounded by an RF heating coil 60, which serves to melt the charge 54 and maintain it in molten state.
The capillary die portion 18 of the crucible/die assembly is provided with an upper end face 64 shaped and dimensioned to determine the form and size of the grown crystalline body 66 (see FIGS. 2 and 3). Preferably the die end face 64 has the shape of an octagon, whereby to promote growth of a hollow thin-walled octagon. End face 64 is further provided with a capillary gap 68 of similar form centered in the face. A plurality of elongate slots 72 are formed on the inside of the side wall of crucible 14 to prove communication between the capillary gap 68 and the interior of the crucible 14, so that the melted charge can flow to the capillary gap and thence rise by capillary action to replenish the material on the die end face 64 as the body 66 is grown.
Mounted on the top end of susceptor 22 is an outer radiation shield 76 in the form of a thin-walled hollow cylinder or prism of similar shape and outside dimension as susceptor 22 and with a flange 80 having an inner edge with the same polygonal configuration as end face 64.
An inner radiation shield 84 is mounted to the interior of capillary die 18 in spaced apart relationship from the die by means of a plurality of pins 94 disposed about the inner periphery of die 18. The inner radiation shield 84 is formed of one or more graphite rings (86, 88, 90) held together in vertically spaced apart opposing relationship. The outside configuration of the inner radiation shield is of similar form but smaller than that of the end face 64 when viewed in plan view (see FIG. 2). The inner edges of such rings may be circular in form.
The outer after-heater 26 and the inner after-heater 30 are disposed above, and in concentric relation to die end face 64, with outer after-heater 26 being disposed outside of an axial projection of the die end face and inner after-heater 30 being disposed inside of an axial projection of the die end face. Outer after-heater 26 is a hollow body having a cross-sectional configuration that preferably is similar to but larger than the configuration of die end face 64. The corresponding faces of after-heater 26 are arranged parallel to the corresponding sides of the octagon 66 (FIG. 2) grown from end face 64 and extend substantially normal to the plane of the end face. Outer after-heater 26 is supported on outer radiation shield 76 by a plurality of pins 96 that engage outer radiation shield 76 and hold the after-heater clear of that shield.
Inner after-heater 30 includes a thin polygonally shaped wall 100 of smaller outside diameter than the circle which can be inscribed within the sides of the polygon defined by the outer edge configuration of die end face 64. The axis of the wall 100 is substantially normal to the plane of end face 64. Inner after-heater 30 is supported on the topmost ring 86 of inner radiation shield 84, preferably centrally of such ring, as shown in FIGS. 2 and 4. The interior of crucible 14 communicates with the interior of the after-heater through the central opening 92 in inner radiation shield 84.
The apparatus thus described above is placed in use by introducing a charge 54 into the crucible, heating that charge so that it becomes molten, and also heating the die face 64 above the melting point of the material of the seed 35 carried by seed assembly 34. The portion of the seed contacting the die end face will melt, wetting the end face and merging with the melt in capillary gap 68 so as to form a thin film of melt on end face 64. The pulling mechanism 50 is activated to raise stem 40 and the seed assembly 34. As seed assembly 34 rises from the die, a crystalline body is grown from the thin film on the die end face and melted charge 54 in capillary 68 rises to replenish the material consumed in growing the crystalline body.
Thermal control of the growing crystal is provided by after-heaters 26 and 30. The after-heaters 26 and 30 serve in effect as susceptors, and are heated primarily by induction from RF as a result of energization of coil 60.
A long-standing objective has been to provide a growing zone of substantially constant temperature horizontally along die end face 64. Despite prior efforts to achieve such a result, it has been found that at the growth interface a polygonally-shaped crystalline body of silicon, such as one having the octagonal configuration shown in the drawings, exhibits a higher temperature at its corners than in the center of each of its faces if the inner radiation shield has straight inner edges. Such a temperature gradient is depicted by curve "a" in FIG. 4, wherein it is seen that at the growth interface the center of a face 104 (FIG. 2) of a growing crystal 66 has a lower temperature than its opposite edges 112, 114. Thus the temperature gradient across a face of a growing polygonally-shaped crystalline body assumes a "smiling" appearance such as shown at curve "a" in FIG. 4, when employing inner radiation shields having straight edges. The lower temperature T 2 experienced at the center of the face 104, as compared to the temperature T 1 at its edges, tends to cause thermoelastic stress that may result in buckling or cracking of that face. Therefore, in order to obtain less stress and flatter faces for the crystalline body, more heat must be put into the center portion of each face of the growing polygonally-shaped crystalline body at the growth interface.
By curving the transverse isotherms in the growing crystalline body close to the growth interface so that the horizontal temperature gradient has a "frowning" shape as represented by curve "b" in FIG. 4, a lowering of stress is obtained in the faces of a growing polygonally shaped crystal. This will reduce the amplitude of any buckle and make the resulting wafers flatter and less susceptible to fracture.
I have discovered that it is possible to decrease the thermoelastic stress acting on the faces of a polygonally shaped crystal by shaping the outside edge or lip of the shield 84 to permit more heat to reach the center of each face of the growing body from the melt, so that the center of the faces become at least as hot as, and preferably hotter than, their edges, e.g., so as to obtain a transverse temperature gradient like the one illustrated by curve "b" on FIG. 4.
FIGS. 2 and 3 provide a comparison that helps distinguish the present invention. FIG. 2 shows the prior art arrangement wherein the top ring 86 of the inner shield 84 extends beyond the outer margin of the inner after-heater 30 that it supports. The outer peripheral portion 108 of ring 86 has an octagonal edge configuration conforming to the shape of the growing crystalline body, and the top die surface from which the body is grown. FIG. 3 shows how the outer edge of heat shield 84 is notched in a manner designed to provide the "frowning" curve "b" of FIG. 4. More specifically, in FIG. 3 the peripheral portion 108 of shield 84 is notched at the center of each of its faces, so as to form recessed areas 109. The recesses 109 are evenly spaced between the corners formed by the side edge faces of the shield. These recesses have the effect of altering the transverse isotherms, by virtue of the fact that the recesses allow more heat to be radiated from the melt 54 in the crucible toward the centers of the faces of the growing body 66 near the growth interface, thus providing a temperature distribution horizontally along the growth interface that has the effect of reducing stresses in the crystalline body.
By way of a specific example of the embodiment shown in FIG. 3, in growing a silicon octagon having faces measuring approximately 10 cm wide, the radial dimension between the inner and outer edges of the top ring 86 of the inner after-heater shield 84 may be approximately 2.54 cm, and the inner after-heater may be placed on the top ring 86 so that the peripheral portion 108 protrudes about 1.24 cm beyond the outer periphery of the inner after-heater, shield 84 is positioned vertically so that ring 86 is substantially in the same plane as the growth interface, and its outer edge is cut back over a span preferably in the range of 5-8 cm (preferably the notches 109 have a span of about 7.6 cm or 3.0 in.), and the depth of the recess cut on the edge of ring 86 does not exceed 10 mm. (preferably recesses 109 have a depth of about 7.6 mm. or 0.3 in. opposite the center of the face of the octagon).
Although a specific preferred embodiment of the present invention has been described and illustrated herein, it should be appreciated that modifications and variations may be readily made by those skilled in the art without departing from the spirit and scope of the invention. For example, the invention may be applied to growing ribbons or any polygonally shaped crystal. Also, although the invention has been illustrated and described in relation to growing octagons, it is to be understand that the invention is applicable to EFG apparatus for growing polygonally shaped hollow bodies having n sides or faces, where n is an integer with a value of three or more, but preferably has a value of eight or nine. Still other changes and modifications of the present invention will be obvious to persons skilled in the art from the foregoing description.
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An apparatus for growing hollow crystalline bodies by the EFG process, comprising an EFG die having a top surface shaped for growing a hollow crystalline body having a cross-sectional configuration in the shape of a polygon having n faces, and a radiation shield adjacent to and surrounded by the top end surface of the die, characterized in that the shield has an inner edge defining a similar polygon with n sides, and the inner edge of the shield is notched so that the spacing between the n faces and the n sides is greatest between the central portions of the n faces and the n sides, whereby the greater spacing at the central portions helps to reduce lateral temperature gradients in the crystalline body that is grown by use of the die.
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FIELD OF THE INVENTION
The present invention relates to those heat exchangers for so called incompatible fluids. By the phrase "incompatible fluids", it should be understood such types of fluids that, when put together, are able to react in a dangerous manner, for example by self ignition, or still such types of fluids that, when mixed in certain conditions, are able to generate toxic compounds, or compounds having any other drawbacks.
BACKGROUND OF THE INVENTION
For having an effective heat exchange, the prior art has taught heat exchangers comprising a vat having an open side on which is fastened a header tank with hair pin shaped tubes secured thereto, those tubes extending within the vat.
In the above known embodiment, a first fluid circulates in the vat, which vat is possibly provided with baffles, while a second fluid circulates in the tubes, which second fluid is brought at one end of the tubes by a first collector box and collected from the second end of the tubes by a second header tank.
The known heat exchangers of the above mentioned type are satisfactory regarding the heat exchange capacity they have. But it may happen that leaks will occur, in particular at the feet of the tubes engaged in the header tanks closing the vat in which circulates the first fluid. Leaks may also be provided through perforations of the thin walled tubes having walls generally of about 6-8 tenths of a millimeter.
Actually, experiments have shown that fluids circulating in heat exchangers can carry waste products, and particularly metal chips. This is for example the case for lubricants of gear mechanisms. It thus happens sometimes that such metal chips will remain at a fixed place in the circuit of the heat exchanger while being submitted to a movement making that these metal chips produce a milling action which may cause a perforation of the wall of the circulation duct.
Present safety requirements in particular in the aeronautical industry, make that some components, such as are the heat exchangers, must be able to work during many hundreds of thousands of hours without any failure occurring because of these heat exchangers.
It has thus been found that the hereabove mentioned problems concerning the safety of use while ensuring a very good effectiveness with respect to the heat exchange lead to avoid to use heat exchangers of the tubular core type.
PURPOSE AND SUMMARY OF THE INVENTION
The invention provides a new heat exchanger which takes into account the hereabove mentioned drawbacks, and has such a construction that any communication between different fluids is effectively eliminated, possible leak being produced only toward the outside of the heat exchanger even if some of the walls of the circulation ducts that it comprises are submitted to an accidental abrasion.
According to the invention, the safety annular heat exchanger for incompatible fluids comprises a hollow body having one end closed by a bottom, a sealed bottle within this body, with this sealed bottle being rigidly and sealingly fixed to the hollow body, the bottle having at least one wall with two sides, heat dissipators being provided on each of these two sides, and this bottle forming a separation wall between a first and a second fluid respectively circulating on either side of the at least one wall of the bottle between an input channel and an output channel of the hollow body for one of the fluids and between an input duct and an output duct for an other one of the fluids.
According to other features of the invention, means are provided for avoiding that a troublesome heat exchange can be produced between the admission and delivery ducts for one fluid and the circulation ducts of this one fluid circulating according to a counter-flow direction around the admission ducts.
There is also provided means carrying into effect thick or composite walls for the heat exchange between the two fluids, the wall thickness of these walls being substantially greater than a corresponding wall thickness coming from a theoretical computation for ensuring an optimum heat exchange between two fluids circulating on either side of said walls. The bottle at least has thus a wall thickness between about one millimeter and a plurality of millimeters.
Further means are also provided according to the invention so that it is possible to make the walls ensuring the heat exchange between the two fluids while providing inner leak channels leading to outside of the heat exchanger.
Furthermore, the invention provides that the heat exchanger can have various shapes, in particular a circular shape, a paralleleliped shape or an arcuate shape, in order to adapt the best exchanger to any suitable machine, for example a jet engine in aeronautics or other similar machines.
Various other features of the invention will moreover be revealed from the following detail description.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention are shown, as non limitative examples, in the accompanying drawings, wherein:
FIG. 1 is an elevation cross-section of an embodiment of the heat exchanger according to the invention.
FIG. 2 is a partial cross-section illustrating an advantageous embodiment of one of the elements shown in FIG. 1.
FIG. 3 is an enlarged half cross-section taken substantially along line III--III of FIG. 2.
FIG. 4 is a half cross-section similar to FIG. 3 illustrating a variant of embodiment.
FIG. 5 is an elevation cross section similar to FIG. 1 illustrating a development of the invention.
FIG. 6 is an elevation view according to line VI--VI of FIG. 5.
FIG. 7 is a partial elevation cross-section of the heat exchanger of FIG. 5 in an embodiment illustrating a development of the invention.
FIG. 8 is a cross-section taken along line VIII--VIII of FIG. 7.
FIG. 9 is a partial cross-section illustrating the development of FIG. 5 in an embodiment similar to that of FIG. 1.
FIG. 10 is a partial elevation cross-section similar to FIG. 9 illustrating a further development of the invention.
FIG. 11 is a partial cross-section similar to FIG. 9 illustrating a simplified embodiment.
FIG. 12 is a cross-section taken along line XII--XII of FIG. 5 illustrating, in cross-section, a particular embodiment of the heat exchanger of FIGS. 1-11.
DESCRIPTION OF PREFERRED EMBODIMENTS
The heat exchanger shown in the drawings comprises a body 1 made by moulding of a metal, for example aluminum or aluminum alloy, "Inconel", or still by machining of metal, either a light alloy, or a stainless steel, titanium or any other suitable metal for the use considered.
The body 1 forms an envelope 2 of a general cylinder shape, and which is closed at one end by a bottom 3 formed in one piece with the envelope 2.
The body 1 delimits an inner cylindrical wall 4 having ends provided with distributing and collecting recesses 5 and 6. The recess 6 has an annular shape while the recess 5 can extend only on a part of the periphery of the cylindrical wall 4.
The recesses 5 and 6 communicate with an input channel 7 and an output channel 8, respectively, designed to be connected to connection members leading to admission and discharge ducts (not shown).
In the embodiment shown in the drawings, the body 1 is provided with a fixation flange 9 designed to be mounted on any suitable support (not shown).
The body 1 could without departing from the scope of the invention, be an integral part of a carter of a motor or an other similar device.
The end of the body 1 which is opposed to the bottom 3 forms a bearing surface 10 for a flange 11 formed at one end of a sheath 12 closed by a bottom 13 so to make a sealed bottle. The sheath 12, the flange 11 and the bottom 13 are made as a single unit, preferably of a light alloy, manufactured by a machining method making that the wall of the sheath is relatively thick and always greater than the thickness which is computed for resisting to mechanical efforts, and the thickness of the wall of the sheath is at least about 1 to 3 mm.
The machining method for manufacturing the sheath 12, bottom 13 and flange 11 is chosen among the methods making that no creek is formed in the fluid separation wall that forms the whole unit in the shape of a bottle as above explained.
A machining of a solid part constitutes a suitable embodiment, as well as an embodiment comprising rolling of the sheath 12 and soldering of the bottom 13. An embossing or forging method can also be used.
A gasket 14, for example a o-ring is installed between the flange 11 and the bearing surface 10 of the body 1.
As shown in the drawings, the respective sizes of the sheath 12 and body 1 are chosen so that a space 15 will exist between the inner wall of the bottom 3 and the outer wall of the bottom 13, and also between the outer wall of the sheath 12 and the inner wall of the envelope 2 of the body 1.
Heat dissipators 16, formed for example by corrugated sheet, a plurality of fins or points, or other similar members, are protruding from the inner wall of the sheath 12 and, samely, heat dissipators 17 are protruding from the outer wall of the sheath 12 to extend on all the useful length thereof.
When the heat dissipators 16 and 17 are made by means of corrugated strips, well known in the heat exchanger art, they are connected to the sheath 12, for example by brazing. When the heat dissipators 16 and 17 are formed by fins, or points, they are manufactured by a machining method, for example by milling in a machining center providing a fluid separation wall partly made of the sheath 12 and the bottom 13. One will not depart from the scope of the invention by making the sheath 12 and the heat dissipators 16 and 17 by means of a casting method, a forging method, a spinning method, or by an other suitable method.
The heat dissipators 17 are surrounded by a sleeve 18 which can be made of metal or, possibly, synthetic material, which sleeve 18 is extending on all the useful length of said heat dissipators 17 while providing an annular free space with the inner wall of the flange 11 and with the inner wall of the bottom 13 of the body 1, respectively.
A sealing gasket 19 is preferably installed between the sleeve 18 and the cylinder wall 4 of the envelope 2, which sealing gasket 19 is possibly provided so to ensure only a relative tightness.
In a similar manner to what has been described in the above disclosure with respect to the heat dissipator 17, a second sleeve 20 is engaged within the heat dissipator 16.
The second sleeve 20 extends on all the useful length of the heat dissipator 16, and is supported in a neck 21 of a distributing cover 22 applied on the outer wall of the flange 11.
A sealing gasket 23 is installed between the distributing cover 22 and the flange 11. Fixing and holding means 24, for example screws or bolts, are provided for securing the distributing cover 22 on the flange 11 and for securing the flange 11 on the body 1.
The distributing cover 22 forms an inlet duct 25, arranged preferably coaxial to the sheath 12, and an annular manifold 26 communicating with the annular space 27 formed between the second sleeve 20 and the inner wall of the sheath 12.
The manifold 26 conducts to an output duct 28.
The above described heat exchanger is principally designed for enabling heat exchange between incompatible fluids, which means fluids that should in no case be put in contact together, as this can be the case between a fuel product, for example kerosene, and the lubrication oil of members of an engine or of a transmission when these two fluids are at very different temperatures, the lubrication oil having for example to be cooled-down by the fuel supplied to the engine.
The first fluid, for example the fuel, is supplied into the heat exchanger through the inlet duct 25 according to arrow F 1 . The first fluid passes then in the space 27 formed between the second sleeve 20 and the outer surface of the sheath 12, which space 27 contains the heat dissipator 16.
This first fluid is then supplied to the annular manifold 26 and then to the outlet duct 28.
The second fluid, for example a lubricant oil, is supplied according to arrow F 2 to the inlet channel 7 that directs the second fluid to the annular recess 6 which forms a distributor that distributes and conducts this fluid within the sleeve 18, thereby flowing outside of the sheath 12 along the heat dissipators 16 and 17 carried by the sheath 12.
The space 15 separating the bottom 13 of the sheath 12 from the bottom 3 of the body 1 forms a manifold for the second fluid that is thus supplied to the recess 5 and then into the outlet channel 8.
The preceding disclosure shows that no passage whatsoever can exist between the circuit of the first fluid and that of the second fluid. If a leak would occur, the leak could only be produced between the flange 11 and the bearing surface 10 of the body 1, in case the gasket 14 is defective. But, in this case, the second fluid would be conducted to the outside without possibly rejoining a part of the circuit of the first fluid.
In a like manner, a leak in the circuit of the first fluid could only be produced between the outside of the flange 11 and the gasket 23 of the distributing cover 22. In this case, such a possible leak which would be caused by a defect in the gasket 23 could conduct the first fluid only to the outside without this first fluid being able in any case to come into the circuit of the second fluid.
In the above described example, the two fluids are circulating in a counter-flow direction. But one will not depart from the scope of the invention by using another way of circulation between the two fluids for means usual in the art. It is in particular possible to arrange partition walls at ends of some of the heat dissipators for establishing a zigzag flow of one and/or the other of the two fluids.
The sleeve 18 can be freely mounted relative to the envelope 2 and heat dissipators 16, or the sleeve 18 can be fixedly mounted with the envelope 2 while remaining free with respect to the heat dissipators 16, or still the sleeve 18 can be fixedly mounted with the heat dissipators 16 while being free with respect to the envelope 2. It is also possible not to use the sleeve 18 if the length of the distributing recess 6 is small relative to the length of the beat dissipators 16, which is illustrated for the heat dissipators shown at 16a in the embodiment to be described later on in reference with FIG. 5.
Samely, the second sleeve 20 is provided to be slidable with respect to the heat dissipators 16 or, if the sleeve 20 is fixedly mounted with the heat dissipators 16, the second sleeve 20 is provided to be movable with respect to the neck 21, thereby also avoiding stresses which could occur because of differential heat dilatations.
In the above disclosure, it has been mentioned that the sheath 12 has a thick wall, for example of about 1 to 3 mm in order to reduce, or even eliminate, any risks of communication between the circuit of the first fluid and that of the second fluids.
For still more eliminating a risk of accidental communication between the two circuits, FIGS. 2 to 4 illustrate means forming some developments of the invention for obtaining thick walls with good heat conductivity.
According to FIGS. 2 and 3, the sheath 12a of the bottle is formed by two tubular members 29, 30 providing therebetween an annular space 31. The tubular members 29, 30 are connected together on a greater part at least of their length by heat conducting members 32, for example strips, which are corrugated or have an other suitable shape, and which can be brazed or connected by any other suitable means to those tubular members 29, 30.
On an other hand, the tubular members 29, 30 are connected together at least at their ends by means of rings 33, 34, which are brazed or soldered in order to provide an absolute tightness.
Various means are known in the art for obtaining such an absolute tightness, and it is for example possible to use an electron beam soldering.
The annular space 31 advantageously communicates with a vent channel 35 provided in the flange 11. In this manner, in case one of the tubular members 29 or 30 has a leak, the first fluid f 1 or the second fluid f 2 will enter the annular space 31 and will be evacuated by the vent channel 35, which makes possible to immediately detect the anomaly.
FIG. 4 shows that the heat conducting members 32 can be made by fins 32a possibly formed by moulding together with one of the tubular members 29 or 30, so to divide the annular space 31 in longitudinal channels 31a.
FIG. 5 illustrates a development of the invention permitting to manufacture heat exchangers having a great output delivery.
In the embodiment of FIG. 5, the sheath 12 made as above described in relation with FIG. 1 comprises an open end provided with a ring 36 in which a socket 37 is centered, the socket 37 having thick walls, i.e. walls of a thickness similar to that of the sheath 12.
O-ring sealing gaskets 38 providing an absolute tightness are installed between the ring 36 and the socket 37, the free end of which socket 37 forms a flange 39 provided with o-ring sealing gaskets 40 which are supported on a bearing surface 41 of the end la of the body 1. The gaskets 40 provide also an absolute tightness.
In this embodiment, the body 1 is provided with a removable bottom 3a that is fixed, for example bolted, on the body 1, with an interposition of o-ring gaskets 42 providing an absolute tightness.
The sleeve 12 is provided, as in the embodiment of FIG. 1, with heat dissipators 16 and 17 and, in a similar manner, the socket 37 is provided with heat dissipators 16a and 17a, respectively, extending on both of its sides.
The beat dissipators 17 and 17a are supported on the inner wall 43 and outer wall 44 of a member forming an annular duct 45 extending from a distributing chamber 46 opening in the inlet duct 25 of the body 1.
The drawings show that sealing gaskets 47 are installed between the inner wall of the inlet duct 25 and the outer wall of the distributing chamber 46. The tightness which is thereby provided is not necessarily an absolute tightness.
The end 1a of the body 1 forms an outlet chamber 48 provided with an outlet nozzle 49.
At least one aperture 50 is provided between the chamber 46 and the annular duct 45 for communicating the chamber 48 with a chamber 51, the chamber 51 then communicating with the annular spaces separating the inner wall 43 and outer wall 44 of the duct 45 from the outside of the sheath 12 and the inside of the socket 37.
The above disclosure shows that the walls 43, 44 fulfill the function of either one of the sleeves 18 or 20 of the embodiment according to FIG. 1, in addition to functions to be described later.
The member that forms the chamber 46 and the walls 43, 44 of the annular duct 45 can be made of various materials, for example this member can be made of metal or of composite or plastic material, according to temperature of the fluids designed to bathe this member. Preferably, the above member is made of a material having a low heat conductivity, which can be obtained as described later-on with reference to FIG. 7.
The drawings show that the annular duct 45 is open at its end opposite the chamber 46 so that the fluid, which is supplied to the inlet duct 25 according to arrow F 2 , is then supplied inside the annular duct 45 and goes out therefrom at its open end as shown by the arrows, and is conducted to the outlet chamber 48 in a counter-flow direction by following the heat dissipators 17 and 17a.
Because of the low conducting nature of the walls 43 and 44, the heat exchange is small between the fluid circulating between the walls 43 and 44 and the fluid circulating outside the walls 43 and 44.
To correspond to what has been discussed above relatively to the working of the heat exchanger of FIG. 1, it is assumed that the fluid circulating according to the arrow F 2 is the second fluid, for example a lubricant, having to be cooled down by a first fluid, for example a fuel having to be supplied to the combustion chamber of an engine.
In the embodiment of FIG. 5, the first fluid is supplied to the input channel 7 according to the arrow F 1 . This first fluid is directed, as shown by the arrows so that the first fluid will circulate around the socket 37 along the heat dissipators 16a in a counter-flow direction to the first fluid circulating along the heat dissipators 17a.
The first fluid is therefore supplied to a passage 52 in the bottom 3a and leading to a median mouth 53 opening inside the bottle that is formed by the sheath 12, which means: inside the sleeve 20 surrounded by the heat dissipators 16 secured to the sheath 12.
Thus, the first fluid is supplied into the bottom 13 of the bottle and directed therefrom to the inside of the sleeve 20. This first fluid circulates then along the heat dissipators 16 on the outer wall of the sheath 12, which means that the first fluid then circulates in a counter-flow direction to the second fluid that circulates according to the arrow F 2 along the heat dissipators 17 which are carried by the outer wall of the sheath 12.
The first fluid is finally supplied into a manifold 54 (FIGS. 5 and 6) defined by the removable bottom 3a, and is thus directed to the outlet channel 8 of the body 1.
As this is clear from the above disclosure, the first fluid always circulates outside of the socket 37 and inside of the sheath 12 so that an absolute tightness is only necessary between these two parts, i.e. at the annular gaskets 38 and also between the socket 37 and the bearing surface 41 of the end la of the body, which is provided by the o-ring sealing gaskets 40.
The second fluid, for its part, circulates only inside the socket 37 and outside the sheath 12. The risks of communication are thus extremely reduced since they are caused, either by a possible porosity of the socket 37 or of the sheath 12, or by an accidental perforation which could be caused by the presence of waste products as for example metal chips.
There is hereinafter described how, according to the invention, it is now possible to get rid of this risk.
In order to still increase tightness between the socket 37 and the sheath 12, it is advantageous to Join the ring 36 to one end to the socket 37 by a weld 55 (FIG. 9), the good carrying out of which weld can easily be checked by means known in the art.
In this case, it is also advantageous as shown in FIG. 9, that the flange 39a of the socket 37 is tightened between complementary flanges 56 and 57, respectively of the body 1 and of the end 1a of the body 1. There is then used for maintaining the socket 37, the same means as that shown in FIG. 1 for maintaining the sheath 12.
Also as in FIG. 1, sealing gaskets 14 and 23 are provided and applied on the flange 39a. According to this embodiment, the only one possibility for the fluid f 1 to leak would be to leak between the flange 39a and the flange 56, which means outside of the body 1 of the heat exchanger and, samely, the only one possibility for the fluid f 2 to leak would be to leak between the flange 39a and the flange 57, which also means outside of the heat exchanger.
It has been mentioned in the above disclosure that it is advantageous to reduce as far as possible the heat exchange between the annular duct 45 and the heat dissipators 17 and 17a, respectively connected to the sheath 12 and to the inner wall of the socket 37.
FIGS. 7 and 8 illustrate an embodiment enabling to reduce such a heat exchange at a very small value. In this case, the member defining the annular walls 44 and 45 is made so that said walls are respectively formed by two concentrical tubes 44a, 44b and 45a, 45b which are spaced apart by means of spacers 58.
One at least of the tubes 44a, 44b and 45a, 45b has one or more apertures 59 so that some fluid f 2 , that circulates inside the annular duct 45, or outside the annular duct 45, will fill the space separating the concentrical tubes 44a, 44b and 45a, 45b.
The apertures 59 are small so that circulation of the fluid contained between said concentrical tubes is reduced and even nil. In this manner, the fluid itself forms a heat screen that limits conduction.
FIGS. 7 and 8 also show an embodiment enabling an escape outside of the heat exchanger of one and/or the other fluid f 1 , f 2 when the socket 37 is arranged as described by reference to FIG. 5, i.e. when the socket 37 comes to bear on the ring 36 of the sheath 12 through the gaskets 38 and bears, on an other hand, on the bearing surface 41 through the gaskets 40.
For this purpose, the socket 37 that is relatively thick for the same reason as the sheath 12 is moreover provided with a small longitudinal bar 60 having a channel 61 therein communicating with ducts 62, 63 opening respectively between the gaskets 40, on one hand, and between the gaskets 38, on the other hand.
The duct 62 is arranged to wards a discharge channel 64 in the end 1a of the body 1. In such a manner, a leak of the fluid f 1 which would occur in case of failure in one of the gaskets 38, would supply, the fluid through the ducts 63, 62 towards the channel 64. Samely, a leak of the fluid f 2 which would be caused by a deficiency in the other gasket 38 or in one of the gaskets 40 would supply this fluid towards the discharge channel 64.
FIG. 10 illustrates a development of the invention by which there is get rid of the risk of leaks through porosity or through a milling action possibly caused by waste products.
As shown in the drawings, the sheath 12, as well as the socket 37 are both made for having two walls 12a, 12b and 37a, 37b, respectively, defining annular chambers 65, 66 in which are arranged heat transmission members 67, 68. The heat transmission members 67, 68 can be formed by fins, coiled strips, bands that have been cut as heat disturbing elements, or still by other members providing a good heat transmission. The heat transmission members 67, 68 are preferably brazed to, or made integral with, one of the walls of the sheath 12 or socket 37.
The annular chambers 65, 66 are on an other hand connected together by the duct 63 as described above with reference to FIG. 7, and the duct 64 is provided in the flange 39a for communicating with the chamber 66 of the socket 37 or with the chamber 65 of the sheath 12 in the case of embodiment of FIG. 1 which does not comprise the socket 37.
The above disclosure shows that the working from a heat exchange point of view is not modified with respect to the embodiments above described with reference to FIGS. 1, 5 and 9 and that, besides, in case of damage to one of the walls 12a, 12b and 37a, 37b, respectively, either one of the fluids f 1 or f 2 is necessarily directed outside the heat exchangers thereby eliminating any risks of contact between the two fluids.
FIG. 11 illustrates a simplified variant of the embodiments according to FIG. 5 or 9. In FIG. 11, the same reference numerals designate the same members as those described in the above embodiments.
The body 1 is made in order to be connected with a tightness, which can be a relative tightness, directly to one end of the sleeve 20 surrounded by the heat dissipators 16.
A single tube 43a is substituted to the tubes 43 and 44 of FIGS. 5 and 9, and this tube 43a is connected through the gasket 47, the tightness of which being possibly a relative tightness, to the mouth 25 of the end 1a of the body 1.
The tube 43a forms a separation wall between the heat dissipators 17 and 17a of the outer surface of the sheath 12 and inner surface of the socket 37, thereby defining a double circuit between said sheath 12 and sockets 37. One of the fluids can be caused to circulate from the mouth 25 by following the arrows F 2 shown in a full line to be supplied to the outlet duct 49, or this fluid can be caused to circulate from the outlet duct 49 by following the arrows illustrated in phantom, i.e. in a direction contrary to that of F 2 . On an other hand, the other fluid can also circulate in one or in the other direction according to the arrows F 1 . It is therefore possible to provide circulations both in a same direction, in a counter-flow direction or at a cross-flow direction.
In the preceding disclosure, it has been mentioned that the envelope 1, the socket 37, the part delimiting the annular duct 45, the sheath 12, the sleeve 20, as well as the hereabove described members associated therewith, have an annular cross-section. FIG. 12 illustrates that it is possible to provide other sectional shape while carrying into effect all the above described features.
In this respect, FIG. 12 shows that the heat exchanger, in its embodiment shown in FIG. 5, can have an arcuate shape in order to be adaptable to a support member of a general cylinder shape, as this is the case for the walls of jet engines in aeronautics.
In FIG. 12, as in the preceding figures, the same reference numerals designate the same members as those detailed in the above disclosure.
It is obvious that other sectional shapes can be samely provided, the heat exchanger having possibly a rectangular cross-section which can be more or less flattened.
In the above disclosure, it has been explained that an absolute tightness should be obtained at various places of the circuits. For other parts of the circuits, for example between the ring 36 and the passage 52, or at the gasket 47, only a relative tightness should be provided. This relative tightness can be made by any suitable means known in the art, such as by gaskets, a tight fitting, interposition of an impregnation product, etc. . . .
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An annular heat exchanger for incompatible fluids, such as reactive compounds, particularly for the aeronautics industry, in which a sealed bottle is fixed interior of a hollow body, with integral heat dissipators and novel fluid passageway orientation, whereby no leak can occur which would commingle the incompatible fluids.
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BACKGROUND OF THE INVENTION
The present invention relates to window and door coverings, and more particularly to window and door coverings with acoustical materials that block transmission of sound and absorb sound energy.
Windows and doors permit a large amount of sound energy to pass through a building or from one area of a building to another, compared with the solid walls and roofs. Window and door coverings, such as shutters and blinds, are used for a variety of reasons; they have been used for decorative purposes, to provide thermal insulation against heat and cold, and to block the transmission of sunlight.
Existing methods for insulating windows and doors against sound transmission involve expensive, unattractive, and inconvenient modifications, such as adding windows on top of windows, multiple doors in a vestibule arrangement, or permanently installed window “plugs” that are not operable and cannot be easily removed and re-installed. Existing methods use lightweight materials that do not provide sufficient noise reduction in situations where traffic, aircraft, and other noises are occurring exterior to a building. Existing methods address either sound blocking or sound absorption rather than providing both characteristics simultaneously.
With the ever-increasing population density throughout the world, and especially in urban and suburban areas, an improved approach to sound reduction using window and door coverings is necessary. This invention provides sound reduction and absorption in various embodiments that allow for operability, ease of installation, and a variety of aesthetic choices for both new construction and retrofit applications, to allow for quieter, more pleasant living, sleeping, and working environments within buildings.
SUMMARY OF THE INVENTION
The present invention is directed to an apparatus for significantly reducing an amount of noise that is emitted through an opening in a wall, such as but not limited to a window or door. Towards this end, an acoustical dampening barrier for an opening in a wall that is translatable to an open position to allow access to the opening is disclosed. The barrier including a first barrier layer made of at least one of a rigid and semi-rigid material, a second barrier layer made of an acoustic material with sound attenuation characteristics that is fixed to the first barrier layer on a side of the first barrier layer where a sound to dampen is emitted, and a third barrier layer made of an acoustic material with sound absorptive characteristics that is fixed to the second barrier layer on a side of the second barrier layer where a sound to dampen is emitted. A seal material is also disclosed that is connected to the opening in the wall, the first barrier layer and/or the third barrier layer to further dampen a sound emitted when the fixed barrier is translated to a closed position to prevent access to the opening. In one preferred embodiment, a track system is also included for securing the first barrier layer, the second barrier layer and the third barrier to the opening and/or allowing the first barrier layer, the second barrier layer and the third barrier to be translated between the open position and the closed position.
In another preferred embodiment, an acoustic reduction system for use with at least one of a door and a window is disclosed. The system comprises a barrier connected to a frame of either the door or window. The barrier comprises a first barrier layer made of at least one of a rigid and semi-rigid material, a second barrier layer made of an acoustic material with sound attenuation characteristics that is fixed to the first barrier layer on a side of the first barrier layer where a sound to dampen is emitted, and a third barrier layer made of an acoustic material with sound absorptive characteristics that is fixed to the second barrier layer on a side of the second barrier layer where a sound to dampen is emitted. A seal material is connected to the frame and/or the barrier to further close an opening between the frame and the barrier. In another preferred embodiment, a track system is further provided for securing the barrier to the frame and/or allowing the barrier to be translated between the open position and the closed position.
In another preferred embodiment of the present invention, an improvement for a window shutter system having a plurality of decorative shutter slats that is placed inside a window is disclosed. The improvement comprises a first barrier layer made of an acoustic material with sound attenuation characteristics fixed to each individual decorative shutter slat of the plurality of decorative shutter slats on a side of the shutter where a sound to dampen is emitted. The improvement further includes a second barrier layer made of an acoustic material with sound absorptive characteristics fixed to the first barrier layer on a side of the first barrier layer where a sound to dampen is emitted.
BRIEF DESCRIPTION OF THE DRAWINGS
The figures shown depict only a sample of configurations that may be employed for the present invention. Those skilled in the art will recognize variations to the figures presented herein. The features and advantages of the present invention will become apparent from the following detailed description of the invention when read with the accompanying drawings in which:
FIG. 1 is a perspective view of a preferred embodiment of bi-fold shutter coverings installed inside a window frame;
FIG. 2 is a perspective view of a preferred embodiment of a single-door shutter covering installed inside a window frame;
FIG. 3 is a perspective view of a preferred embodiment of multi-fold shutter coverings installed inside a window frame;
FIG. 4 is a perspective view of a preferred embodiment of sliding multiple door shutters installed on a track within a window frame;
FIG. 5 is a perspective view of a preferred embodiment of vertical vanes covering installed inside a window frame;
FIG. 6 is a perspective view of a preferred embodiment of a horizontal vane covering installed outside a window frame; and
FIG. 7 is an illustration of a preferred embodiment of a track that is used to create a positive seal between vertical and/or horizontal slats and a window frame.
DETAILED DESCRIPTION OF THE INVENTION
Before proceeding to a detailed description of the preferred embodiment of the present invention and alternate embodiments, several general comments should be made about the applicability and the scope of the present invention.
First, while FIG. 1 illustrates a multiple door shutter with four doors, any number of door sections may be used to cover larger or smaller openings within the scope of the invention. Furthermore even though variations of the use of shutter doors is illustrated, these are only exemplary embodiments and those skilled in the art will readily recognize other variations that are possible that are still within the scope of the invention. Second, while the present invention illustrates three layers of material to make up the covering, more or fewer layers may be used to achieve the same acoustical properties without departing from the intended scope of the invention. Third, the cross-sectional shape of the vanes can vary without departing from the intended scope of the invention. Fourth, while FIG. 7 illustrates a design for a track that is used to create a complete positive seal between slats, other track designs may be used without departing from the intended scope of the invention. Finally, while the invention is disclosed as being used for windows and doors, the scope of the invention is also applicable with other apparatus that would benefit from a reduction of noise being transmitted therethough, such as a wall in a multi-room conference facility. Fifth, though illustrated embodiments show the invention connected or attached to a frame or wall, in another exemplary embodiment, the present invention is completely removable from a wall and/or frame, instead of being hinged, sliding or on a track. Finally, the 3-layers of material described herein is the minimum number of layers for proper functionality and performance, but there could be more than 3 layers. For example, use of two layers of a mass loaded vinyl may be used, and/or acoustically absorptive fabric may be used on both exterior sides of the assembly.
Now proceeding to a description of FIG. 1 , a partial wall section 1 is shown. In this preferred embodiment a shutter assembly 10 , having four shutter doors 15 , 16 , 17 , 18 , is shown installed inside a window frame 12 . The shutter assembly 10 is shown with three layers, an outer decorative layer 3 which can be made of wood, plastic or any rigid material. An inner layer 4 is made of an acoustic material designed with high sound attenuation characteristics to block sound transmission through the shutter 10 . An additional layer 5 facing the window 14 or door (not shown) is made of an acoustic material designed with high sound absorptive characteristics. The shutter doors 15 , 16 , 17 , 18 are hinged and may be swung out of the way to allow access to the window 14 . When the doors 15 , 16 , 17 , 18 are closed a flexible seal 2 contacts the frame 12 and makes a positive seal. Flexible seals 2 are also installed between doors 15 , 16 , 17 , 18 for a positive seal. A positive seal results when no openings remain through which sound could pass without first encountering either the seals, or the layers of material described above. As illustrated, the flexible seals 2 are connected either around the perimeter of the door or window. In another preferred embodiment, the flexible seals are attached to the window frame or doorframe.
A preferred embodiment of the invention is shown in FIG. 2 . This embodiment shows a partial wall section 1 with single door shutter 20 . In this embodiment the shutter 20 is shown installed inside a window frame 12 . The shutter 20 is shown with three layers, an outer decorative layer 3 which can be made of wood, plastic or any rigid material. An inner layer 4 is made of an acoustic material designed with high sound attenuation characteristics to block sound transmission through the shutter. An additional layer 5 facing the window or door is made of an acoustic material designed with high sound absorptive characteristics. As illustrated, the shutter 20 is hinged to a side of the frame 12 and may be swung out of the way to allow access to the window 14 or door (not shown). When the door 20 is closed a flexible seal 2 contacts the frame 12 and makes a positive seal. In another preferred embodiment, the flexible seals are attached to the window frame or doorframe.
Yet another preferred embodiment of the invention is shown in FIG. 3 . This embodiment shows multiple-door shutters. As illustrated, three door panels 22 , 23 , 24 are shown but additional panels may be used if desired. In this embodiment the shutter assembly 25 is shown installed inside a window frame 12 . Each panel 22 , 23 , 24 of the shutter assembly 25 is shown with three layers, an outer decorative layer 3 which can be made of wood, plastic or any rigid material. An inner layer 4 is made of an acoustic material designed with high sound attenuation characteristics to block sound transmission through the shutter. An additional layer 5 facing the window or door is made of an acoustic material designed with high sound absorptive characteristics. The doors 22 , 23 , 24 are hinged and may be swung out of the way to allow access to the window 14 or door (not shown). When the shutter assembly 25 is closed a flexible seal 2 contacts the frame 12 and makes a positive seal. Flexible seals 2 are also installed between door sections 22 , 23 , 24 .
Another preferred embodiment is illustrated in FIG. 4 . As illustrated, the door sections ride upon a track 31 that is fixed to and/or within the frame 12 . When fully opened, the doors are hidden within the wall section 1 . As with the prior described embodiments, the door sections 20 have an outer decorative layer 3 , an inner high sound attenuation layer 4 , and an additional high sound absorption layer 5 . Flexible seals 2 are placed along edges of the tracks 31 and on an edge 33 of the door sections 20 that contact an adjacent door section to insure that the door panels contact the track, each other, and make positive seals at these locations. Though a plurality of doors 20 are illustrated a single sliding door 20 may also be used.
In another preferred embodiment shown in FIG. 5 , a partial wall section 1 is shown. In this embodiment vertical vanes 30 , or slats, are shown installed inside a window frame 12 or door frame (not shown). The vanes 30 are made of three layers. The outer decorative layer 3 is made of wood, plastic or any rigid material. An inner layer 4 is made of an acoustic material designed with high sound attenuation characteristics to block sound transmission through the vane. An additional layer 5 facing the window or door, in other words, towards a sound emission, is made of an acoustic material designed with high sound absorptive characteristics. The vanes 30 are designed to overlap when closed so there are no gaps between the vanes 30 . The vanes 30 are attached to a track 6 at the top and bottom of the window frame 12 . The tracks 6 are sealed to the window frame or doorframe 12 with a flexible gasket 2 . The tracks 6 can translate the vanes 30 from fully open to fully closed as well as rotate the vanes 30 .
In FIG. 6 an exemplary embodiment of the invention is shown as horizontal blinds. A partial wall section 1 is shown. In this embodiment horizontal vanes 35 , or slats, are shown installed inside a window frame 12 or door frame (not shown). The vanes 35 are shown to be made of three layers. The outer decorative layer 3 is made of wood, plastic or any rigid material. An inner layer 4 is made of an acoustic material designed with high sound attenuation characteristics to block sound transmission through the vane. An additional layer 5 facing the window or door is made of an acoustic material designed with high sound absorptive characteristics. The vanes 35 are designed to overlap so there are no gaps between the vanes 35 when the vanes are closed. The vanes 35 are attached to a track 6 on both sides of the blinds. The tracks 6 are sealed to the window frame or doorframe with a flexible gasket 2 . The tracks 6 can translate the vanes 35 from fully open to fully closed as well as rotate the vanes 35 .
An exemplary example of the inner layer 4 that is made of an acoustic material designed with high sound attenuation characteristics to block sound transmission is a mass loaded vinyl. Currently, the sound transmission class rating (STC) for this material is 25 to 40 wherein the thickness of the material ranges from an eighth of an inch to a quarter of an inch. Those skilled in the art will recognize that in time, the STC ratings and thickness may improve or that the type of materials may be improved upon, such as new materials, composites, etc., which will also result in improved ratings. Towards this end, this invention is not limited to the current state of the technology.
An exemplary example of the additional layer 5 facing the window 14 or door that is made of an acoustic material designed with high sound absorptive is acoustically absorptive fabric. Such material is typically one sixteenth of an inch to half an inch thick. It has an outward surface similar to carpet, but without the heavy backing, wherein its acoustical absorption characteristics is attributed to it having a high surface area of fibers that absorb sound, preferably with a noise reduction coefficient (NRC) rating of 0.8 to 1.25. Those skilled in the art will recognize that in time, the NRC ratings and thickness may improve or that the type of materials may be improved upon, such as new materials, composites, etc. which will also result in improved ratings. Towards this end, this invention is not limited to the current state of the technology.
The outer layer 3 made of wood, plastic or any rigid material. In a preferred embodiment this layer is decorative in nature. For example, the outer layer may be configured to match cabinetry, molding, or furniture located within the room. When used as disclosed, the invention will result in a total noise reduction between 20 to 50 dB(A).
FIG. 7 shows an exemplary embodiment of a track and sealing mechanism that could be utilized with either a vertical vane or horizontal vane covering. In this embodiment, the vertical blind implementation as discussed above is shown installed inside a window frame 1 or door frame (not shown). A track mechanism 40 is provided above and below the vane 30 , and attached to the window frame 12 . The track mechanisms are able to rotate and translate the vertical vanes 30 about each vanes axis. On an edge 41 of each track mechanism 40 , a flexible gasket 2 , or seal, is placed that reaches to the window frame 12 . When the vertical vanes 30 are in a fully closed position, the seals 2 provide a positive seal for the vanes against the track. Those skilled in the art will readily recognize that a similar embodiment can be used for horizontal vanes.
While the invention has been described in what is presently considered to be a preferred embodiment, many variations and modifications will become apparent to those skilled in the art. Accordingly, it is intended that the invention not be limited to the specific illustrative embodiment but be interpreted within the full spirit and scope of the appended claims.
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An acoustical dampening barrier, for an opening in a wall, that is translatable to an open position to allow access to the opening, the fixed barrier including a first barrier layer made of at least one of a rigid and semi-rigid material, a second barrier layer fixed to the first barrier layer on a side of the first barrier layer where a sound to dampen is emitted made of an acoustic material with sound attenuation characteristics, a third barrier layer fixed to the second barrier layer on a side of the second barrier layer where a sound to dampen is emitted made of an acoustic material with sound absorptive characteristics, and a seal material connected to at least one of the opening in the wall, the first barrier layer and the third barrier layer to further dampen a sound emitted when the fixed barrier is translated to a closed position to prevent access to the opening.
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TECHNICAL FIELD
[0001] This invention relates to a culture container for culturing cells or micro-organisms and a method of culture and, more particularly, to a culture container which has excellent capability for preservation of culture medium, achievement of an optimum culture environment and easiness for extracting contents of a culture container and is suitable for culture of floating cell and culture of deposited cell which uses a carrier such as beads or non-woven cloth, and also to a method of culture using this culture container.
BACKGROUND ART
[0002] As a culture container for culturing cells, known in the art is a culture bag made of gas-permeable plastic used for filling culture medium therein. For example, Japanese Utility Model Application Laid-open Publication No. Hei 2-93999 discloses a culture bag in which a main body in the form of a bag made of a flexible plastic sheet has, in its upper portion, a solvent injection tube provided with a filter for separating micro-organism and also a culture medium outlet and a sterilized culture medium is filled in the main body of the bag. Japanese Utility Model Application Laid-open Publication No. Hei 3-172169 discloses a preservation and tissue culture container in which air-permeable sealing container for tissue culture containing a culture medium for tissue culture is sealingly wrapped with an impermeable material and this impermeable material is removed during tissue culture. Japanese Patent Application Laid-open Publication No. Hei 4-71482 discloses a method for manufacturing a culture bag filled with culture medium according to which culture medium which has been filtered for sterilization is filled in a sterilizing manner into a culture bag made of a film having large gas permeability and sterilized with γ-ray, the filling inlet is sealed in a sterilizing manner and then the culture bag is wrapped in a sterilizing manner with a secondary wrapping material which has small gas permeability and has been sterilized with γ-ray.
DISCLOSURE OF THE INVENTION
Problem to be Solved by the Invention
[0003] Cell culture is usually conducted in an incubator in which gas composition is controlled and, therefore, when it is necessary to culture plural types of cells which like different gas concentrations simultaneously, plural incubators having different gas concentrations become necessary if conventional culture bags are used. This requires a large space and complex and troublesome operations. Moreover, during culture, the conventional culture bags are arranged flatly on a rack in an incubator and cannot be superposed one upon another or suspended perpendicularly and this requires a further large space.
[0004] Further, since the conventional culture bags are made of a thin material, they lack stability in the shape and there is likelihood of damage in the course of commercial circulation and therefore handling of the culture bags needs special care which is rather troublesome. In the course of the culture bags disclosed in the above described literature which are wrapped with impermeable wrapping material during preservation, the culture bags are either in floating state inside the wrapping materials and therefore are in an instable shape or in close contact with the outside wrapping material in which case the culture bag as a whole becomes substantially the same as a single layer culture bag. Thus, they are also instable in the shape and there is likelihood of damage in the course of commercial circulation.
[0005] Furthermore, when contents are taken out of the culture bags after completion of cell culture, the conventional culture bags are suspended perpendicularly and contents are taken out of the bag by gravity. This requires time and inefficient. If an attempt is made to apply internal pressure to the culture bags to facilitate taking out of the contents, the bags are swollen and this makes it difficult to take out the contents smoothly.
[0006] It is therefore an object of the present invention to eliminate the problems of the conventional culture containers and provide a culture container which does not require plural different incubators even when plural types of cells which like different gas concentrations are cultured simultaneously, which can be superposed one upon another or suspended perpendicularly during culture and thereby can save space, which is not likely to be damaged during commercial circulation and therefore is excellent as a container suitable for commercial circulation, and which enables efficient taking out of contents after completion of culture.
[0007] It is another object of the invention to provide a method of culture of cells or micro-organisms using the culture container of the present invention.
Means for Solving the Problem
[0008] A culture double container achieving the above described objects of the invention comprises a gas-permeable culture container having an inlet and an outlet, a gas-impermeable container covering the culture container, and culture container holding means for holding the culture container in the gas-impermeable container in such a manner that space is defined between the culture container and the gas-impermeable container, said culture double container receiving gas controlled in its composition in the space defined between the culture container and the gas-impermeable container during culture of cell or micro-organism.
[0009] In one aspect of the invention, there is provided a culture double container wherein the culture container holding means joins the culture container partially to the gas-impermeable container.
[0010] In another aspect of the invention, there is provided a culture double container wherein the gas-impermeable container has a passage for gas which communicates with the space between the culture container and the gas-impermeable container.
[0011] In another aspect of the invention, there is provided a culture double container wherein a wall of the culture container is substantially formed during culture in either one of a cylindrical shape, a polygonal case shape having a cross-section of a regular polygon, a spherical shape and a semi-spherical shape.
[0012] In another aspect of the invention, there is provided a culture double container wherein culture medium is sealingly filled in the culture container and air in the space between the culture container and the gas-impermeable container is substituted by an inert gas or a mixed gas of an inert gas and carbonic acid gas.
[0013] In another aspect of the invention, there is provided a culture double container wherein culture medium is sealingly filled in the culture container and gas in the space between the culture container and the gas-impermeable container is removed.
[0014] In another aspect of the invention, there is provided a culture double container wherein culture medium is sealingly filled in the culture container and an oxygen absorbing agent is filled in the space between the culture container and the gas-impermeable container.
[0015] In another aspect of the invention, there is provided a culture double container wherein the gas-impermeable container has an oxygen absorbing portion or an oxygen absorbing layer.
[0016] In another aspect of the invention, there is provided a method of culture comprising a step of culturing, in a culture double container comprising a gas-permeable culture container having an inlet and an outlet, and a gas-impermeable container covering the culture container, space being defined between the culture container and the gas-impermeable container, by controlling composition of a gas filled in said space.
[0017] In another aspect of the invention, there is provided a method wherein the gas which has been controlled in composition is filled in and taken out of a gas passage communicating with the space between the culture container and the gas-impermeable container.
[0018] In another aspect of the invention, there is provided a method wherein, in a culturing process, a compressed gas is filled in the space between the culture container and the gas-impermeable container for extracting contents of the culture container.
[0000] has air therein substituted by an inert gas or a mixed gas of an inert gas and carbonic acid gas.
ADVANTAGEOUS RESULTS OF THE INVENTION
[0019] According to the invention, since gas controlled in its composition is filled in the space defined between the culture container and the gas-impermeable container during cell culture, in a case where plural types of cells which like different gas concentrations are required to be cultured simultaneously, plural culture double containers containing these cells for culture are arranged in a common incubator and gases having necessary gas concentrations are filled in these culture double containers. Thus, cell culture can be performed in a simple manner without requiring plural incubators. Besides, according to the invention, since the space is defined between the culture container and the gas-impermeable container and the culture container is held in the gas-impermeable container by the culture container holding means, in a case where the culture double containers are superposed one upon another during culture, gas can penetrate into each of the culture containers without causing any trouble to culture. Moreover, the culture double container does not change its form when it is suspended perpendicularly, a number of the culture double containers can be suspended in an incubator and therefore can save a lot of space for disposing culture containers as compared with a case where the conventional culture containers are used.
[0020] According to the invention, by filling compressed gas such as compressed air in the space between the culture container and the gas-impermeable container after completion of culture, contents of the culture container can be taken out promptly and thus taking out of contents can be performed much more efficiently than the conventional method depending upon gravity.
[0021] According to one aspect of the invention, since a wall of the culture container is formed during culture in either one of a cylindrical shape, a polygonal case shape having a cross-section of a regular polygon, a spherical shape and a semi-spherical shape, gas diffuses toward the center of the culture container from 360 degree directions and difference in concentration of gas between a position in the vicinity of the wall of the container and the remotest position from the wall becomes small as compared with the conventional culture container consisting of a flat bag. Consequently, culture condition which is nearer to an optimum culture condition can be achieved whereby efficiency and activity of culture of cells can be improved.
[0022] According to still another aspect of the invention, since air in the space between the culture container and the gas-impermeable container is substituted by an inert gas or a mixed gas of an inert gas and carbonic acid gas or air in this space is removed, oxidation of culture medium can be more perfectly prevented whereby preservation time of culture medium can be prolonged. Similarly, by filling an oxygen absorbing agent in this space or providing an oxygen absorbing portion or an oxygen absorbing layer in the gas-impermeable container, similar oxidation prevention effect can be achieved.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 . is a plan view showing an embodiment of a culture double container of the present invention.
[0024] FIG. 2 is a sectional view taken along arrows A-A in FIG. 1 .
[0025] FIG. 3 is a perspective section taken along arrows B-B in FIG. 1 .
[0026] FIG. 4 is a plan view of a culture container.
[0027] FIG. 5 is a perspective view of a gas-impermeable container shown with a part thereof being cut off for illustrating a gas passage provided during manufacture of the container.
[0028] FIG. 6 is a sectional view of a culture double container showing a gas passage attached at a later stage.
[0029] FIGS. 7A to 7E are sections showing shapes of walls of the container.
[0030] FIGS. 8A and 8B are side sectional views of a prior art container and the culture double container of the present invention shown respectively in a perpendicularly suspended state.
[0031] FIG. 9 is a sectional view showing a method for manufacturing a culture container.
[0032] FIG. 10 is plan view of a culture container of another embodiment of the culture double container of the present invention.
[0033] FIG. 11 is a plan view of the other embodiment of the culture double container of the present invention.
[0034] FIG. 12 is a sectional view showing another example of the culture container holding means.
[0035] FIG. 13 is a sectional view showing another embodiment of the present invention.
[0036] FIG. 14 is a sectional view showing another embodiment of the present invention.
[0037] FIGS. 15A and 15B are views showing another embodiment of the present invention in which FIG. 15A is a sectional view and FIG. 15B is a perspective section taken along arrows E-E in FIG. 15A .
[0038] FIG. 16 is a sectional view showing another embodiment of the present invention.
[0039] FIG. 17 is a sectional view showing still another embodiment of the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0040] Preferred embodiments of the invention will now be described with reference to the accompanying drawings.
[0041] FIG. 1 to FIG. 4 show an embodiment of the invention wherein FIG. 1 is a plan view, FIG. 2 is a view taken along arrows A-A in FIG. 1 , FIG. 3 is a perspective view taken along arrows B-B in FIG. 1 and FIG. 4 is plan view of the culture container.
[0042] A culture double container 1 comprises a culture container 2 and a gas-impermeable container 3 .
[0043] In the present invention, a wall of the culture container 2 should preferably be substantially formed during culture in either one of a cylindrical shape, a polygonal case shape having a cross-section of a regular polygon, a spherical shape and a semi-spherical shape. In the present specification, the shape of “substantially cylindrical” means not only a cylinder having a cross-section of a perfect circle as shown in FIG. 7A but also a cylinder having a cross-section of a circle which is distorted to such a degree as will not obstruct achievement of the object of the invention, e.g., a slightly distorted circle as shown in FIG. 7D or an ellipse. Likewise, the shape of “a polygonal case having a cross-section of a substantially regular polygon” means not only cases having a cross section of a regular polygon such as a regular triangle, a regular square (shown in FIG. 7E ), a regular pentagon, a regular hexagon (shown in FIG. 7B ) and a regular octagon (shown in FIG. 7C ) but also cases having a cross-section of a polygon which is distorted to such a degree as will not obstruct achievement of the object of the invention.
[0044] The culture container 2 is a container in the form of a generally rectangular bag as a whole in its plan view which is made of plastic having sufficient gas-permeability and comprises a cylinder section 4 consisting of a plurality (five in the illustrated example) of cylinders 5 arranged in the form of a beach mat and end portions 2 a and 2 b which are formed adjacent to the end portions in the longitudinal direction of the cylinder section 4 . The outer edge portions of the end portions 2 a and 2 b are respectively closed. The end portions 2 a and 2 b have flat surfaces and the respective cylinders 5 are communicated with one another via the end portions 2 a and 2 b . The end portion 2 a is provided with an injection-extraction opening 6 for culture medium, cells, cell growth element etc. which communicates with the inside of the culture container 2 . The injection-extraction opening 6 may be provided in necessary number for the purpose of culture and a connection tube may be attached to the injection-extraction opening 6 with a connector attached to the tip of a connection tube, if necessary.
[0045] For manufacturing the culture container 2 , as shown in FIG. 9 , rectangular flexible plastic sheets 7 and 8 are disposed face to face with an interval between them and four edge portions 7 a and 8 a of the sheets 7 and 8 are joined together by heat sealing. Then, the opposing sheets 7 and 8 are partially heat sealed along corresponding longitudinal lines 7 b and 8 b , 7 c and 8 c , 7 d and 8 d and 7 e and 8 e thereby to form five cylinders 5 which form the cylinder section 4 .
[0046] By heat sealing the opposing wall surfaces of the soft, flexible culture container 2 and filling culture medium in the container in a predetermined amount, a shape holding property can be imparted to the culture container 2 whereby close contacting between the culture container 2 and the gas-impermeable container 3 can be prevented or reduced and, as a result, obstruction to diffusion of gas to the culture container can be prevented or reduced. As alternative means for imparting the shape holding property to the culture container 2 , container holding means such as jigs, clips or magnets may be used to hold the opposing flexible walls of the container so that they will come into partial contact with each other. For preventing or reducing close contact, a member for preventing close contact may be inserted between the walls of the culture container 2 and the gas-impermeable container 3 or projections and depressions may be provided on the respective walls.
[0047] As the gas-permeable culture container 2 , it is preferable to use a material which has excellent gas permeability and a property to endure sterilization with γ-ray. Such material includes a film bag or a blow bag made of soft plastic such, for example, as polyethylene (PE), polyvinyl chloride (PVC), ethylene vinyl acetate copolymer (EVA), ethylene ethyl acrylate copolymer (EEA), ethylene methyl methacrylate copolymer (EEMA), and a polymer blend of styrene-ethylene-butylene-styrene and polypropylene (PP) or polyethylene.
[0048] In a case where γ-ray is not used for sterilization, Teflon (registered trademark), silicone rubber, a single polymer or a copolymer of 4-methyl-1-pentene or a single polymer or a copolymer of butadiene may be used. As other monomer of a copolymer, 2-24 carbon α-olefin or styrene, for example, may be used or a blend of one or more polymers of such α-olefin may also be used.
[0049] In the embodiment of FIG. 1 , as shown in FIG. 3 , gas diffuses in the directions of arrow C, namely toward the center of each cylinder 5 from 360 degree directions and, therefore, difference in concentration of gas between a position in the vicinity of the wall of the container and the remotest position from the wall becomes small and, consequently, culture condition which is nearer to an optimum culture condition can be achieved. During culture, the culture container 2 may be shaken, vibrated or rotated in a level not to give damage to the cell whereby sedimentation of cell or micro-organism observed in culturing of floating cell or micro-organism can be prevented and, moreover, stirring of culture medium is enhanced and this is desirable from the standpoint of maintaining homogeneity.
[0050] As will be apparent from FIG. 4 , in the portion of the culture container 2 outside of the end portions 2 a and 2 b in the longitudinal direction of the culture container and in the portions of the culture container outside of the cylinder section 4 in the width direction of the culture container, namely in four edge portions of the culture container 2 , there are formed seal portions 2 c , 2 d , 2 e and 2 f by heat sealing the two sheets. The seal portion 2 d among these seal portions is formed in the shape which is formed by cutting off a portion where a gas extraction opening of the gas-impermeable container 3 is provided as will be explained later so as not to obstruct provision of such gas extraction opening.
[0051] The gas-impermeable container 3 is a container having a size which is large enough for forming space which is sufficient for circulating gas between the container 3 and the inside culture container 2 . The container 3 is formed generally in a rectangular shape in a plan view with its four edges being closed. The gas-impermeable container 3 may be manufactured by, for example, superposing two gas-impermeable plastic sheets together and heat forming the two sheets so that the central portions is swollen out and seal portions 3 a , 3 b , 3 c and 3 d are formed in their four edge portions.
[0052] A gas injection opening 9 is provided in one end portion of the gas-impermeable container 3 and a gas exhaustion opening 10 is provided in the other end portion thereof. These openings communicate with the inside of the container 3 . Each of the gas injection opening 9 and the gas exhaustion opening 10 constitutes a gas passage of the present invention. The gas passage may be formed as a single opening functioning as both the injection opening 9 and the exhaustion opening 10 concurrently and at least one gas passage and preferably two gas passages are provided. The composition of culture gas may be suitably determined in accordance with the cell or micro-organism to be cultured. The culture gas may be supplied intermittently or continuously. By adjusting pressure of the culture gas, culture in which pressure is applied or culture in which pressure is varied can be realized.
[0053] The seal portions 3 a and 3 b of the gas-impermeable container 3 are fused to the seal portions 2 c and 2 d of the culture container 2 in such a manner that the seal portions 3 a and 3 b clamp the seal portions 2 c and 2 d between them thereby to form joint portions 12 and 13 of the gas-impermeable container 3 and the culture container 2 . The joint portions 12 and 13 function to hold the culture container 2 in the gas-impermeable container 3 in such a manner that space is formed between the culture container 2 and the gas-impermeable container 3 and constitute the culture container holding means of the present invention.
[0054] The gas passages may be formed previously during manufacture of the culture double container in the end portions the gas-impermeable container 3 as shown in FIG. 5 or, alternatively, a culture double container having no gas passage may be first circulated and, as shown in FIG. 6 , a gas passage 14 may be attached to a portion other than the seal portions of the gas-impermeable container 3 at a later stage.
[0055] As the gas-impermeable container 3 , there is no particular limitation. It may be formed as a blow-bag of a single layer or multiple layers or as a film bag of a single layer or multiple layers. In the case of a blow bag or film bag of a single layer, it should preferably be made of a film of a material which can be heat sealed easily to the surface layer of the culture container and has flexibility, e.g., a plastic film of polyethylene (PE), polypropylene (PP), ethylene-olefin copolymer, ethylene-vinyl acetate copolymer (EVA) etc. It is particularly preferable that the film should be the same material or a material of the same type as the surface layer of the container main body. It is also preferable that the container 3 should be used with an oxygen absorbing agent.
[0056] For imparting high impermeability, a multiple layer film is preferable. As a material having gas-impermeability, a multiple layer film of the above described plastic film used as a sealant and one or more of synthetic resin films including, for example, oriented films of a single layer or multiple layers such as a biaxially oriented polyethylene terephthalate film and a biaxially oriented nylon film, a film made of ethylene-vinyl alcohol copolymer (EVOH), polyglycol acid, aromatic polyamide or polyvinylidene chloride (PVDC), polyvinylidene chloride coated films, an alumina-deposited or silica deposited polyester or polyamide film etc.
[0057] For laminating these films, a known lamination method such as co-extrusion blow forming, dry lamination, sandwich lamination or extrusion lamination may preferably be used.
[0058] In a circulation process of the culture double container 1 , preservation property of culture medium can be improved and preservation time thereby can be prolonged by substituting air in the space between the culture container 2 and the gas-impermeable container 3 by an inert gas or a mixed gas of an inert gas and carbonic acid gas, or by removing air in this space. Similarly, a similar effect can be achieved by filling an oxygen absorbing agent in this space or providing an oxygen absorbing portion or an oxygen absorbing layer in the gas-impermeable container 3 .
[0059] As an oxygen absorbing agent or an oxygen absorbing resin, any known material may be optionally used. As an iron type oxygen absorbing agent, for example, a mixture of iron powder of iron or iron compound and a metal halogenide is preferable. As iron powder, there is no particular limitation in purity or other factors so long as it can produce oxygen absorbing reaction. For example, powder such as reduced iron powder, spray iron powder and electrolytic iron powder, crushed or ground cast iron or steel and powder of iron alloys such as iron carbide, iron carbonyl, ferrous oxide, ferrous hydroxide and iron silicate may be used. Powder of a granular shape is generally preferable and its particle diameter should preferably be within a range from 1 μm to 80 μm and, more preferably, within a range from 1 μm to 50 μm from the standpoints of easiness in handling, thick film thickness of an oxygen absorbing layer and projections and depressions of the oxygen absorbing agent appearing on the film.
[0060] As metal halogenide used as an additive to the iron type oxygen absorbing agent, chloride, bromide or iodide of alkali metal or alkaline earth metal may for example be used. Among them, chloride or iodide of lithium, sodium, potassium, magnesium, calcium or barium may preferably be used. A preferable amount of metal halogenide per 100 weight parts of iron powder is 0.1-20 weight parts and, more preferably, 0.1-5 weight parts. It is preferable to add and mix metal halogenide with iron powder previously for preventing separation of the respective materials. A preferable oxygen absorbing agent is an iron powder type composition including iron powder and metal halogenide and, more preferably, a metal halogenide covered iron powder type composition in which metal halogenide is deposited on iron powder.
[0061] The iron type oxygen absorbing agent may be filled in the space defined between the gas-permeable culture container 2 and the gas-impermeable container 3 covering it or space communicating with this space in the sate in which the agent is packed in non-woven cloth or paper in a manner not to leak out or may be mixed with a part of resin of a spout or cap constituting the container. Alternatively, it may be used in the form of an oxygen absorbing layer as any desired layer of the gas-impermeable container 3 . In this case, the oxygen absorbing layer should preferably be formed in one side or a part only of the gas-impermeable container 3 so that the inside of the gas-impermeable container 3 may be observed.
[0062] A preferable amount of the iron type oxygen absorbing agent to the resin is within a range from 10 weight % to 70 weight % and, more preferably, within a range from 10 weight % to 60 weight %. If the amount of the oxygen absorbing agent is less than 10 weight %, sufficient oxygen absorbing capacity cannot be secured whereas if the amount is higher than 70 weight %, processing such as injection molding, compression molding and film forming may become difficult. A preferable thickness of film of the oxygen absorbing layer is within a range from 10 μm to 100 μm and, more preferably, within a range from 20 μm to 80 μm regardless of the material of the film. If the thickness of the film is less than 10 μm, an oxygen absorbing amount per unit area of the film becomes small and sufficient oxygen absorbing capacity may not be secured. If the thickness of the film exceeds 100 μm, total thickness of the film becomes large with resulting inconvenience in handling and occurrence of a cost problem.
[0063] As the oxygen absorbing resin, a resin comprising a metal type oxidative catalyst and oxidative resin or oxidative organic ingredient, or a resin comprising polyphenols, ascorbic acids or the like and a basic material may be used.
[0064] As the oxidative resin or oxidative organic ingredient, a resin or organic ingredient which is subject to oxidation by oxygen in the air under the action of a transition metal type catalyst may be used.
[0065] As the oxidative resin may be used (1) a resin having class 3 carbon such as polypropylene, (2) a resin having a carbonyl group such as ethylene-carbon monoxide copolymer, (3) a polyamide resin having benzene ring such as MXD 6, (4) a resin having an unsaturated double bond in a main chain such as polybutadiene, polyisoprene and their copolymers, (5) a resin having an unsaturated double bond in a side chain such as cyclohexane group, and (6) a cyclic conjugated diene type resin such as polycyclohexadiene. As the oxidative organic ingredient may be cited (7) ascorbic acid and (8) cystein. They absorb water and oxygen under coexistence with a basic material such as sodium carbonate and potassium acetate.
[0066] As the metal type oxidative catalyst, metal compounds of Group VIII such as iron, cobalt and nickel are preferable. Other metal compounds such as copper and silver (Group I), tin, titanium and zirconium (Group IV), vanadium (Group V), chromium (Group VI) and manganese (Group VII) may also be used. Among these metal compounds, cobalt compound is particularly preferable because of its high oxygen absorbing speed. The transition metal catalyst is generally used in the form of an inorganic salt or organic salt of low valence or complex salt of the above described transition metals. These catalysts may preferably used in an amount of 100 ppm to 2000 ppm for each resin.
[0067] The oxidative resin or oxidative organic ingredient is advantageous over the iron type oxygen absorbing agent in that it can be applied without impairing observing capability and may be used as an oxygen absorbing layer in a desired portion or in entire surface of either one or both of the gas-permeable culture container 2 and the gas-impermeable container 3 . It may also be mixed with a part of resin of a desired container constituting component such as a spout or cap which is positioned in the space between the culture container 2 and the gas-impermeable container 3 or space communicating with this space.
[0068] In the case of providing the oxygen absorbing layer in the gas-impermeable container 3 , the container 3 may be formed in any desired structure, such, for example and not limited thereto, as an oxygen absorbing layer (single layer only), an outer layer and an oxygen absorbing layer (two layers), an outer layer, an oxygen absorbing layer and a sealant layer, an outer layer, a gas-impermeable layer and a sealant layer, and an outer layer, a gas-impermeable layer, an oxygen absorbing layer, a gas impermeable layer and a sealant layer.
[0069] For manufacturing the culture double container of the present embodiment, a culture double container filled with an oxygen absorbing agent if necessary is produced and then is subjected to sterilization by γ-ray (or sterilization by ultra-violet ray, electron ray or heating etc.). Then, culture medium is filled in the container and the filling opening of the container is sealed in a sterilizing manner to complete the manufacture.
[0070] In the case of the conventional container, if it is suspended perpendicularly, its shape is changed as shown in FIG. 8A and lack of uniformity in diffusion of gas becomes serious between a position in the vicinity of the wall of the container and the remotest position from the wall and an optimum gas composition therefore cannot be realized. For this reason, it cannot be suspended in this manner. In the case of the culture double container of the present embodiment, if the culture double container is suspended perpendicularly as shown in FIG. 8B during culture, the shape of the container remains unchanged. Accordingly, a number of the culture double containers 1 can be arranged in the perpendicularly suspended state whereby space for disposing the culture double containers can be saved.
[0071] FIGS. 10 and 11 show another embodiment of the culture double container of the present invention. In this embodiment, a culture container 2 provided with an injection-extraction openings 6 a and 6 b is produced and then two sheets of gas-impermeable materials are heat sealed to the culture container 2 in a manner to cover the culture container 2 as shown in FIG. 11 to form a gas-impermeable container 3 and thereby manufacture a culture double container 1 .
[0072] In this embodiment, an injection-extraction openings and gas exhaustion opening housing section 16 , a gas injection opening housing section 17 and an injection-extraction opening housing section 18 are first provided. A portion 19 including the injection and extraction opening housing section 18 and being defined by lines C-C is formed as an unsealed portion while injection-extraction openings 6 a and 6 b , a gas injection opening 9 and a gas exhaustion opening 10 are covered with an impermeable material constituting the gas-impermeable container 3 . In this case, an oxygen absorbing agent may be filled in the injection and extraction openings and gas exhaustion opening housing section 16 . By this arrangement, a function of removing oxygen in the container main body can be imparted via the gas exhaustion opening 10 and the oxygen absorbing agent may be removed during use of the container.
[0073] Then, one or more of the culture double containers produced in this manner are put in a sterilizing bag and is subjected to sterilization. Then, the bag is opened in a sterilized environment and culture medium is filled in a sterilizing manner through the injection-extraction opening 6 a provided in the unsealed portion 19 and is opened along lines C-C and this portion is sealed in a sterilizing manner. The container is then heat sealed leaving the injection-extraction opening housing section 18 to make a culture double container. By this arrangement, the injection-extraction openings 6 a and 6 b are advantageously protected by the impermeable material.
[0074] During use of the container, the extraction opening and gas exhaustion opening housing section 16 is opened along line D-D. Since the injection-extraction openings 6 b are already maintained in a sterilized state by the sterilization by γ ray, there is the advantage that the outside portion only has to be sterilized and the injection-extraction openings 6 b need not be sterilized.
[0075] In a case where the gas exhaustion opening 10 is used also as the gas injection opening 9 , the gas injection opening 9 and the gas injection opening housing section 17 need not be provided and even if they are provided, the housing section 17 need not be opened.
[0076] In the previously described embodiment, the culture container holding means is constituted by the joint portions 12 and 13 but the culture container holding means is not limited to such joint means but, as shown in the sectional view of FIG. 12 , culture container support arms 15 which support the culture container 2 by abutting against outside four corners of the culture container 2 may be formed in the longitudinal direction of inside four corners of the gas-impermeable container 3 made of rigid plastic. Any means may be employed as the culture container holding means if it can hold the culture container 2 in the gas-impermeable container 3 in such a manner that space is defined between the culture container 2 and the gas-impermeable container 3 .
[0077] In the above described embodiments, the culture containers are arranged in parallel in the form of a beach mat. Alternatively, the culture container may consist of a single cylinder. Likewise, in case the container wall is formed in the shape of a polygonal case, a sphere or a hemisphere, various modifications may be conceived.
[0078] Each of the culture container and the gas-impermeable container may be formed in the form of a pouch made of soft flexible plastic, or a container having rigidity such as a bottle or may be a combinations of these.
[0079] FIGS. 13 to 17 are sectional views of other embodiments of the present invention shown in the same section as FIG. 2 . In the embodiment of FIG. 3 , the culture containers 2 are heat sealed with adjacent culture containers in their opposite walls in the form of a beach mat thereby to impart the shape holding property. In FIGS. 13 to 17 , heat sealing is not made in the culture container 2 and the shape holding property is not imparted to the culture container 2 . In the present invention, any means may be adopted if space is defined between the culture container 2 and the gas-impermeable container 3 to prevent or reduce obstruction to diffusion of gas to the culture container 2 and the culture container 2 can be held in the gas-impermeable container 3 . Explanation will be made about FIGS. 13 to 17 which show examples of such means. In FIGS. 13 to 17 , the same component parts as those shown in the embodiments of FIGS. 1 to 12 are shown by the same reference characters and description thereof will be omitted.
[0080] In the embodiment of FIG. 13 , the gas-impermeable container 3 is a container made of plastic having rigidity and the gas-permeable culture container 2 is a container made of soft flexible plastic. A gas-permeable mat 17 made of a material having gas permeability such as non-woven cloth is filled between the containers 2 and 3 . By this gas-permeable mat 17 , space for housing gas controlled in its composition is defined between the containers 2 and 3 . In the cell culture process, it is necessary to observe growth capacity of cells with a microscope or the like and, therefore, the gas-permeable mat 17 need not necessarily be provided over the entire surfaces of the containers but a part thereof may be omitted. In short, it may be provided within a range capable of performing its function. For preventing shifting of the gas-permeable mat 17 , it may be adhered or fixed to the gas-impermeable container 3 by any known means. In this embodiment, the inner end portion 6 a of a culture medium injection-extraction opening 6 is not projecting into the inside portion of the culture container 2 and this is advantageous in that, when culture medium is taken out, there is no possibility that a part of the culture medium is left in the culture container 2 .
[0081] In the embodiment of FIG. 14 , both the gas-impermeable container 3 and the culture container 2 are made of soft flexible plastic and the gas-permeable mat 17 is filled between the containers 2 and 3 to defined space for housing gas. In the case of suspending this double container 1 perpendicularly, the container is supported on both sides thereof by reinforcing jigs 18 made of rigid members such as plates or a plurality of bars. By this arrangement, the same effect as shown in FIG. 8B can be obtained whereby the shape holding property can be imparted without requiring the culture container 2 made in the form of a beach mat.
[0082] In the embodiment shown in the sectional view of FIG. 15A and FIG. 15B which is a perspective sectional view taken along arrows E-E of FIG. 15A , both the gas-impermeable container 3 and the culture container 2 are made of soft flexible plastic. Reinforcing jigs 19 each of which consists of a rectangular rigid frame member and a net 20 stretched over the frame member are interposed between peripheral edge portions of the inner flat surfaces of the container 3 and peripheral edge portions of the outer flat surfaces of the container 2 and space for housing gas is defined between the containers 2 and 3 by these reinforcing jigs 19 . The inner surfaces of the gas-impermeable container 3 are not fixed to the reinforcing jigs 19 so that a gap 21 can be formed between the inner surfaces of the container 3 and the outside surfaces of the reinforcing jigs 19 . By this arrangement, in a case where contents of the culture container is taken out by filling compressed gas in the space between the containers 2 and 3 , the compressed gas can be circulated without obstruction.
[0083] In each of the embodiments of FIGS. 16 and 17 , the gas-impermeable container 3 is made of rigid plastic in one side only and the other side is made of soft flexible plastic. The gas-permeable culture container 2 is made of soft flexible plastic. The side of the culture container 2 facing the rigid side of the gas-impermeable container 3 is adhered closely to the inside of the gas-impermeable container 3 and space for housing gas is defined only between the other side of the culture container 2 and the inside of the soft side of the gas-impermeable container 3 . In these embodiments, walls of both sides of the gas-impermeable container 3 may be made soft and flexible or rigid according to necessity.
INDUSTRIAL UTILITY
[0084] The present invention is applicable to a culture container for cells or micro-organisms and a method of culture. Particularly the present invention is applicable to a culture container which has excellent capability for preservation of culture medium, achievement of an optimum culture environment and easiness for extracting contents of a culture container and is suitable for culture of floating cell and culture of deposited cell which uses a carrier such as beads or non-woven cloth, and also to a method of culture using this culture container.
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A culture container and a method of culture which do not require a plurality of incubators in a case where a plurality of cells of different kinds which like different gas concentrations should be cultured simultaneously.
A culture double container 1 comprises a gas-permeable culture container 2 having an inlet and an outlet 6 , a gas-impermeable container 3 covering the culture container 2 , and joint portions 12 and 13 for holding the culture container 2 in the gas-impermeable container 3 in such a manner that space is defined between the culture container 2 and the gas-impermeable container 3 . The culture double container 1 receives gas controlled in its composition in the space defined houses the culture container 2 and the gas-impermeable container 3 during culture of cell or micro-organism.
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CROSS-REFERENCE(S) TO RELATED APPLICATION(S)
[0001] This application is a continuation of application Ser. No. 11/569,430, filed Nov. 20, 2006, which is a 371 of International Patent Application No. PCT/NZ05/000103, filed May 20, 2005, which claims priority to New Zealand Patent Application No. 533,049, filed May 20, 2004, all of which are hereby expressly incorporation by reference.
FIELD OF INVENTION
[0002] This invention relates to a multi-compartment food container for housing materials separately. More particularly, but not exclusively the invention relates to a multi-compartment container capable of housing salad and salad dressing separately.
BACKGROUND
[0003] If certain food stuffs for example, a salad is to be provided to consumers in an optimum state it needs to be kept in a substantially airtight container to prevent moisture being lost leaving the salad wilted. In addition, any dressing provided with the salad should only be introduced to the salad just before the salad is consumed to prevent it from becoming soggy.
[0004] Accordingly salads are typically sold in a closed container without having the dressing mixed in. In most cases the dressing is contained in a sachet or tub which can be loose within the closed container in which case the consumer has no choice which dressing they will have. Alternatively the sachet or tub will need to be carried separately.
[0005] The risk with storing the dressing in the same container is that the dressing can leak through the packaging and into the salad. In some cases the packaging of the dressing can also interfere with or break the closure mechanism of the container allowing moisture to escape.
[0006] In addition, prior art containers require the individual packaging of the dressing to firstly be opened and then poured over the salad. This arrangement is messy and requires disposal of the dressing packaging. Mixing normally occurs by stirring the salad with a fork, which is not ideal for producing an even mixture of salad and dressing. Stirring can be very messy and often some of the salad spills out of the container.
[0007] Finally, over recent years the growth in “drive through” fast food restaurants has seen a rise in so-called “dashboard dining”—eating whilst at the wheel of a vehicle. Although not recommended, many so-called dashboard dining connoisseurs will attempt to open a sachet of salad dressing with one hand whilst steering a vehicle with the other. There are always going to be individuals prepared to attempt this task in spite of the risk that they pose to other road users, so, accepting this, it may be better to look at the entire current concept of for example, salads and dressings that are currently used in fast food outlets and see whether the packaging of these items cannot be improved.
[0008] What is required is a container capable of securely storing the salad and dressing separately to ensure the salad is in an optimum state when it is consumed. In addition a container which also allows the salad and dressing to be easily and thoroughly mixed would be advantageous.
[0009] In addition, a container which enables the separate compartments for the salad and dressing to be interchangeable so that consumers or sellers of the salad can match the salad they want with the dressing they want would also be desirable.
SUMMARY
[0010] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
[0011] It is an object of the present invention to provide an improved multi-compartment container for housing a food stuff (typically a salad {potato, leaf, Waldorf} or chips or meat} and dressing (typically salad dressing, vinegar, mint sauce) separately or at least to provide the public with a useful choice. Although the invention is embodied in several different aspects, it will be apparent from this broad background review that each of these aspects are so linked as to form part of the same general inventive concept.
[0012] In one aspect the invention can broadly be said to comprise of a multi compartment food stuff container suitable for housing a salad and a salad dressing comprising: a food storage compartment; and a food dressing storage compartment; wherein, said compartments are linked by a communication means adapted to allow mixing of a food dressing stored in the food dressing compartment with a food stored in the food storage compartment if the container is shaken.
[0013] Such an arrangement should tend to alleviate the problem of premature mixing of the components and will also make mixing of the components easier as only one hand is required. The multi compartment container could be integrally formed or assembled with a removable lid and/or the food storage compartment could be glued to the food dressing storage compartment.
[0014] In fact, those skilled in the art will appreciate that there are many different ways of releasably engaging the food storage compartment to the food dressing compartment (e.g. by way of example a threaded screw-on arrangement may be used). Preferably, the food storage compartment and food dressing storage compartment are provided with complementary engagement means so adapted as to allow both compartments to be releasably engaged with one another to form the multi compartment container.
[0015] The communication means could be a nozzle or aperture forming part of a base of the food storage compartment. Similarly, the communication means could be a nozzle or aperture forming part of a top or wall of the food dressing storage compartment. In fact the food storage compartment could have a base with an aperture (or a weakened portion or removable tab that could reveal/form an aperture) and the food dressing compartment could have a top or wall with a nozzle, the latter being able to either insert through the aperture of the base of the food storage compartment or punch its way through the weakened portion.
[0016] The base, top or wall either in combination or on their own act as a partition separating the compartments. Preferably, the communication means comprises a partition (separating the compartments) that incorporates a nozzle or aperture. The aperture in the nozzle can be any diameter and will depend on how viscous the dressing is.
[0017] The nozzle may have a removable tear-away cap which would be removed before the food storage and food dressing storage compartments are engaged.
[0018] Preferably the container is provided with a lid, the lid and container being provided with complementary engaging means adapted to releasably engage the lid to the container in a substantially fluid tight manner.
[0019] The base of the food storage compartment could be integral with and thus substantially rigid with the rest of the compartment. Alternatively, no rigid base could be present and simply a flexible microporous film could span the base of the compartment to provide a floor of sorts. Preferably the food storage compartment is sealed with a microporous film Preferably the food dressing storage compartment is substantially concentric with a longitudinal axis of the container and located below the food storage compartment.
[0020] The partition could be flat or could be downwardly depending, however, preferably the partition is raised at its centre and the nozzle is located substantially in the centre of the partition.
[0021] Preferably the aperture of the nozzle is of a size which also provides some controlled resistance to the flow of a dressing located within the dressing storing compartment.
[0022] A labelling system could be used to indicate different types of food dressing compartment. For example different symbols or colours could be used to identify different foods such as salad types and different dressings. The size of the food dressing compartment can vary depending on the nature of the dressing to be contained therein. A dressing could be fluid or fluid like (e.g. a salad dressing) or it could be a solid (e. g. seasoning such as salt).
[0023] Preferably, the food storage compartment of the container contains any appropriate selection or combination of food selected from the group comprising meat, salad, chips and a beverage.
[0024] Preferably, the food dressing compartment of the container contains any appropriate selection or combination of dressings selected from the group comprising salad, seasoning, vinegar, tartar sauce and vitamins.
[0025] The invention includes within its scope a food retail outlet incorporating a container as specified herein.
[0026] According to a second aspect of the present invention there is provided a food storage compartment as specified herein, adapted to receive a food dressing storage compartment and a lid also as specified herein.
[0027] According to a third aspect of the present invention there is provided a food dressing storage compartment as specified herein for use with a food storage compartment as specified herein.
[0028] Although the food dressing storage compartment can be formed from a body which could be then filled with dressing and a lid welded or otherwise fitted to the top of the food dressing storage compartment to complete it, preferably, the food dressing storage compartment is formed as a single piece item from the outset. In this way, the dressing could be fed into the food dressing storage compartment by injection or pumping through an opening in the top of the compartment.
[0029] Preferably, the compartment contains a dressing.
DESCRIPTION OF THE DRAWINGS
[0030] Preferred embodiments of the present invention will now be more particularly described by way of example only with reference to the accompanying sheets of drawings in which:
[0031] FIG. 1 is a schematic isometric view of a container of the present invention.
[0032] FIG. 2 is a schematic side view of the container shown in FIG. 1 .
DETAILED DESCRIPTION
[0033] We refer to the drawings, wherein like numerals designate corresponding parts throughout the two embodiments.
EXAMPLE 1
[0034] Referring to FIGS. 1 and 2 , it can be seen that the elongate columnar clear plastics container generally referenced ( 5 ), when assembled, comprises (from top to bottom) a lid ( 10 ), a salad storing compartment ( 6 ) and a tubular salad dressing storing compartment ( 7 ) separated by a partition ( 9 ) that forms the top of the salad dressing storing compartment ( 7 ). The body of the salad storing compartment ( 6 ) flanges outwards towards the top in its normal attitude of operation. The circumferential periphery of the partition ( 9 ) is configured to engage with the top of the salad dressing compartment ( 7 ) by a snap-on arrangement, which would typically occur after the dressing storing compartment ( 7 ) is filled with dressing.
[0035] The partition ( 9 ) in this example is raised at its centre forming a nozzle ( 8 ). The curved nature of the partition is desirable as it assists in collecting and funnelling the dressing into the salad compartment when the container is inverted. The aperture in the nozzle ( 8 ) is of a diameter that provides some restriction to the flow of the dressing into the salad compartment ( 6 ) in the event that the container ( 5 ) is for example, accidentally knocked over on its side. This will minimise any leakage.
[0036] The container ( 5 ) has a lid ( 10 ), which is adapted to be securely fixed to the salad compartment ( 6 ) of the container ( 5 ). i The dressing compartment ( 7 ) with partition ( 9 ) is connected to the container ( 5 ) by a snap-on arrangement. Once this occurs, salad can be added to the container. When the consumer is ready to consume the salad stored in the container ( 5 ), he/she can mix a dressing stored in the container ( 5 ) throughout the salad by inverting or shaking the ridded container ( 5 ).
[0037] Such an action e.g. inversion will cause the dressing to leave the dressing storing compartment; ( 7 ) by gravity and allow it to be released into the salad storing compartment ( 6 ) via the nozzle ( 8 ). Shaking the container ( 5 ) will assist the flow of the dressing into the salad storing compartment ( 6 ) and thoroughly mix the salad and dressing together. The lid ( 10 ) will ensure I the salad and dressing do not escape from the container ( 5 ).
[0038] The colour of the salad dressing storing compartment ( 7 ) is different to the rest of the container ( 5 ) as a visual aid to ensure that the correct dressing is supplied with the salad.
EXAMPLE 2
[0039] In this example (not illustrated) the salad storing compartment ( 6 ) includes an integrally formed complementary floor at its base with a circular weakened portion of plastics material that is concentric and a mating fit with the nozzle of the dressing storing compartment ( 6 ). This means that the salad can be housed without the need for the dressing compartment ( 7 ) to be present (which formed the floor of the salad storing compartment in Example 1).
[0040] This means that both the salad and dressing can be housed in their separate compartments ( 6 ) & ( 7 ) irrespective of whether the salad storing and dressing storing compartments ( 6 ) & ( 7 ) are engaged with one another.
[0041] The floor of the salad storing compartment ( 6 ) will be configured to engage with the top and nozzle ( 8 ) from the dressing storing component ( 7 ). The nozzle ( 8 ) has a tear-away cap (not illustrated) which is removed before the salad storing and dressing storing compartments ( 6 ) & ( 7 ) are connected.
[0042] Accordingly as the two compartments ( 6 , 7 ) are engaged, the circular weakened portion is broken by the nozzle ( 8 ) as it punctures the portion during the engagement. This would be more hygienic when the dressing compartment ( 7 ) is separately stored before sale and would also further minimise any unwanted leakage.
[0043] This arrangement is useful particularly if the salad and dressing are likely to be pre packaged in their compartments ( 6 , 7 ) before sale. The consumer could separately choose the salad variety that they wanted and the dressing they wanted. The tear away cap on the dressing storing compartment ( 7 ) could be removed just before the salad is to be consumed. The dressing storing compartment and salad storing compartments ( 6 , 7 ) would then need to be engaged. The lid ( 10 ) should also be affixed to the salad storing container ( 5 ). The dressing from the dressing storing compartment ( 7 ) can then be released to the salad storing compartment ( 6 ) by inverting the container. Gravity will cause the dressing to be released into the salad storing compartment ( 6 ) via the nozzle ( 8 ). Shaking the container will assist the flow of the dressing through the nozzle into the salad compartment and thoroughly mixes the salad and dressing together.
[0044] The present invention allows for a salad and dressing to be separately and safely stored before the salad is consumed. The arrangement with the present invention tends to minimise or prevent the dressing from leaking into the salad. This ensures that the salad remains fresh and will not end up getting soggy due to unwanted leakage of the dressing.
[0045] The present invention allows for the dressing to be easily released into the salad by simply inverting the container. By subsequently shaking the container the user ensures that the dressing; is evenly and thoroughly distributed throughout the salad. The container of the present invention also allows for the dressing storing compartment to be interchanged easily with the salad storing compartment allowing the user to match the salad they want with the dressing they want giving them more choice.
[0046] Throughout the description and claims of this specification the word “comprise” and variations of that word, such as “comprises” and “comprising”, are not intended to exclude other additives, compartments, integers or steps. In either embodiment, it is most likely the container (a) will be a single use item.
[0047] While illustrative embodiments have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.
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A multi compartment food container ( 5 ) suitable for housing a salad and a salad dressing comprising a food storage compartment ( 6 ) and a food dressing storage compartment ( 7 ) wherein said compartments are operatively linked by a communication means ( 9 ) adapted to allow mixing of a salad dressing stored in the food dressing compartment with a food stored in the food storage compartment if the container is shaken.
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FIELD OF THE INVENTION
[0001] The disclosure relates to a conduit cutter for cutting electrical conduit. More particularly, the disclosure concerns an attachment for a device such as a reciprocating saw to cut pipe or electrical conduit.
BACKGROUND
[0002] Electricians and do it yourself (DIY) owners performing electrical installations and/or electrical remodeling work at some phase usually need to install and/or modify electrical conduit routings. Current methods of cutting metallic electrical conduit involve using devices that are positioned or placed on a workbench or other ground level surface. Other known manual devices for cutting electrical conduit include a manual conduit cutter and/or a hacksaw. Though the manual conduit cutter and hacksaw are portable devices, a significant amount of room is needed to utilize these devices. In tight or overhead locations, use of a manual conduit cutter and/or hacksaw is difficult. Furthermore, use of a manual conduit cutter may be time consuming and include excessive physical exertion which may be additive and tiring for the user if numerous cuts have to be made over a short time period.
[0003] Currently, for overhead and tight locations electricians or other workers having to install conduit may carry portions of conduit that need to be cut to a physical location where cutting may take place with adequate space for the selected cutting tool. However, physically transporting sections of conduit to be cut to another area is time consuming and in some locations not practical. For example, an electrician working on a scaffold having to come down off of the scaffold to ground level with a piece of conduit that needs to be cut is a significant waste of man-hours.
[0004] Therefore, there is a need in the art for a portable conduit cutter that may be removably attached to a power tool for use in tight locations having limited space for cutting.
SUMMARY
[0005] One or more of the above-mentioned needs in the art are satisfied by the disclosed conduit cutter of the present disclosure. The conduit cutter may be a portable device removably attachable to different power tools such as a reciprocating saw.
[0006] The portable conduit cutter may include a plate for use in attaching the conduit cutter to the different power tools. The plate may be adapted to fit different power tools depending upon the attachment requirements of the particular power tool.
[0007] In an aspect of the disclosure, a portable conduit cutter may include a jaw attached to a jaw slide for securing a piece of conduit or pipe for cutting. A compression spring and spring can assembly may be attached to the jaw slide and used to allow the jaw slide to move parallel with respect to the plate. The compression spring and spring can assembly along with a spring latch may be used to secure the conduit in the jaw and hold the jaw slide in a loading position prior to cutting the conduit or pipe.
[0008] Upon activation of the power tool, the jaw slide moves to a finished position after cutting through the conduit or pipe.
[0009] The advantages and features of novelty characterizing the present invention are pointed out with particularity in the appended claims. To gain an improved understanding of the advantages and features of novelty, however, reference may be made to the following descriptive matter and accompanying drawings that describe and illustrate various embodiments and concepts related to the invention.
DESCRIPTION OF THE DRAWINGS
[0010] The present disclosure is illustrated by way of example and not limited in the accompanying figures in which like reference numerals indicate similar elements and in which:
[0011] FIG. 1 illustrates a side view of a conduit cutter in a loading position attached to a reciprocating saw in accordance with an aspect of the disclosure;
[0012] FIG. 2 illustrates another side view of a conduit cutter in a finished position attached to a reciprocating saw in accordance with an aspect of the disclosure;
[0013] FIG. 3 illustrates a front view of a conduit cutter in a finished position attached to a reciprocating saw in accordance with an aspect of the disclosure;
[0014] FIG. 4 illustrates detailed front and side views of components of a conduit cutter in accordance with an aspect of the disclosure; and
[0015] FIG. 5 illustrates an expanded side view of a conduit cutter in a finished position attached to a reciprocating saw in accordance with an aspect of the disclosure.
DETAILED DESCRIPTION
[0000]
The following discussion and accompanying figures disclose various embodiments of a conduit cutter in accordance with various aspects of the disclosure. Referring to FIG. 1 , a conduit cutter 102 is illustrated in a loading position 104 attached to a reciprocating saw 106 in accordance with an aspect of the disclosure. In an embodiment, conduit cutter 102 may be in the form of an attachment that may be removably attached to various cutting devices such as reciprocating saw 106 . Those skilled in the art will realize that conduit cutter 102 may be adapted to attach to different manufactures of power equipment by changing the attachment mechanism to accommodate different manufactures attachment specifications. In addition, conduit cutter 102 may also be adapted for use with different power tools such a jig saw. Those skilled in the art will realize that the attachment mechanism is defined by the tool being used and that different attachment configurations may be utilized so that conduit cutter 102 may be universally used on different power devices.
[0017] Referring back to FIG. 1 , conduit cutter 102 is shown in loading position 104 . Loading position 104 secures a piece of conduit 108 in a locked position using jaw 110 . Jaw 110 may accommodate conduits of various sizes such as half inch up to and including three inch as illustrated in FIG. 1 . Those skilled in the art will realize that jaw 110 may be sized to secure in place the maximum sized conduit an attached power tool may cut based on its nameplate power rating. In other embodiments of the disclosure, conduit cutter 108 may be configured to cut smaller or larger diameter conduits or pipes.
[0018] FIG. 2 illustrates a side view of a conduit cutter 102 in a finished position 202 attached to a reciprocating saw 106 in accordance with an aspect of the disclosure. Finished position 202 is illustrated by cutting blade 204 having cut through a conduit 108 and the bottom portion of jaw 110 being in close proximity to blade 204 as compared to the blade position shown in the loading position 104 of FIG. 1 .
[0019] In an aspect of the disclosure, conduit cutter 102 may be removably attached to various power cutting devices such as reciprocating saw 106 . For instance, FIG. 2 further illustrates a front view of a mounting plate 206 that may be representative of a mounting plate found on a typical reciprocating saw 106 . The mounting plate 206 may have an aperture 208 through which blade 204 may pass and be secured to reciprocating saw 106 . As shown in the mounting plate 206 of FIG. 2 , blade 204 may be off centered as it passes through aperture 208 per the reciprocating saws manufacturer's specifications. A slot 210 may be located on mounting plate 206 for securing attachments such as conduit cutter to reciprocating saw 106 . Those skilled in the art will realize that conduit cutter 102 may include different attachment mechanisms so that conduit cutter 102 may be attached to different power tools (or attached to other structural features located on different brands of reciprocating saws) and allow for proper blade 204 positioning.
[0020] FIG. 3 illustrates a front view of conduit cutter 102 in a finished position attached to a reciprocating saw 106 in accordance with an aspect of the disclosure. In accordance with an aspect of the disclosure, conduit cutter 102 may include a jaw slide 301 . Jaw slide 301 may be able to move with respect to plate 303 in a parallel direction so that conduit cutter 102 may transition from a loading position to a finished position. In an embodiment, compression springs 308 may be housed in spring cans 310 located on plate 303 . Those skilled in the art will realize that the use of compression springs 308 and spring cans 310 enable conduit cutter 102 to hold in place the piece of conduit to be cut. Also, in an embodiment, the use of compression springs 308 and spring cans 310 enables an operator of the conduit cutter to cut conduit without having to hold the conduit in place. This feature allows for working in tight places or overhead as the conduit cutter 102 holds the conduit to be cut in a fixed position for a precise cut.
[0021] In FIG. 3 , a handle 316 may be attached to conduit cutter 102 via screws 318 . In an aspect of the disclosure, handle 316 may be mounted on either side of conduit cutter 102 for use by either left handed or righted hand operators. The handle 316 may be used to hold the conduit cutter 102 in place and/or assist in latching jaw slide 301 into loading position 104 ( FIG. 1 ).
[0022] FIG. 3 further illustrates in at least one embodiment of the disclosure, attachment of conduit cutter 102 to reciprocating saw 106 . Mounting plate 206 of reciprocating saw 106 may have an aperture 208 ( FIG. 2 ) through which blade 204 may pass. Similarly, plate 303 and jaw slide 301 may include apertures ( 311 and 312 ) through which blade 204 protrudes through to enable cutting of a positioned piece of conduit. As shown in FIG. 3 , blade 204 may be off centered as it passes through apertures 208 , 310 , and 312 . The placement of blade 204 is dependent upon the power tools manufacturer's specifications. Slot 210 may be located on mounting plate 206 for securing conduit cutter 102 .
[0023] FIG. 4 illustrates detailed front and side views of conduit cutter 102 in accordance with an aspect of the disclosure. In FIG. 4 , the front and side views represent various components that may be used in assembly of conduit cutter 102 . For instance, conduit cutter may comprise but is not limited to components such as handle 316 , screws 318 , jaw slide 301 , spring cans 310 , compression springs 308 , and plate 303 . In an embodiment of the disclosure, jaw slide 301 , spring cans 310 , and plate 303 may be comprised of different materials such as steel, titanium, aluminum, tungsten, graphite, polymers, or composites. For instance, in an embodiment jaw slide 301 may be composed of titanium but jaw 110 may be made from tungsten. As those skilled in the art will realize, each component may be made from different materials which include thermoplastic composite materials
[0024] In addition, FIG. 4 further illustrates that a spring latch 402 may be used to latch jaw slide 301 into loading position 104 . In an embodiment, a jaw slide stop mechanism 404 may also be used so that jaw slide 301 does not over extend compression springs 308 . Overextending compression springs 308 may shorten their rated life span. Screws 406 may be used to hold spring latch 402 and/or jaw slide stop mechanism 404 in position.
[0025] FIG. 5 illustrates an expanded side view of a conduit cutter 102 in a finishing position attached to a reciprocating saw 106 in accordance with an aspect of the disclosure.
[0026] The present invention is disclosed above and in the accompanying drawings with reference to a variety of embodiments. The purpose served by the disclosure, however, is to provide an example of the various features and concepts related to the invention, not to limit the scope of the invention. One skilled in the relevant art will recognize that numerous variations and modifications may be made to the embodiments described above without departing from the scope of the present invention, as defined by the appended claims.
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A portable conduit cutter for attaching to a power tool is disclosed. The portable conduit cutter includes a plate for use in attaching the conduit cutter to the different power tools. The plate may be adapted to fit different power tools depending upon the attachment requirements of the particular power tool. A compression spring and spring can assembly may be attached to a jaw slide and used to allow the jaw slide to move parallel with respect to the plate.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This patent application claims priority to U.S. Provisional Patent Application Ser. No. 61/262,756 filed Nov. 19, 2009 which is incorporated herein by reference hereto in its entirety.
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 the payment of any royalties thereon or therefor.
FIELD OF THE INVENTION
The invention is in the field of dual-mode combustors for use as a ramjet and a scramjet.
BACKGROUND OF THE INVENTION
Combined-cycle propulsion is considered when the high efficiency of air-breathing propulsion is desired over a broad Mach number range. Air-breathing access to space is one such application of current interest to NASA. The dual-mode scramjet is central to most combined-cycle schemes. Turbine-based combined-cycle (TBCC) systems use a turbine engine for low speed acceleration, and operate to a maximum flight Mach number in scramjet mode dictated by system considerations. TBCC systems are normally assumed to take-off horizontally, and use a second, rocket-powered stage to achieve orbit. Rocket-based combined-cycle (RBCC) schemes use chemical rocket propulsion for low speed acceleration. The high thrust-to-weight ratio of the rocket component allows for its integration within the air-breathing duct. RBCC systems are normally assumed to be launched vertically, and can operate from lift-off to orbit. Turbine-engines reach temperature and thrust limitations as Mach number increases. Rocket thrusters provide a high ratio of thrust-to-weight at any speed, but are very inefficient from the standpoint of specific impulse. In either case, it is advantageous to extend dual-mode scramjet operation to as low a Mach number as possible.
Supersonic combustion has long been recognized as a solution to problems associated with the severe stagnation conditions within a ramjet engine at high flight Mach number. Diffuser momentum loss, dissociation, non-equilibrium expansion losses, and structural loading are all relieved by transition to a supersonic combustion process. In general, the cross-sectional area of the supersonic combustor increases in the downstream direction to avoid thermal choking and excessive pressure gradients. The subsequent nozzle expansion process requires a more dramatic increase in cross-sectional area and is usually integrated with the vehicle aft end to provide the maximum possible area ratio.
In order to extend the operable flight Mach number range of the scramjet engine downward, toward the upper limit for turbojets or to limit rocket operation to as low a ΔV (speed range) as possible, “dual-mode” operation was introduced by Curran, et al. in U.S. Pat. No. 3,667,233. U.S. Pat. No. 3,667,233 is incorporated herein by reference hereto.
FIG. 1 is a prior art drawing from Curran et al., U.S. Pat. No. 3,667,233, and, in particular, is a schematic diagram partially in block form of a dual mode combustion chamber according to the invention.
FIG. 2 is a prior art drawing from Curran et al., U.S. Pat. No. 3,667,233, and, in particular, is a schematic cross section of the device of FIG. 1 showing one possible arrangement of the fuel injectors.
FIG. 3 is a prior art drawing from Curran et al., U.S. Pat. No. 3,667,233, and, in particular, is a schematic diagram partially in block form showing an annular configuration for the combustion chamber of FIG. 1 .
FIG. 4 is a prior art drawing from Curran et al., U.S. Pat. No. 3,667,233, and, in particular, is a schematic end view of the device of FIG. 3 from the exhaust end.
FIG. 5 is a prior art drawing from Curran et al., U.S. Pat. No. 3,667,233, and, in particular, is a schematic diagram partially in block form of a modified fuel supply system for the device of FIG. 1 .
Conceptually, a thermally-choked combustion process is established in the aft regions of the scramjet flowpath where the cross-sectional areas are greatest. As depicted in FIG. 7 , the diverging scramjet duct acts as a subsonic diffuser, and the thermal throat is positioned so as to produce the required back-pressure.
FIGS. 6 and 7 are another illustration of the structure and process of the prior art Curran et al., U.S. Pat. No. 3,667,233.
Curran et al., U.S. Pat. No. 3,667,233, states at col. 1, Ins. 29 et seq. that:
“A combustor with a fixed geometry has one parallel combustion section with a substantially uniform cross section along its length. Fuel is injected into this section and the flame is stabilized on recessed flameholders. As the fuel burns it causes choked flow in this section which sends a shock wave upstream to convert the normal supersonic flow through the combustor to subsonic flow. For transition from subsonic mode to the supersonic mode, fuel is injected into a diverging section upstream of the parallel section which causes the shock to move downstream until it is ejected from the engine. In the final transition to supersonic mode, fuel is supplied only to the upstream injectors.”
Further, Curran et al., U.S. Pat. No. 3,667,233, states at col. 2, Ins. 4 et seq. that:
“At these speeds fuel is supplied to nozzles 36 . Burning of the fuel in the uniform cross section combustion chamber 24 causes choked flow which sends a shock wave upstream of the flow to convert the supersonic flow to subsonic flow within the combustion chamber. As the speed of the aircraft increases to a speed between Mach 4 and Mach 5, fuel control 30 starts a flow of fuel to nozzles 32 as the fuel control 34 gradually decreases the fuel flow to nozzles 36 . This causes the shock wave to gradually recede as fuel to nozzles 32 is increased and fuel flow is decreased to nozzles 36 . At a speed of about Mach 8 fuel to nozzles 36 is further reduced and supersonic combustion now occurs throughout the divergent and parallel ducts. The expansion of the heated gases in expansion section 22 permits higher Mach speeds to be attained.”
The cross-sectional area of the thermal throat must increase as flight Mach number decreases, unless fuel-to-air ratio is reduced. For a given duct, this effect determines the minimum flight Mach number for dual-mode operation. At Mach 2.5, the required thermal throat area approaches that of the inlet capture area. The primary technical challenges in practical application of the dual-mode scramjet scheme of Curran et al., U.S. Pat. No. 3,667,233, are modulation of the thermal throat location, modulation of fuel distribution, ignition, and flame-holding in the large cross-section. Any in-stream devices must be retractable or expendable so as not to inhibit supersonic combustion operation.
Curran et al., U.S. Pat. No. 3,667,233, controls fuel flow to modulate the position of the thermal throat at low flight Mach numbers and then, subsequently, to transition to supersonic ramjet operation. If Curran doesn't modulate the position of the choked flow correctly, the shock wave moves further upstream into the inlet passage 21 of Curran and un-start of the engine may occur.
FIG. 6 shows a cross-sectional view 600 of a prior art (Curran et al.) scramjet engine operating in the scramjet mode. Processes that govern scramjet efficiency are inlet momentum losses, Rayleigh losses due to heat addition, heat loss to the combustor walls, skin friction, and non-equilibrium expansion. Other factors that must be considered include separation of boundary layers due to adverse pressure gradients, intense local heating at re-attachment points and shock impingements, and fuel staging or variable geometry to accommodate the variation of combustion area ratio with free stream stagnation enthalpy.
Referring to FIG. 6 , fuel injection nozzle 601 , inlet contraction section 602 , diverging supersonic combustion section 603 , and exit nozzle 604 are illustrated. As stated above, in the scramjet mode, this engine is fed with fuel injector 601 . Reference numeral 608 illustrates and internal wall of the engine. Reference numeral 606 signifies incoming air being compressed. Reference numeral 605 represents the fuel-air mixture being combusted. And, reference numeral 607 signifies expanded gas/combustion products being expelled from the engine.
FIG. 7 is the cross-sectional view 700 of FIG. 6 (Curran et al. prior art engine) in the ramjet mode illustrating choked flow 702 and a shock waves 701 . Fuel injectors 703 , 704 are illustrated and are operable in the ramjet mode. Curran et al. must delicately control the insertion of fuel. First, fuel is inserted with injectors 703 , 704 and then fuel is inserted using injector 601 to prevent the shock wave from being expelled leftwardly into the inlet contraction section 602 which may result in un-start of the engine. Reference numeral 606 A indicates incoming compressed air and reference numeral 607 A represents combustion products expelled from the engine.
SUMMARY OF THE INVENTION
The supersonic free jet mode of a new combined-cycle combustor is disclosed herein at various scramjet flight Mach numbers including 5, 8, and 12. The dual-mode combustor has the ability to operate in ramjet mode to lower flight Mach numbers than current dual-mode scramjets, thereby bridging the gap between turbine or rocket-based low speed propulsion and scramjets.
One important feature of the invention is the use of an unconfined free jet for supersonic combustion operation at high flight mach numbers. The free-jet traverses a larger combustion chamber that is used for subsonic combustion operation at lower flight Mach numbers. The free-jet expands at constant pressure due to combustion and rejoins the nozzle throat contour. Recirculating flow in the combustion chamber equilibrates to a pressure slightly lower than that of the free-jet causing under-expansion features to appear in the free-jet. The free-jet joins the nozzle throat contour with little interaction and expands through the nozzle expansion section.
At scramjet flight Mach numbers from 5 to 12, the supersonic free jet traverses the combustion chamber and rejoins the nozzle contour at the combustor exit. Periodic wave structure occurs in the free-jet and is initiated by an entry interaction caused by pressure mismatch and rapid mixing and combustion at the combustion chamber entrance and upstream in the inlet section. The periodic nature of the free-jet also led to an exit interaction determined by the phase of the wave structure with respect to the throat location. The effect of reducing nozzle throat area was to increase the combustion chamber pressure, and reduce the period of the wave structure, but not its amplitude. A viscous loss due to momentum transfer to the recirculation zone is also apparent in each case.
Calculated heat loads were commensurate with previous estimates for air breathing systems. Peak heat flux occurred upstream of the throat at an impingement point separating the free-jet from recirculation zone. For a given wall temperature, heat load depends on the recirculation zone temperature and volume, the severity of the exit interaction, and the fuel injection scheme.
The new combustor is disclosed for use over a wide range of flight Mach numbers, operating in both subsonic and supersonic combustion modes. It operates as a conventional ramjet at low speed, eliminating the aforementioned issues with dual-mode operation. Transition to supersonic combustion in a free-jet mode occurs at the appropriate flight condition upon the rapid opening of the nozzle throat.
A supersonic combustion ramjet engine is disclosed and claimed. The terms supersonic combustion ramjet engine, supersonic combustion ramjet and dual-mode combustor are used interchangeably herein. The supersonic combustion ramjet engine is operable in a ramjet mode and a scramjet mode. The ramjet mode extends from about flight Mach number 2.5 up to about flight Mach number 6. The scramjet mode extends from about flight Mach number 5 up to about flight Mach number 12. An inlet passageway receives compressed combustion air from a supersonic diffuser. The inlet passageway includes a fuel injector. A subsonic diffuser and a combustion chamber follow the inlet passageway. The subsonic diffuser (sometimes referred to herein as the diffusion section) includes an inner periphery. A radial step is interposed between and links the inlet passageway and the diffusion section.
The inlet passageway is in communication with the diffusion section and the diffusion section is in communication with the combustion chamber. A ramjet-mode flame holder array is located between the subsonic diffuser and the combustion chamber. The flame holder array includes a central circular aperture therethrough. The flame holders are affixed to the inner periphery of the combustion chamber.
The engine also includes a contraction section, a variable nozzle throat and an expansion section. The combustion chamber is in communication with the nozzle contraction section and the nozzle contraction section is in communication with the variable nozzle throat. And, the variable nozzle throat is in communication with the expansion section.
A nozzle positioner drives and moves the arc section forming the variable nozzle throat to a desired diametrical opening according to an algorithm which is a function of flight Mach number and combustor mode. The algorithm has a discontinuity at a given flight mach number transitioning from the ramjet mode to the scramjet mode forming a free jet from the inlet section, through the subsonic combustion chamber and reattaching at the variable nozzle throat. The ramjet mode includes subsonic operation from about flight Mach number 2.5 up to about flight Mach number 5.0 to 6.0. The scramjet mode includes supersonic operation from about flight Mach number 5.0 to 6.0 up to about flight Mach number 12.0 and greater. The nozzle positioner divergingly adjusts the nozzle throat to a relatively larger diameter between about flight Mach number 5.0 to 6.0 transitioning from the ramjet mode to the scramjet mode forming a free jet extending from the inlet section at the location of the radial step to the variable nozzle throat. The free-jet does not engage the subsonic diffuser. Nor does the free jet engage the combustion chamber. The free-jet rejoins the variable nozzle throat.
A supersonic diffuser is used to compress combustion air into a combustion air passageway. Fuel is injected from the combustion air passageway into the combustion air in the combustion air passageway creating a stoichiometric fuel-air mixture. In the scramjet mode, the stoichiometric fuel-air mixture is fed from the combustion air passageway into a free jet that traverses the subsonic diffuser. Operation in the scramjet mode is premised on previous operation and ignition in the ramjet mode using flame holders in the subsonic diffuser.
In ramjet mode, fuel is in injected from the combustion air passageway. In the ramjet mode, the fuel-air mixture is combusted in the combustion chamber. The combusted fuel-air mixture is evacuated from the combustion chamber and into the variable area nozzle throat. The variable nozzle throat is modulated and positioned according to an algorithm creating and controlling the position of a terminal shock in the subsonic diffuser. The algorithm is a function of flight Mach number.
The step of discontinuing operation of the igniters, and the step of modulating and positioning a variable nozzle throat according to an algorithm, includes transitioning, using the algorithm, the dual-mode combustor from a ramjet mode to a scramjet mode by rapidly opening the variable nozzle throat at a specified flight Mach number. The algorithm includes a discontinuity where there are two values for a specified flight mach number and it is this discontinuity, and the action based upon it, which shifts the dual-mode combustor from the ramjet mode to the scramjet mode. Shifting from the scramjet mode to the ramjet mode is also possible.
The algorithm includes the variable nozzle position as a ratio A/Ac of the actual nozzle throat area, A, to the inlet capture area, Ac, of the supersonic diffuser. The nozzle position varies from a ratio of about 0.8=A/Ac at about flight Mach number 2.5 in the ramjet mode to a ratio of about 0.18=A/Ac at about flight Mach number 5.0 in the ramjet mode. The nozzle position varies rapidly from a ratio of about 0.18=A/Ac at about flight Mach number 5.0 in the ramjet mode to a ratio of about 0.41=A/Ac at about flight Mach number 5.0 transitioning to the scramjet mode. Thereafter, the nozzle position varies from about 0.41=A/Ac at flight Mach number 5.0 in the scramjet mode to a ratio of about 0.15=A/Ac at about flight Mach number 12 in the scramjet mode.
In the scramjet mode, the fuel-air mixture and the combustion products are separated into a free-jet beginning at the exit of the combustion air passageway/radial step and extends to the variable nozzle throat. The free jet does not engage the subsonic diffuser, the combustion chamber or the contraction section.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a prior art drawing from Curran U.S. Pat. No. 3,667,233 and, in particular, is a schematic diagram partially in block form of a dual mode combustion chamber according to the invention.
FIG. 2 is a prior art drawing from Curran U.S. Pat. No. 3,667,233 and, in particular, is a schematic cross section of the device of FIG. 1 showing one possible arrangement of the fuel inlet jets.
FIG. 3 is a prior art drawing from Curran U.S. Pat. No. 3,667,233 and, in particular, is a schematic diagram partially in block form showing an annular configuration for the combustion chamber of FIG. 1 .
FIG. 4 is a prior art drawing from Curran U.S. Pat. No. 3,667,233 and, in particular, is a schematic end view of the device of FIG. 3 from the exhaust end.
FIG. 5 is a prior art drawing from Curran U.S. Pat. No. 3,667,233 and, in particular, is a schematic diagram partially in block form of a modified fuel supply system for the device of FIG. 1 .
FIG. 6 is another cross-sectional view of the prior art Curran device operating in scramjet mode.
FIG. 7 is the cross-sectional view of FIG. 6 in the ramjet mode illustrating choked flow and a shock wave.
FIG. 8 is a perspective view of the dual-mode combustor in the ramjet mode.
FIG. 8A is a cross-sectional schematic view of the dual-mode combustor of FIG. 8 in the ramjet mode.
FIG. 8B is a quarter-sectional schematic view of the dual-mode combustor of FIG. 8 in the ramjet mode.
FIG. 8C is an enlargement of a portion of FIG. 8B illustrating, diagrammatically, the step between the inlet cylinder and the subsonic diffuser.
FIG. 9 is a perspective view of the dual-mode combustor in the scramjet mode.
FIG. 9A is a cross-sectional schematic view of the dual-mode combustor of FIG. 9 in the scramjet mode illustrating the free-jet extending from the inlet cylinder to the variable nozzle throat.
FIG. 9B is a quarter-sectional schematic view of the dual-mode combustor of FIG. 9 in the scramjet mode.
FIG. 9C is a sectioned view of the dual-mode combustor of FIG. 9 illustrating the flame-holder having a central aperture therein for the passage of the free-jet.
FIG. 10 is another example of the dual-mode combustor employing different geometry.
FIG. 11 is a quarter-sectional diagrammatic view of the dual mode combustor in the scramjet mode for flight mach number 8 illustrating a step, a hinged diffuser section, a fixed combustion chamber section, a hinged contraction section, a hinged nozzle throat section (circular arc section) and a hinged expansion section.
FIG. 11A is a table of values relating to FIG. 11 .
FIG. 11B is a schematic view of an example of a receiving joint forming the nozzle throat
FIG. 12 is a plot of the prior art thermal throat of Curran, the geometric/nozzle throat of the dual-mode combustor in ramjet mode and in scramjet mode, and the inlet diameter of the dual-mode combustor as a function of the inlet capture area.
FIG. 12A is a table of inlet contraction ratios as a function of the inlet capture area for a range of flight Mach numbers.
FIG. 12 B is a control system for positioning the variable (geometric) nozzle throat.
FIG. 13A is a generalized quarter-sectional diagrammatic view of the flight Mach number 2.5 ramjet.
FIG. 13B is a generalized quarter-sectional diagrammatic view of the flight Mach number 3.0 ramjet.
FIG. 13C is a generalized quarter-sectional diagrammatic view of the flight Mach number 4.0 ramjet.
FIG. 14A is a generalized quarter-sectional diagrammatic view of the flight Mach number 5.0 ramjet.
FIG. 14B is a generalized quarter-sectional diagrammatic view of the flight Mach number 5.0 scramjet.
FIG. 15A is a generalized quarter-sectional diagrammatic view of the flight Mach number 6.0 ramjet.
FIG. 15B is a generalized quarter-sectional diagrammatic view of the flight Mach number 6.0 scramjet.
FIG. 16A is a generalized quarter-sectional diagrammatic view of the flight Mach number 8.0 scramjet.
FIG. 16B is a generalized quarter-sectional diagrammatic view of the flight Mach number 10.0 scramjet.
FIG. 16C is a generalized quarter-sectional diagrammatic view of the flight Mach number 12.0 scramjet.
FIG. 17A is an illustration of the pressure contours within the engine for the flight Mach number 5.0 scramjet.
FIG. 17B is an illustration of the pressure contours within the engine for the flight Mach number 8.0 scramjet.
FIG. 17C is an illustration of the pressure contours within the engine for the flight Mach number 12.0 scramjet.
FIG. 18A is an illustration of the Mach number contours within the engine for the flight Mach number 5.0 scramjet.
FIG. 18B is an illustration of the Mach number contours within the engine for the flight. Mach number 8.0 scramjet.
FIG. 18C is an illustration of the Mach number contours within the engine for the flight Mach number 12.0 scramjet.
FIG. 19A is an illustration of the static temperature contours within the engine for the flight Mach number 5.0 scramjet.
FIG. 19B is an illustration of the static temperature contours within the engine for the flight Mach number 8.0 scramjet.
FIG. 19C is an illustration of the static temperature contours within the engine for the flight Mach number 12.0 scramjet.
FIG. 20 illustrates ideal net thrust per unit airflow against flight Mach numbers for a conventional ramjet, thermally-choked ramjet and a scramjet.
FIG. 21 illustrates the mass-averaged static pressure distributions with the pressure at the nozzle throat station (supersonic combustor exit) denoted by symbols.
FIG. 21A illustrates the mass-averaged axial velocity distributions for various flight conditions.
FIG. 21B illustrates the mass-averaged temperature distributions for flight Mach numbers 5, 8 and 12.
FIG. 22A illustrates the static pressure ratio for scramjet mode flight Mach number 8 with the variable nozzle throat positioned at 110% of the design operating point.
FIG. 22B illustrates the static pressure ratio for scramjet mode flight Mach number 8 with the variable nozzle throat positioned at 100% of the design operating point.
FIG. 22C illustrates the static pressure ratio for scramjet mode flight Mach number 8 with the variable nozzle throat positioned at 90% of the design operating point.
FIG. 22D illustrates the static pressure ratio for scramjet mode flight Mach number 8 with the variable nozzle throat positioned at 80% of the design operating point.
FIG. 23 illustrates the effect of nozzle throat area variation for scramjet mode flight Mach number 8 on the rate of ethylene fuel-depletion.
FIG. 23A illustrates the ethylene mass fraction for flight Mach numbers 5, 8 and 12 versus axial position.
FIG. 24 illustrates the effect of nozzle throat area variation on mass-averaged static pressure distribution for scramjet mode flight Mach number 8.
FIG. 25 illustrates the ideal net thrust per unit of airflow plotted against combustor exit pressure ratio and nozzle throat area variation for scramjet mode flight Mach number 8.
DESCRIPTION OF THE INVENTION
In the design of the dual-mode combustor all processes were assumed adiabatic. Air capture, inlet contraction ratio, and total pressure recovery were specified as a function of flight Mach number illustrated in FIG. 12A . These characteristics are representative of a single-cone, axi-symmetric inlet design with forebody pre-compression. Air was assumed to be a mixture of nitrogen and oxygen at 78.85% and 21.15% by volume, respectively.
In the analysis of all ramjet cases, ethylene fuel entered at sonic velocity, normal to the propulsion axis at 5180 R. The energy required to raise the ethylene fuel to this condition was ignored. Constant-area combustion in a cross-sectional area equal to 83.3% of the inlet capture area was assumed. This area was chosen to allow operation at a minimum flight Mach number of 2.5 without thermal choking. For comparison, calculations were also done assuming a thermally-choked combustion process. For these cases, the diffuser exit Mach number was set to result in a combustion area ratio of 1.5.
The AIAA (American Institute of Aeronautics and Astronautics), paper entitled Supersonic Free-Jet Combustion in a Ramjet Burner, by Charles J. Trefny and Vance F. Dippold III, NASA Glenn Research Center, Cleveland, Ohio, 44135 was published and presented on Jul. 26, 2010 is incorporated herein by reference hereto.
The dual-mode combustor is illustrated in FIGS. 9 , 9 A and 9 B in scramjet mode wherein supersonic combustion in an unconfined free-jet 943 traverses a larger subsonic combustion chamber 805 , a contraction section 806 , and a variable nozzle throat 807 . FIG. 9 is a perspective view 900 of the dual-mode combustor in the scramjet mode. FIG. 9A is a cross-sectional schematic view 900 A of the dual-mode combustor 899 of FIG. 9 in the scramjet mode illustrating the free-jet 943 extending from the inlet cylinder 802 to the variable nozzle throat 807 which yields a nozzle throat diameter D 1 . Nozzle throat diameter D 1 as illustrated in FIG. 9A is larger than nozzle throat diameter D illustrated in FIG. 8A . The nozzle throat area is dictated by the curves illustrated in FIG. 12 for both the ramjet and the scramjet. The examples of nozzle position 807 given here for the ramjet and the scramjet are the portions of the curves 1202 , 1205 where FIG. 8A ramjet mode uses a smaller nozzle throat area than FIG. 9A (scramjet mode).
FIG. 9B is a quarter-sectional schematic view 900 B of the dual-mode combustor of FIG. 9 in the scramjet mode. In the scramjet mode, reference numeral 845 A signifies supersonic combustion and reference numeral 847 A represents expansion. FIG. 9C is a sectioned view 900 C of the dual-mode combustor of FIG. 9C illustrating the flame-holder 810 having a central aperture 850 therein for the passage of the free jet 943 there through.
During scramjet mode, of operation, the propulsive stream 943 is not in contact with the combustor walls 805 , and equilibrates 943 A to the combustion chamber pressure 944 . Boundary 943 A represents the interface of the free-jet/propulsive stream 943 with the recirculation zone/combustion chamber pressure 944 . Thermodynamic efficiency is similar to that of a traditional scramjet, under the assumption of constant-pressure combustion. Qualitatively, a number of possible benefits exist. Fuel staging is eliminated since the cross-sectional area distribution required for supersonic combustion is accommodated aerodynamically without regard for wall pressure gradients and boundary-layer separation because the free-jet does not touch the walls of the diffuser and the combustion chamber. Variable exit diameter D 1 must be set to the proper size for a given flight Mach number. The axial distance available for supersonic mixing and combustion includes the subsonic diffuser 804 , combustion chamber 805 and nozzle contraction sections 806 required for ramjet operation. Heat loads, especially localized effects of shock-boundary-layer interactions, are reduced. Reference numeral 880 signifies incoming air being compressed and reference numeral 881 signifies exiting combustion gases.
FIG. 8 is a perspective view 800 of the dual-mode combustor 899 in the ramjet mode. FIG. 8 illustrates the frusto-conical inlet contraction section 801 , the cylindrical inlet passageway 802 , the diffuser section 804 , the combustion chamber 805 , the contraction section 806 and the variable diameter nozzle throat 807 . Reference numeral 807 signifies the variable nozzle throat at the joining point of the contraction section 806 and the expansion section 808 in the ramjet mode. In the scramjet mode, reference numeral 807 also signifies the variable nozzle throat at the joining point of the contraction section 806 and the expansion section 808 .
FIG. 8A is a cross-sectional schematic view 800 A of the dual-mode combustor 899 of FIG. 8 in the ramjet mode. FIG. 8A illustrates substantial differences in construction when compared to Curran U.S. Pat. No. 3,667,233. First, the flame holders 810 are arranged so as to not obstruct the free-jet as illustrated in FIG. 9A . The flame holders 810 have a central, circular aperture 850 therein. Reference numeral 810 A signifies the flame holders in operation. Reference numeral 830 represents a terminal shock wave and its location as illustrated diagrammatically in FIG. 8A is important. Location of the terminal shock wave 830 in the ramjet mode is important and is controlled by the position of the nozzle throat 807 diameter D. Reference numeral 872 signifies heat release within the combustor.
There is no thermal throat in the dual-mode combustor 899 because the variable nozzle throat 807 is positioned so as to control the terminal shock wave 830 .
FIG. 12 is a plot 1200 of the prior art thermal throat of Curran 1201 , the geometric/nozzle throat 1202 of the dual-mode combustor 899 in ramjet mode, the geometric/nozzle throat 1205 in scramjet mode, and the inlet throat 1203 , 1203 A of the dual-mode combustor 899 as a ratio of A/A capture area. FIG. 12A is a table 1200 A of inlet contraction ratios 1231 as a ratio ((A/A capture area) 1231 ) for a range of flight mach numbers and combustion processes 1230 . FIG. 12 B is a control system 1200 B for positioning the variable (geometric) nozzle throat 807 . FIG. 12 indicates a discontinuity or jump 1204 between the ramjet mode plot 1202 and the scramjet mode plot 1205 .
A nozzle positioner 1212 drives and moves the arc section 1125 forming the nozzle throat 1108 , to a desired diametrical opening according to an algorithm ( FIG. 12 curves, 1202 , 1205 ) which is a function of flight Mach number and combustor mode (ramjet or scramjet). The algorithm has a discontinuity at a given flight mach number, in this example, flight Mach number 5.0, transitioning from the ramjet mode to the scramjet mode forming a free-jet 943 from the inlet section 802 , through the subsonic diffuser 804 , through the combustion chamber 805 , through the contraction section, and rejoins the nozzle throat 807 (diameter D 1 ). The ramjet mode includes subsonic operation from about flight Mach number 2.5 up to about flight Mach number 5.0 to 6.0 and the cross-sectional area of the nozzle throat 807 divided by the inlet capture area, A inlet capture area, should follow curve 1202 .
The scramjet mode includes supersonic operation from about flight Mach number 5.0 to 6.0 up to about flight Mach number 12.0 and greater. The nozzle positioner divergingly adjusts the nozzle throat diameter (nozzle area) rapidly to a relatively larger diameter between about flight Mach number 5.0 to 6.0 rapidly transitioning from the ramjet mode to the scramjet mode forming a free-jet 943 extending from the inlet section 802 at the location of the radial step 812 , 812 A to the nozzle throat 807 . The free-jet does not engage the subsonic diffuser 804 . Nor does the free-jet 943 engage the combustion chamber 805 . The free-jet 943 rejoins the nozzle throat 807 as illustrated in FIG. 9A .
Referring to FIG. 8A and FIG. 12 , reference numeral 1201 indicates the algorithm for the position of the nozzle throat 807 (diameter D) as a ratio of the inlet capture area (area=A inlet capture area). Specifically, the nozzle throat area must be positioned on the line 1202 for ramjet mode operation for flight numbers between 2.5 to 5.0. Further, the nozzle throat 807 (diameter D 1 ) in the scramjet mode must be positioned on the line 1205 for the scramjet mode operation for flight numbers between 5.0 and 12.0. Reference numeral 1204 represents the transition between the ramjet mode (pursuant to curve or algorithm 1202 ) and the scramjet mode (pursuant to curve or algorithm 1205 ). Operation between the modes is switched back and forth between the curves 1202 , 1205 .
Referring to FIG. 8A and FIG. 12 , the location of the shock wave 830 is important. If the nozzle throat area ratio is positioned below the line 1201 in FIG. 12 , the engine will un-start as the shock wave moves leftwardly and is expelled from the engine in order to spill air around and past the inlet capture area. Similarly, if the nozzle throat area ratio is positioned above the line 1202 in FIG. 12 , the engine may prematurely transition to the scramjet mode if the flight Mach number is sufficiently high. Transition to the scramjet mode is accomplished by rapidly changing the nozzle throat ratio (A/A inlet capture area) from curve 1202 to curve 1205 in combination with radially oriented step 1203 which causes the free-jet to separate from the diffuser surface and the combustion chamber. The flame holders 810 have no function.
FIGS. 12 and 12A also indicate that the diameter of the cylindrical inlet 802 changes as a function of ramjet mode (see curve 1203 ), and also cylindrical inlet 802 changes as a function of scramjet mode (see curve 1203 A). FIG. 12A indicates that the inlet contraction ratio (A inlet capture area/A inlet cylinder) increases as flight Mach number increases in the ramjet mode up to about flight Mach number 6.0. Further, FIG. 12A indicates that the inlet contraction ratio increases as flight Mach number increases in the scramjet mode up to about flight Mach number 12.0. FIG. 12 reference numerals 1203 , 1203 A represent the inverse of this data, in other words, the inlet throat diameter ratios (A inlet cylinder/A capture area) are the inverse of the previously defined contraction ratio.
As a general rule the nozzle throat 1202 and the inlet throat 1203 decrease with increasing flight Mach number in ramjet mode. Similarly, as a general rule the geometric/nozzle throat 1205 and the inlet throat 1203 A decrease with increasing flight Mach number in scramjet mode.
Cycle analysis was performed over the flight Mach number range of 2.5 to 12 at a dynamic pressure of 1500 psfa in order to establish the variable geometry requirements for the inlet area and nozzle throat area. For supersonic combustion cases, a constant-pressure combustion process was assumed with ethylene fuel entering at sonic velocity, parallel to the propulsion axis at the diffuser exit static pressure and 10000 R.
FIG. 12 presents the variation of inlet and nozzle throat areas with flight Mach number for various operating modes. Of primary interest is the large variation in nozzle throat area required in the low flight Mach number range. The dual-mode ramjet's thermal throat area must vary by a factor of 4.5 from Mach 2.5 to 5. The required throat area variation for the conventional ramjet is slightly less over the same range. The thermally-choked cases require a larger throat area at a given flight Mach number because of the greater total pressure loss associated with the transonic combustion process. In the dual-mode engine, the axial location of combustion in a diverging flow path is varied. The fuel distribution and flame-holding mechanisms used for axial modulation of the heat release must not interfere with scramjet-mode operation. These are the fundamental issues associated with extension of the dual-mode to low Mach number flight. Also shown in FIG. 12 is the inlet throat area variation representative of the contraction ratio. Finally, the combustor-exit area variation as a result of constant-pressure supersonic combustion is shown in FIG. 12 , and represents the free-jet combustor nozzle throat area design values.
The area ratio due to combustion of the propulsive stream decreases with flight Mach number as the incoming energy increases. A factor of 2.5 reduction in nozzle throat area is required between Mach 5 and 12. For all modes of operation, the required variations in throat area shown are a function of the inlet mass capture and pressure recovery characteristics assumed, and while representative for the purposes herein, could be reduced by integration, or other inlet design that results in greater spillage and higher recovery at the lower end of the flight Mach number range. Nozzle throat area variation requirements could also be relieved by a reduction in fuel-air ratio at the lower flight Mach numbers at the expense of net thrust. Obviously, limiting the flight Mach number range would also diminish the variable geometry requirements.
FIG. 128 is a control system 1200 B for positioning the variable (geometric) nozzle throat 807 . FIG. 12B illustrates desired 1206 ramjet mode (A nozzle/A inlet capture area) ratios switched into a controller 1210 when in the ramjet mode. Similarly, FIG. 12B illustrates desired 1208 scramjet mode (A nozzle/A inlet capture area) ratios switched into controller 1210 when in the scramjet mode. Controller 1210 , based on any differences between desired and actual (A nozzle/A inlet capture area), outputs corrective action to the nozzle positioner 1212 which then positions 1214 the variable geometric nozzle throat. A nozzle positioner sensor 1216 in combination with interconnecting lines 1215 , 1217 communicate the actual (A nozzle/A inlet capture area) signal to controller 1210 for comparison to the desired (A nozzle/A inlet capture area) pursuant to curve or algorithm 1202 , 1204 and 1205 .
FIG. 8B is a quarter-sectional schematic view 800 B of the dual-mode combustor 899 of FIG. 8 in the ramjet. mode. Supersonic compression 841 occurs in the inlet contraction section 801 leading to the cylindrical inlet passageway 802 . Arrow 842 indicates fuel injected perpendicularly to the variable diameter inlet cylindrical passageway/section 802 . Multimode fuel injector 8421 injects fuel radially into passageway 802 . Reference numeral 844 illustrates a region of subsonic diffusion and fuel mixing and reference numeral 845 illustrates a region of subsonic combustion. Reference numeral 846 illustrates contraction to a choked throat 807 and reference numeral 847 illustrates expansion and exhaust.
FIG. 8C is an enlargement 800 C of a portion of FIG. 8B illustrating, diagrammatically, the radial step 803 between the inlet 802 cylinder and the subsonic diffuser 804 . FIG. 8C also illustrates the fuel injector 8421 and the injection of fuel 842 .
One of the important benefits of the dual-mode combustor 899 , however, is that the combustion chamber 805 can be used for robust, subsonic combustion at low flight Mach numbers. Operation as a subsonic combustion ramjet (ramjet mode) is illustrated in FIGS. 8 , 8 A and 8 B. Fuel injection can be accomplished with a single array of injectors upstream in the inlet section 802 . Ignition and flame-holding 810 can be accomplished with an in-stream device as shown in FIGS. 8 and 9 .
FIGS. 8 , 8 A and 8 B illustrate the subsonic combustion ramjet mode. At the desired flight condition, transition to free jet mode is effected by increasing the nozzle throat 807 area suddenly and inducing separation at the radial step 803 located at the diffuser inlet. The flame-holding array 810 does not extend across the subsonic diffuser 804 . In particular, the flame-holding array includes an aperture 850 therein which accommodates passage of the free-jet therethrough in the scramjet mode. The subsonic diffuser section, sometimes referred to herein as the subsonic diffuser 804 , satisfies the requirements of operation as a diffuser in ramjet mode, and separated operation in free jet mode.
In free-jet mode (scramjet mode) the propulsive stream re-joins the nozzle throat section, D 1 , with a minimum of disruption. The combustion chamber pressure equilibrates to near that of the diffuser exit, and will depend on many factors such as the nozzle throat area, A, the rate of fuel entrainment, and the aerodynamics of the re-circulation region. Overall heat load to the combustion chamber walls depends on the temperature in the recirculation region, and the competing effects of low velocity and increased surface area.
FIG. 10 is a perspective of the dual-mode combustor 1000 employing rectangular geometry. FIG. 10 illustrates inlet contraction section 1000 , inlet minimum area 1002 , subsonic diffuser section 1004 , combustion chamber 1005 , nozzle contraction section 1006 , variable nozzle throat at the joining point of the contraction section 1006 and the expansion section 1007 . Step 1003 and the expansion section 1008 are illustrated in FIG. 10 . All components of the dual-mode combustor 1000 can vary dimensionally. In general the various components in FIG. 10 are rectangularly shaped. In this example, the nozzle throat would be rectangular and would be adjustable.
FIG. 11 is a quarter-sectional diagrammatic view 1100 of the dual mode combustor 899 in the scramjet mode for flight Mach number 8 illustrating a radial step 1121 A, a hinged diffuser section 1122 , a hinged combustion section 1123 , a hinged contraction section 1124 , a hinged nozzle throat/arc section 1125 and a hinged expansion section 1126 . FIG. 11A provides dimensional information 1100 A relating to FIG. 11 including the radius of the engine at different stages thereof and the axial position of different stages thereof. Reference numeral 1101 represents station 1 (end of cylindrical inflow section), reference numeral 1102 represents the beginning of cylindrical combustion chamber, reference numeral 1107 represents station 7 (end of cylindrical combustion chamber), reference numeral 1108 represents station 8 (nozzle throat), reference numeral 1121 represents the cylindrical inflow chamber, reference numeral 1121 A represents the hinge and aft facing step, reference numeral 1122 represents the diffuser section, reference numerals 1122 A, 1123 A, 1127 , 1128 represent hinges, reference numeral 1123 represents the combustion chamber, reference numeral 1124 represents the contraction section, reference numeral 1125 represents the arc section, reference numeral 1126 represents exhaust section, reference numeral 1129 represents the termination of the exhaust section, reference numeral 1180 represents station zero (air inlet from air inlet contraction device), reference numeral 1180 A represents the multi-mode fuel injectors, and reference numeral 1181 indicates arrows of incoming air.
Also, hinges, H, indicate herein that the geometry of the dual-mode combustor may change around these points between component sections thereof to accommodate flight conditions. Reference numerals 1127 and 1128 signify the interconnection of the arc section 1125 to the contraction section and the expansion section, respectively. In reviewing FIG. 11 tangency is maintained and required in all examples between the arc sections and the contraction and expansion sections. This means that the hinges are the equivalent of sliding joints. Specifically, although joints 1127 , 1128 are illustrated diagrammatically as hinges, in fact these diagrammatic “hinges” are limited in their movement such that tangency between the contraction section and the arc section is maintained and the arc section may not bend back or extend such that a line coincident with the contraction section would intersect with the arc section 1125 . Similarly, the hinges illustrated in FIGS. 13-16 , inclusive, may be considered as sliding joints.
Still referring to FIG. 11 , the hinges diagrammatically indicate that the geometry of the engine changes pursuant to the flight Mach number conditions. Now referring to FIG. 12A , as a general rule the geometric/nozzle throat 1202 and the inlet throat 1203 decrease with increasing flight Mach number in ramjet mode. See FIG. 12 . Similarly, as a general rule the geometric/nozzle throat 1205 and the inlet throat 1203 A decrease with increasing flight Mach number in scramjet mode. The axi-symmetric geometry used for the analysis consists of the fixed-length, hinged panels and cylindrical sections is shown in FIG. 11 . The fixed-length cylindrical inlet section diameter varies with flight Mach number to match the contraction ratio schedule given in FIG. 12A with an allowance for fuel injection. A small radial step was placed at station 1 to facilitate flow separation. Generally the radial step is one-tenth the radius of the inlet cylinder. The cylindrical combustor section is sized to accommodate ramjet combustion for the Mach 2.5 flight condition. The nozzle throat is formed by a circular arc of radius equal to one-half that of the inlet capture area. As the required throat area varies with flight condition, the nozzle throat arc length varies such that the contraction and expansion panels maintain tangency. The expansion panel trailing edge is maintained at a fixed radius, giving an exit area equal to twice the inlet capture area. Coordinates for the Mach 8 geometry shown in FIG. 11 are given in FIG. 11A . Ethylene fuel enters axially at station 1 ( 1101 ) through injectors 1180 A as illustrated in FIG. 11 .
FIG. 11B is a view of a receiving joint forming the nozzle throat. Reference numeral 1124 B signifies a nozzle contraction section having a receiving joint 1125 R. Reference numeral 1126 B signifies a nozzle expansion section having a receiving joint 1126 R-receiving. Arc section 1125 B slidingly resides within joints/openings 1124 R, 1126 R such that the rotation of the nozzle contraction section 1124 B and/or the rotation of the nozzle expansion section 1126 R moves the nozzle throat 1108 while maintaining a tangential relationship between the sections 1124 B, 1126 E and the arc section 1125 B.
FIG. 13A is a generalized quarter-sectional diagrammatic view 1300 A of the flight Mach number 2.5 ramjet. FIG. 13B is a generalized quarter-sectional diagrammatic view 1300 B of the flight Mach number 3.0 ramjet. FIG. 13C is a generalized quarter-sectional diagrammatic view 1300 C of the flight Mach number 4.0 ramjet.
All numerical values in FIGS. 13A-16C , inclusive, are in inches with the radius being indicated on the ordinate (“y”) axis and the axial length indicated on the abscissa (“x”) axis. Also, hinges, H, indicate herein that the geometry of the dual-mode combustor may change around these pivot points between component sections thereof to accommodate flight conditions. Reference numerals H 1 and H 2 signify the interconnection of the arc section to the contraction section and the expansion section, respectively. In reviewing FIGS. 13A-16C , tangency is maintained and required in all examples between the arc sections and the contraction and expansion sections.
The reference numerals used in FIGS. 13A , 13 B and 13 C are set forth below. Reference numerals 1301 I, 11311 I, 1321 I represent the respective inlet sections illustrated in FIGS. 13A , 13 B and 13 C, respectively. Reference numerals 1301 A, 1311 A, 1321 A represent the arc sections illustrated in FIGS. 13A , 13 B and 13 C, respectively. Reference numerals 1301 N; 1311 N, 1321 N represent the variable nozzle throat sections illustrated in FIGS. 13A , 13 B and 13 C, respectively. A review of FIGS. 13A , 13 B and 13 C, respectively, yields the conclusion that the inlet diametrical section, which is cylindrical, is decreasing in diameter as the flight Mach number is increasing from 2.5 to 4.0 in the ramjet mode while the nozzle throat radius is decreasing with increased flight Mach number. Tangency is maintained in all examples of FIGS. 13A , 13 B and 13 C between the arc sections and the contraction and expansion sections.
FIG. 14A is a generalized quarter-sectional diagrammatic view 1400 A of the flight Mach number 5.0 ramjet. FIG. 14B is a generalized quarter-sectional diagrammatic view 1400 B of the flight Mach number 5.0 scramjet. Reference numerals 1401 I, 1411 I represent the respective inlet sections illustrated in FIGS. 14A and 14B , respectively. Reference numerals 1401 A, 1411 A represent the arc sections illustrated in FIGS. 14A and 14B , respectively. Reference numerals 1401 N, 1411 N represent the variable nozzle throat sections illustrated in FIGS. 14A and 14B , respectively. A review of FIGS. 14A and 14B , respectively, yields the conclusion that the inlet diametrical section, which is cylindrical, is slightly increasing in diameter as the engine is transitioning from ramjet flight Mach number 5 to scramjet flight Mach number 5 while the nozzle throat radius is substantially increasing while transitioning from ramjet flight Mach number 5 to scramjet flight Mach number 5. Tangency is maintained in all examples of FIGS. 14A and 14B between the arc sections and the contraction and expansion sections.
FIG. 15A is a generalized quarter-sectional diagrammatic view 1500 A of the flight Mach number 6.0 ramjet. FIG. 15B is a generalized quarter-sectional diagrammatic view 1500 B of the flight Mach number 6.0 scramjet. Reference numerals 1501 I, 1511 I represent the respective inlet sections illustrated in FIGS. 15A and 15B , respectively. Reference numerals 1501 A, 1511 A represent the arc sections illustrated in FIGS. 15A and 15B , respectively. Reference numerals 1501 N, 1511 N represent the variable nozzle throat sections illustrated in FIGS. 15A and 15B , respectively. A review of FIGS. 15A and 15B , respectively, yields the conclusion that the inlet diametrical section, which is cylindrical, is slightly increasing in diameter as the engine is transitioning from ramjet flight Mach number 6 to scramjet flight Mach number 6 while the nozzle throat radius is substantially increasing while transitioning from ramjet flight Mach number 6.0 to scramjet flight Mach number 6.0. Tangency is maintained in all examples of FIGS. 15A and 15B between the arc sections and the contraction and expansion sections.
FIG. 16A is a generalized quarter-sectional diagrammatic view 1600 A of the flight Mach number 8.0 scramjet. FIG. 16B is a generalized quarter-sectional diagrammatic view 1600 B of the flight Mach number 10.0 scramjet. FIG. 16C is a generalized quarter-sectional diagrammatic view 1600 C of the flight Mach number 12.0 scramjet. Reference numerals 1601 I, 1611 I, 1621 I represent the respective inlet sections illustrated in FIGS. 16A , 16 B and 16 C, respectively. Reference numerals 1601 A, 1611 A, 1621 A represent the arc sections illustrated in FIGS. 16A , 16 B and 16 C, respectively. Reference numerals 1601 N, 1611 N, 1621 N represent the variable nozzle throat sections illustrated in FIGS. 16A , 16 B and 16 C, respectively. A review of FIGS. 16A , 16 B and 16 C, respectively, yields the conclusion that the inlet diametrical section, which is cylindrical, is slightly decreasing in diameter as the flight Mach number is increasing from 8.0 to 10.0 in the scramjet mode while the nozzle throat radius is moderately decreasing with increased flight Mach number. Tangency is maintained in all examples of FIGS. 16A , 168 and 16 C between the contraction and expansion sections.
Contours of static pressure ratio for flight Mach numbers 5, 8 and 12 in the scramjet mode flight conditions appear in FIGS. 17A , 17 B, and 17 C. FIG. 17A is an illustration of the pressure contours 1700 A within the engine for the flight Mach number 5.0 scramjet. FIG. 17B is an illustration of the pressure contours 1700 B within the engine for the flight Mach number 8.0 scramjet. FIG. 17C is an illustration of the pressure contours 1700 C within the engine for the flight Mach number 12.0 scramjet.
Referring to FIG. 17A , pressure ratio contours, P/Pinlet, for the flight Mach number 5.0 scramjet are illustrated and pressure ratio, P/Pinlet, 1701 , has a magnitude of about 1.04 and is located generally in the recirculation zone, forward portion of the combustion chamber. Reference numeral 1731 is a stagnation streamline. When viewing FIG. 17A , everything leftwardly of stagnation streamline 1731 is in the recirculation zone. Reference numeral 1731 A represents a free-jet streamline.
Referring to FIG. 17B , pressure ratio, P/Pinlet, 1711 , for the flight Mach number 8.0 scramjet, pressure ratio has a magnitude of about 1.32 and is located generally in the recirculation zone of the forward portion of the combustion chamber. When viewing FIG. 17B , everything leftwardly of stagnation streamline 1732 is in the recirculation zone. Reference numeral 1732 A represents a free-jet streamline.
Referring to FIG. 17C , pressure ratio, P/Pinlet, 1712 , for the flight Mach number 12.0 has a magnitude of about 1.18 and is located generally in the recirculation zone of the forward portion of the combustion chamber. When viewing FIG. 17C , everything leftwardly of stagnation streamline 1733 is in the recirculation zone. Reference numeral 1733 A represents a free jet streamline.
Reviewing FIG. 17 , the recirculation zone pressure ratios increase from scramjet flight Mach number 5 to 8 and then decrease from between flight Mach number 8 to 12.
Contours of Mach number for flight Mach numbers 5, 8 and 12 in the scramjet mode flight conditions appear in FIGS. 18A , 18 B, and 18 C. All three cases for flight Mach numbers 5, 8 and 12 exhibit periodic wave structure in the free-jet, and an overall increase in cross-sectional area due to combustion as the jet traverses the combustion chamber. In all cases the free-jet rejoins the nozzle throat contour and expands to the exit area. The free jet drives a primary recirculation zone in the combustion chamber, the center of which moves aft with increasing flight Mach number. Streamlines in the combustion chamber define the recirculation zone. In the inlet section, and continuing in a conical non-influence region of the free-jet, supersonic combustion elevates the pressure to a level higher than that of the reference pressure at the inflow plane. The highest pressure occurs on the axis, followed by an expansion initiated at the jet boundary. In the Mach 8 and 12 cases, the recirculation zone equilibrates to the pressure at the radial step and the bounding streamline issues axially with little initial deflection. In the Mach 5 case, the recirculation zone equilibrates to a lower pressure, causing an initial expansion of the free-jet at the step. All cases show a subsequent divergence of streamlines required to accommodate the continuing supersonic combustion process while matching combustion chamber pressure. This “entry interaction” initiates the repetitive streamline structure characteristic of an under-expanded jet. The severity of the entry interaction depends on the initial rate of mixing and combustion in the free-jet, and its initial pressure with respect to the recirculation zone. The wavelength and shock losses associated with the streamline structure depend on the entry interaction. At the combustor exit, the Mach 5 case approaches a sonic condition, and its wave structure disappears. Streamlines in the Mach 8 case appear to be approximately in phase with the throat geometry, and the streamlines merge smoothly into the minimum area. The Mach 12 case however, exhibits an “exit interaction” as streamlines are forced to converge, resulting in a strong shock wave on the axis. This interaction could obviously be eliminated by reducing the wavelength of the shock structure or moving the throat, but of most benefit from a propulsion standpoint would be to eliminate the periodic streamline structure altogether by mitigating the entry interaction.
FIG. 18A is an illustration 1800 A of the Mach number contours within the engine for the flight Mach number 5.0 scramjet. FIG. 18B is an illustration 1800 B of the Mach number contours within the engine for the flight Mach number 8.0 scramjet. FIG. 18C is an illustration 1800 C of the Mach number contours within the engine for the flight Mach number 12.0 scramjet. Referring to FIG. 18A , reference numeral 1801 indicates a magnitude of about Mach 0.0 located in the recirculation zone of the forward portion of the combustion chamber.
Referring to FIG. 18B , reference numeral 1810 indicates a magnitude of about Mach 0.0 located in the recirculation zone in the middle of the combustion chamber. Referring to FIG. 18C , reference numeral 1821 represents a magnitude of about Mach 0.0 located in the recirculation zone of the aft portion of the combustion chamber.
FIG. 19A is an illustration of the static temperature contours 1900 A within the engine for the flight Mach number 5.0 scramjet. FIG. 19B is an illustration of the static temperature contours 1900 B within the engine for the flight Mach number 8.0 scramjet. FIG. 19C is an illustration of the static temperature contours 1900 C within the engine for the flight Mach number 12.0 scramjet.
Referring to FIG. 19A , reference numeral 1901 indicates a temperature of about 3500° R and reference numeral 1903 indicates a temperature of about 5000° R. Referring to FIG. 19B , reference numeral 1906 indicates a temperature of about 6000° R. Referring to FIG. 19C , reference numeral 1910 indicates a temperature of about 9000° R.
Temperature contours appear in FIGS. 19A , 19 B and 19 C. The effects of combustion are apparent in the individual shear layers. The Mach 5 case shows a degree of stratification that persists into the nozzle throat. The recirculation zone equilibrates to greater than 90% of the ethylene-air theoretical value in the Mach 8 and 12 cases, but is significantly cooler in the Mach 5 case. This is likely due to the two-injector arrangement used in the Mach 5 case, and suggests that the recirculation zone temperature and combustor heat load depend on the fuel injection method, and could be reduced in future design iterations. Exit interaction in the Mach 12 case may also contribute to elevated temperature in the recirculation zone.
In order to make a quantitative assessment of the losses in the free-jet combustion process, and their effect on net thrust, mass-averaged axial distributions of pressure, temperature, and velocity were obtained during the analysis. The combustor friction coefficient thus represents the momentum loss associated with the recirculation zone and shock structure in the free-jet. The ideal net thrust per unit airflow is illustrated in FIG. 20 .
FIG. 20 illustrates the ideal net thrust per unit airflow based on use of different computational methods/tools. FIG. 20 illustrates ideal net thrust per unit of airflow against flight Mach numbers for a conventional ramjet, thermally-choked ramjet and a scramjet. Reference numeral 2001 represents the ideal net thrust for scramjet mode operation. Reference numeral 2003 represents the ideal net thrust for the thermally choked operation such as in Curran et al. Reference numeral 2002 represents the ideal net thrust for the ramjet disclosed herein. FIG. 20 illustrates a comparison of a thermally choked ramjet to the dual-mode ramjet disclosed herein. The subsonic combustion ramjet disclosed herein is 6-8% more efficient than the thermally-choked or “dual-mode” ramjet as a consequence of lower combustion Mach number. Of greater significance than higher performance however, is the practicality of fuel distribution and flame-holding in the conventional ram burner.
FIG. 21 illustrates the mass-averaged static pressure distributions 2100 with the pressure at the nozzle throat station denoted by symbols (supersonic combustor exit) for various flight conditions, to with, scramjet flight Mach numbers 5, 8 and 12. Reference numeral 2101 represents Mach 5 pressure ratio data, reference numeral 2102 represents Mach 8 pressure ratio data, and reference numeral 2103 represents Mach 12 pressure ratio data. Compression due to mixing and combustion in the cylindrical inlet section from station zero to 0.36 feet is evident, as is the subsequent expansion and periodic streamline structure. As the free-jet traverses the combustion chamber, the mean pressure is generally above the inflow value, consistent with the elevated recirculation zone pressures. The Mach 5 pressure distribution shows a damped character as combustion drives the free-jet toward a sonic condition. Of interest is the phase shift and elevated amplitude of the last peak in the Mach 12 case consistent with the exit interaction seen in the pressure contours. Note that the combustor exit pressure (at the minimum area) used for cycle analysis of the Mach 8 and 12 solutions is significantly higher than the inflow, and would cause a discrepancy with cycle analysis assuming combustion at constant pressure.
FIG. 21A illustrates the mass-averaged axial velocity ratio (V/V inlet) distributions 2100 A for various flight conditions, to with, scramjet flight Mach numbers 5, 8 and 12. Reference numeral 2111 represents Mach 5 velocity ratio data, reference numeral 2112 represents Mach 8 velocity ratio data, and reference numeral 2113 represents Mach 12 velocity ratio data. A marked reduction in velocity occurs upstream of the throat station for the Mach 8 and 12 cases, and is more gradual for the Mach 5 case, consistent with the pressure distributions. The loss coefficients used to match the combustor exit velocities are listed in the FIG. 21A . Shock and viscous losses are represented in these values, and an estimate of their relative contributions to the total is not determined. Shock losses arise from the entry and exit interactions discussed above, and may be reduced by better tailoring of the combustion process, and optimization of the combustion chamber geometry. The viscous loss arises from the momentum required to drive the recirculating flow in the combustion chamber, which presumably is a function of the combustion chamber volume and wetted area. These are determined by the cross-sectional area required at the minimum ramjet Mach number, subsonic diffuser length requirements, and the free jet length required for supersonic mixing and combustion.
FIG. 21B illustrates the mass-averaged temperature distributions 2100 B for scramjet mode flight Mach numbers 5, 8 and 12. Reference numeral 2121 indicate Mach 5 temperature data as a function axial position, reference numeral 2122 indicate Mach 8 temperature data as a function axial position, and reference numeral 2123 represents Mach 12 temperature data as a function of axial position. Temperatures increase with increasing Mach flight numbers.
FIG. 23A illustrates the ethylene mass fraction 2300 A for flight Mach numbers 5, 8 and 12 versus axial position. Reference numeral 2305 signifies the flight Mach number 5, reference numeral 2306 signifies the flight Mach number 8, and reference numeral 2307 signifies the flight Mach number 12.
Calculations at various nozzle throat areas were performed in order to evaluate the effect on recirculation zone pressure, entry and exit interactions, and performance at the flight Mach number 8 as illustrated in FIGS. 11 and 16A . FIGS. 22A , 22 B, 22 C and 22 D illustrate static pressure contours for throat areas equal to 110%, 100%, 90% and 80% of the design value. FIG. 17B and FIG. 22B are identical but different data is presented and discussed in connection with each drawing figure.
FIG. 22A illustrates the static pressure ratio 2200 A for scramjet mode flight Mach number 8 with the variable nozzle throat positioned at 110% of the design operating point. Reference numeral 2201 indicates a stagnation streamline and reference numeral 2202 indicates the pressure ratio of 0.95 located in recirculation zone of the combustion chamber (110% nozzle throat ratio). When viewing FIG. 22A , everything to the left of stagnation streamline 2201 is in the recirculation zone. Reference numeral 2221 T is the nozzle throat location (110% nozzle throat area ratio).
FIG. 22B illustrates the static pressure ratio 2200 B for scramjet mode flight Mach number 8 with the variable nozzle throat positioned at 100% of the design operating point. Reference numeral 2203 represents a stagnation streamline and reference numeral 2204 indicates a pressure ratio of 1.32 located in the recirculation zone of combustion chamber (100% nozzle throat ratio). When viewing FIG. 22B , everything to the left of stagnation streamline 2203 is in the recirculation zone. Reference numeral 2223 T is the nozzle throat location (100% nozzle throat ratio).
FIG. 22C illustrates the static pressure ratio 2200 C for scramjet mode flight Mach number 8 with the variable nozzle throat positioned at 90% of the design operating point. Reference numeral 2205 represents a stagnation streamline and reference numeral 2206 is the pressure ratio of 1.60 located in recirculation zone of combustion chamber (90% nozzle throat ratio). When viewing FIG. 22C , everything to the left and above the stagnation streamline 2205 is in the recirculation zone. Reference numeral 2225 T is the nozzle throat location (90% nozzle throat ratio).
FIG. 22D illustrates the static pressure ratio 2200 D for scramjet mode flight Mach number 8 with the variable nozzle throat positioned at 80% of the design operating point. Reference numeral 2207 represents the stagnation streamline and reference numeral 2208 represents the pressure ratio of 1.87 located in recirculation zone of combustion chamber (80% nozzle throat ratio). When viewing FIG. 22D , everything to the left and above stagnation streamline 2207 is in the recirculation zone. Reference numeral 2227 T is the nozzle throat location (80% nozzle throat ratio).
As throat area is reduced, combustion chamber pressure increases, and the period of the streamline structure decreases. As expected, combustion in the inlet section, and a short distance downstream is not affected. Beyond this however, increased pressure increases the rate of combustion, reinforcing the tendency toward shorter wavelengths. Reference numerals 2201 , 2203 , 2205 and 2207 represent the streamlines and streamline 2207 (variable nozzle throat at 80% of design value) has a shorter wavelength than streamline 2201 (variable nozzle throat at 110%) or streamline 2203 (variable nozzle throat at 100%). Further, the pressure increase in the combustion chambers is viewed in FIGS. 22A , 22 B, 22 C and 22 D as the variable nozzle's area is reduced. Referring back now to FIGS. 22A-D , it is evident that the free jet entry conditions range from under-expanded at 110% throat area to over-expanded at 80%, but the streamline structure is never eliminated due to the rapidity of combustion and divergence of streamlines in the inlet region. The severity of the exit interaction depends on synchronization of the streamline structure with the throat geometry. The streamline 2203 associated with the variable nozzle throat at 100% of the design case appears to be in phase and exhibits almost no exit interaction with the nozzle throat. Reference numeral 2223 T represents the variable nozzle throat for the 100% example. Reference numerals 2221 T, 2225 T and 2207 T represent the throats in the examples where the variable nozzle throat is 110%, 90% and 80%, respectively. Interference with the throat is greatest for the 80 and 110% cases which show the strongest interactions.
FIG. 23 illustrates the effect of nozzle throat area variation 2300 for scramjet mode flight Mach number 8 on the rate of ethylene fuel depletion. Reference numeral 2301 signifies the effect of throat area variation on ethylene mass fraction (110% nozzle throat ratio), reference numeral 2302 signifies the effect of throat area variation on ethylene mass fraction (100% nozzle throat ratio), reference numeral 2303 signifies the effect of throat area variation on ethylene mass fraction (90% nozzle throat ratio), and reference numeral 2304 signifies the effect of throat area variation on ethylene mass fraction (80% nozzle throat ratio).
FIG. 24 illustrates the effect of nozzle throat area variation on mass-averaged static pressure distribution 2400 for scramjet mode flight Mach number 8. Reference numeral 2401 signifies the effect of throat area variation on mass averaged static pressure distribution for the flight Mach number 8 (110% nozzle throat ratio), reference numeral 2402 signifies the effect of throat area variation on mass averaged static pressure distribution for the flight Mach number 8 (100% nozzle throat ratio), reference numeral 2403 signifies the effect of throat area variation on mass averaged static pressure distribution for the flight Mach number 8 (90% nozzle throat ratio), and reference numeral 2404 signifies the effect of throat area variation on mass averaged static pressure distribution for the flight Mach number 8 (80% nozzle throat ratio).
Mass-averaged pressure distributions for scramjet mode flight Mach number 8 illustrated in FIG. 24 also show that as throat area is reduced, the initial pressure rise increases, the period of the streamline structure decreases, and the mean is approximately equal to the recirculation zone pressure. Peak-to-peak amplitude is roughly the same for all cases. Note that for the 100% case, the waveform merges smoothly with the nozzle expansion. The designation A 8 in FIG. 24 refers to FIG. 11 , station 8 , reference numeral 1108 . The 110% case shows a slight slope discontinuity just prior to the throat station and the 80 and 90% cases show out-of-phase features at the throat, consistent with the interactions seen in the pressure contours.
The effect of throat area variation was to change the combustion chamber pressure and the period of the streamline structure without significantly altering its amplitude. The amplitude of the primary streamline structure is, therefore, most likely dependent on the initial rate of combustion. The exit interaction was affected by the phasing of the shock structure and was nearly eliminated in the 100% throat area case. The adiabatic wall temperature and the gas temperature in the recirculation zone were not significantly affected by throat area variation.
FIG. 25 illustrates 2500 the ideal net thrust per unit of airflow plotted against combustor exit pressure ratio and nozzle throat area variation for scramjet mode flight Mach number 8. The ideal net thrust per unit airflow for the example of scramjet flight Mach number 8 for variable nozzle throat opening ratios (80%, 90%, 100% and 110%) is plotted 2501 versus the mass-averaged combustor exit pressure ratio in FIG. 25 . Reference numeral 2502 represents the ideal net thrust per unit airflow with a Cf of 0.0025. Friction loss coefficients required to match the exit velocities are also listed with the throat area for each point. The 90% variable nozzle throat case exhibits the least momentum loss, the 110% case the greatest, and despite the entry and exit interactions seen in pressure contours for the 80% case, its loss coefficient is slightly less than the 100% case which showed little interaction. This relative insensitivity and lack of correlation of loss coefficient to throat area is not unexpected however, since the amplitude of the basic streamline structure, and presumably the viscous loss component were not significantly affected. Cycle analysis results at the corresponding pressure ratios and with nominal momentum loss are also plotted for reference and to show the basic sensitivity of scramjet net thrust to combustor pressure ratio.
REFERENCE NUMERALS
Reference numerals 10 - 86 pertain to the prior art.
10 —aircraft 12 —ramjet combustion engine 14 —inlet scoop 16 —exhaust outlet 17 , 18 , 19 —walls 20 —fourth wall 21 —converging inlet cowl passage 22 —diverging supersonic combustion section 24 —substantially uniform cross section subsonic combustion section 26 —exit nozzle 27 —pilot zone recesses 28 —fuel pump 30 —fuel control system 32 —plurality of nozzles 34 —fuel control system 36 —plurality of nozzles 40 —central body 42 —elongated inlet spike 43 —flameholders 44 —exhaust plug 46 —annular member 47 , 48 —struts 49 —fuel pump 50 —subsonic combustion chamber 51 —fuel control 52 —nozzles 52 in the struts 47 55 —nozzles supplied from fuel ducts 56 —fuel ducts 58 —recesses 60 —supersonic combustion chamber 61 —fuel control 62 , 64 —nozzles 65 —ducts 70 , 72 —pumps 74 , 75 —nozzles 76 , 78 —fuel control system 80 —supersonic combustion chamber 82 —subsonic chamber 86 —recess pilot zones 600 —cross-sectional view of a prior art dual mode supersonic ramjet engine operating in the scramjet mode 601 —fuel injection nozzle 602 —inlet contraction section 603 —diverging supersonic combustion section 604 —exit nozzle 605 —fuel-air mixture 606 , 606 A, 880 —incoming air being compressed 607 , 607 A, 881 —exiting combustion gases 608 —interior wall of engine 700 —cross-sectional view of a prior art dual mode supersonic ramjet engine operating in the thermally-choked ramjet mode 701 —shock train to subsonic ramjet mode 702 —beginning of shock train to subsonic ramjet mode 703 —fuel injector 704 —fuel injector
Reference numerals 800 and above pertain to the disclosed and claimed invention.
800 —perspective view of dual-mode combustor operating in the ramjet mode 800 A—cross-sectional schematic view of the dual-mode combustor operating in the ramjet mode 800 B—quarter sectional schematic view of the dual-mode combustor operating in the ramjet mode 800 C—enlarged portion of FIG. 8A illustrating the radial step and the multimode fuel injector 801 —inlet contraction section 802 —inlet minimum area, variable diameter inlet cylindrical passageway/section 803 —radial step 804 —subsonic diffuser section 805 —combustion chamber 806 —nozzle contraction section 807 —variable nozzle throat at the joining point of the contraction section 806 and the expansion section 808 in the ramjet mode or the scramjet mode 808 —nozzle expansion section 810 —ramjet mode flame holder 812 —beginning of radial step 803 812 A—end of radial step 803 830 —terminal shock waves, position controlled by algorithm governing nozzle throat position 841 —supersonic compression 842 —arrow indicating fuel injected 8421 —multimode fuel injector 844 —subsonic diffusion and fuel mixing 845 —subsonic combustion 845 A—supersonic combustion 846 —contraction to choked throat 847 , 847 A—expansion 850 —aperture in flame holder 810 for the passage of the free-jet 872 —heat release 899 —dual-mode combustor 900 —perspective view of dual-mode combustor operating in the scramjet mode 900 A—cross-sectional schematic view of the dual-mode combustor operating in the scramjet mode 900 B—quarter sectional schematic view of the dual-mode combustor operating in the scramjet mode 900 C—cross-sectional perspective view of the diffuser illustrating the array of flame holders 810 and a central aperture 850 within the array of flame holders 810 943 —free-jet in the scramjet mode 943 A—supersonic free jet boundary wherein the pressure is approximately equal with that of the recirculation zone 944 —recirculation zone 972 —heat release 1000 —perspective view of a dual-mode combustor using different geometry 1001 —inlet contraction section 1002 —inlet minimum area 1003 —step 1004 —subsonic diffuser section 1005 —combustion chamber 1006 —nozzle contraction section 1007 —variable nozzle throat at the joining point of the contraction section 1006 and the expansion section 1008 1008 —expansion section 1100 —quarter sectional view of the dual-mode combustor in the scramjet mode for flight Mach number 8 1100 A—dimensional information for the quarter sectional view of the dual-mode combustor in the scramjet mode for flight Mach number 8 1100 B—view of receiving joint forming the nozzle throat 1101 —station 1 , end of cylindrical inflow section 1102 —station 2 , beginning of cylindrical combustion chamber 1107 —station 7 , end of cylindrical combustion chamber 1108 —station 8 , nozzle throat 1121 —cylindrical inflow chamber 1121 A—hinge and aft facing step 1122 —diffuser section 1122 A, 1123 A, 1127 , 1128 —hinge, sliding joint 1123 —combustion chamber 1124 —contraction section 1125 —arc section 1126 —expansion section 1124 B—nozzle contraction section 1126 B—nozzle expansion section 1126 R—receiving joint 1125 B—arc section 1125 R—receiving joint 1129 —termination of expansion section 1180 —station zero, station i, air inlet from air inlet contraction device 1180 A—multi-mode fuel injectors 1181 —arrows representing incoming air 1200 —illustration of flight Mach number versus thermal throat for prior art device, geometric/nozzle throat for dual-mode combustor of present invention in ramjet mode and in scramjet mode as a ratio of inlet capture area, and inlet throat in ramjet mode and scramjet mode as a ratio of inlet capture area 1200 A—table of flight Mach numbers versus inlet contraction ratios, Ac/Ai 1200 B—variable nozzle throat position schematic 1201 —thermal throat of prior art device 1202 —geometric/nozzle throat expressed as a ratio of nozzle throat area to inlet capture area in ramjet mode 1203 —dual mode combustor, inlet throat in ramjet mode 1203 A—dual mode combustor, inlet throat in scramjet mode 1204 —discontinuity/jump of variable nozzle throat position between the ramjet mode 1202 and the scramjet mode 1205 1205 —geometric/nozzle throat expressed as a ratio of nozzle throat area to inlet capture area in scramjet mode 1206 —desired ramjet nozzle throat position as a function of flight Mach number for the ramjet mode 1207 , 1209 —switch 1208 —desired ramjet nozzle throat position as a function of flight Mach number for the scramjet mode 1210 —controller operating on the difference of desired position of the nozzle throat minus the actual position of the nozzle throat 1211 —output of controller 1212 —nozzle throat positioner 1213 —position signal 1214 —variable geometric nozzle throat 1215 , 1217 —interconnecting signal transmission lines 1216 —nozzle throat position sensor 1218 —actual nozzle throat position as a function of flight Mach number 1230 —inlet contraction ratio 1231 —combustion process 1300 A—quarter-sectional schematic profile of the dual-mode combustor in the ramjet mode, flight Mach number 2.5 1300 B—quarter-sectional schematic profile of the dual-mode combustor in the ramjet mode, flight Mach number 3 1300 C—quarter-sectional schematic profile of the dual-mode combustor in the ramjet mode, flight Mach number 4 1301 A, 1311 A, 1321 A—arc section 1301 C, 1311 C, 1321 C—combustion chamber 1301 D, 1311 D, 1321 D—diffuser section 1301 E, 1311 E, 1321 E—expansion section 1301 I, 1311 I, 1321 I—inlet section 1301 N, 1311 N, 1321 N—variable nozzle throat section 1301 X, 1311 X, 1321 X—contraction section 1400 A—quarter-sectional schematic profile of the dual-mode combustor in the ramjet mode, flight Mach number 5 1400 B—quarter-sectional schematic profile of the dual-mode combustor in the scramjet mode, flight Mach number 5 1401 A, 1411 A—arc section 1401 C, 1411 C—combustion chamber 1401 D, 1411 D—diffuser section 1401 E, 1411 E—expansion section 1401 I, 1411 I—inlet section 1401 N, 1411 N—variable nozzle throat section 1401 X, 1411 X—contraction section 1500 A—quarter-sectional schematic profile of the dual-mode combustor in the ramjet mode, flight Mach number 6 1500 B—quarter-sectional schematic profile of the dual-mode combustor in the scramjet mode, flight Mach number 6 1501 A, 1511 A—arc section 1501 C, 1511 C—combustion chamber 1501 D, 1511 D—diffuser section 1501 E, 1511 E—expansion section 1501 I, 1511 I—inlet section 1501 N, 1511 N—variable nozzle throat section 1501 X, 1511 X—contraction section 1600 A—quarter-sectional schematic profile of the dual-mode combustor in the scramjet mode, flight Mach number 8 1600 B—quarter-sectional schematic profile of the dual-mode combustor in the scramjet mode, flight Mach number 10 1600 C—quarter-sectional schematic profile of the dual-mode combustor in the scramjet mode, flight Mach number 12 1601 A, 1611 A, 1621 A—arc section 1601 C, 1611 C, 1621 C—combustion chamber 1601 D, 1611 D, 1621 D—diffuser section 1601 E, 1611 E, 1621 E—expansion section 1601 I, 1611 I, 1621 I—inlet section 1601 N, 1611 N, 1621 N—variable nozzle throat section 1601 X, 1611 X, 1621 X—contraction section 1700 A—pressure ratio, P/Pinlet, for the flight Mach number 5.0 1700 B—pressure ratio, P/Pinlet, for the flight Mach number 8.0 1700 C—pressure ratio, P/Pinlet, for the flight Mach number 12.0 1701 —pressure ratio, P/Pinlet, about 1.04 located generally in the forward portion of the combustion chamber 1711 -pressure ratio, P/Pinlet, about 1.32 located generally in the forward portion of the combustion chamber 1721 —pressure ratio, P/Pinlet, about 1.18 located generally in the forward portion of the combustion chamber 1731 , 1732 , 1733 —stagnation streamline 1731 A, 1732 A, 1733 A—free-jet streamline 1800 A—Mach number contours for the flight Mach number 5.0 1800 B—Mach number contours for the flight Mach number 8.0 1800 C—Mach number contours for the flight Mach number 12.0 1801 —about Mach 0.0, located in the recirculation zone of the forward portion of the combustion chamber 1810 —about Mach 0.0, located in the recirculation zone in the middle of the combustion chamber 1821 —about Mach 0.0, located in the recirculation zone of the aft portion of the combustion chamber 1900 A—static temperature contours for the flight Mach number 5.0 1900 B—static temperature contours for the flight Mach number 8.0 1900 C—static temperature contours for the flight Mach number 12.0 1901 —3500° R 1903 —5000° R 1906 —6000° R 1910 —9000° R 2000 —ideal net thrust per unit airflow over various flight Mach numbers 2001 —scramjet mode net thrust 2002 —conventional, prior art, net thrust in the ramjet mode 2003 —Curran (prior art) ramjet mode net thrust 2100 —mass averaged pressure distributions for scramjet flight mach numbers 5, 8 and 12 2100 A—mass averaged axial velocity distributions for scramjet flight mach numbers 5, 8 and 12 2100 B—mass averaged temperature distributions for scramjet flight mach numbers 5, 8 and 12 2101 —Mach 5 pressure ratio data as a function of axial position 2102 —Mach 8 pressure ratio data as a function of axial position 2103 —Mach 12 pressure ratio data as a function of axial position 2111 —Mach 5 axial velocity ratio data as a function of axial position 2112 —Mach 8 velocity ratio data as a function of axial position 2113 —Mach 12 velocity ratio data as a function of axial position 2121 —Mach 5 temperature data as a function of axial position 2122 —Mach 8 temperature data as a function of axial position 2123 —Mach 12 temperature data as a function of axial position 2200 A—static pressure plot for variable area nozzle throat position at 110% of design point for the flight Mach number 8 2200 B—static pressure plot for variable area nozzle throat position at 100% of design point for the flight Mach number 8 2200 C—static pressure plot for variable area nozzle throat position at 90% of design point for the flight Mach number 8 2200 D—static pressure plot for variable area nozzle throat position at 80% of design point for the flight Mach number 8 2201 —stagnation streamline 2202 —pressure ratio of 0.95 located in recirculation zone of combustion chamber (110% nozzle throat ratio) 2203 —stagnation streamline line 2204 —pressure ratio of 1.32 located in recirculation zone of combustion chamber (100% nozzle throat ratio) 2205 —stagnation streamline line 2206 —pressure ration of 1.60 located in recirculation zone of combustion chamber (90% nozzle throat ratio) 2207 —stagnation streamline line 2208 —pressure ratio of 1.87 located in recirculation zone of combustion chamber (80% nozzle throat ratio) 2221 T—nozzle throat location (110% nozzle throat ratio) 2223 T—nozzle throat location (100% nozzle throat ratio) 2225 T—nozzle throat location (90% nozzle throat ratio) 2227 T—nozzle throat location (80% nozzle throat ratio) 2300 —effect of throat area variation on ethylene mass fraction for the flight Mach number 8 2300 A—ethylene mass fraction for scramjet mode flight Mach numbers 5, 8 and 12 versus axial position 2301 —effect of throat area variation on ethylene mass fraction (110% nozzle throat ratio) 2302 —effect of throat area variation on ethylene mass fraction (100% nozzle throat ratio) 2303 —effect of throat area variation on ethylene mass fraction (90% nozzle throat ratio) 2304 —effect of throat area variation on ethylene mass fraction (80% nozzle throat ratio) 2305 —Mach flight number 5 axial position and ethylene mass fraction 2306 —Mach flight number 8 axial position and ethylene mass fraction 2307 —Mach flight number 12 axial position and ethylene mass fraction 2400 —effect of throat area variation on mass averaged static pressure distribution for the flight Mach number 8 2401 —effect of throat area variation on mass averaged static pressure distribution for the flight Mach number 8 (110% nozzle throat ratio) 2402 —effect of throat area variation on mass averaged static pressure distribution for the flight Mach number 8 (100% nozzle throat ratio) 2403 —effect of throat area variation on mass averaged static pressure distribution for the flight Mach number 8 (90% nozzle throat ratio) 2404 —effect of throat area variation on mass averaged static pressure distribution for the flight Mach number 8 (80% nozzle throat ratio) 2500 —ideal net thrust per unit airflow as a function of nozzle throat pressure ratio, Pnozzle/Pinlet 2501 —net thrust per unit airflow for the current free-jet disclosed herein 2502 —net thrust per unit airflow with a Cf of 0.0025. A=Cross-sectional area Cf=Friction coefficient D=Nozzle throat diameter ramjet mode D 1 =Nozzle throat diameter scramjet mode H=Hinge/sliding joint H 1 =First Arc Hinge/sliding joint H 2 =Second Arc Hinge/sliding joint M=Mach number P=Pressure r=Radial distance x=Axial distance Z=Altitude
SUBSCRIPTS
0 =Freestream
1 =Cylindrical inflow section exit station
2 =Combustion chamber inlet station
7 =Combustion chamber exit station
8 =Nozzle throat station
C=Inlet capture area
i=Inflow station
min=Minimum
T=Total
Those skilled in the art will readily recognize that the invention has been set forth by way of example only and that changes may be made to the examples without departing from the spirit and the scope of the claims which follow herein below.
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A new dual-mode ramjet combustor used for operation over a wide flight Mach number range is described. Subsonic combustion mode is usable to lower flight Mach numbers than current dual-mode scramjets. High speed mode is characterized by supersonic combustion in a free-jet that traverses the subsonic combustion chamber to a variable nozzle throat. Although a variable combustor exit aperture is required, the need for fuel staging to accommodate the combustion process is eliminated. Local heating from shock-boundary-layer interactions on combustor walls is also eliminated.
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FIELD OF THE INVENTION
[0001] The present invention relates to a wristband radio frequency identification tag, particularly to an intertalk wristband radio frequency identification tag with two-way radio functionality that can simultaneously transmit and receive radio-frequency signal to perform bidirectional communication.
BACKGROUND OF THE INVENTION
[0002] In many countries, the original agricultural society has evolved into an industrial society. In the traditional agricultural society, women play the role of raising children and taking care of the elderly. However, in an industrial society, many women enter the employment market to achieve a dual-income family with the elderly or the patient left lonely and uncared at home.
[0003] According to statistics, about 13% of the elderly have the experience of falls. A fall may only result in a slight harm, such as an abrasion or a bruise, which will heal in few days, but may also result in a serious injury, such as a fracture, which needs a surgical operation and rehabilitation. Sometimes, the injured elderly cannot regain the original mobility, which will deeply beset the injured and his family. Besides, illness increases the probability of falls, such as myocardial infraction, pneumonia, urinary-tract infection, etc. Further, once there was a fall, the probability of falling again is very high. If the fall of the elderly is found late, the elderly may have some physical and/or psychological sequelae.
[0004] If there is an emergency-informing system, the medical personnel can provide immediate rescue to reduce harm or even save a life in an emergency. Thereby, an irrecoverable damage may be avoided. Further, the family members can thus keep their minds on working without worry.
[0005] For the past ten years, the concept of home security has been gradually popularized. The service contents of home security are no more limited to only guards and alarms but have gradually grown to include lock design, induction illumination, intrusion detection, fire alarm, emergency informing, etc. The emergency-informing service may include providing assistance in the cases: medical rescue, harassment or threat to the residence, fire, emergency, and physical discomfort during outgoing.
[0006] When the nursed living alone, who may be an elderly or disabled person, falls or slips, he may ask for rescue via a telephone, a mobile phone or an emergency button with a cable. However, if the injured loses his mobility and cannot move, he is unable to inform the related persons; rescue is thus postponed, which may bring about some sequelae or even an irrecoverable result. Besides, a residence should have privacy. Therefore, how to take care of the elderly or the nursed without the appearance of strange security personnel is a topic deserving to be studied.
SUMMARY OF THE INVENTION
[0007] One objective of the present invention is to provide an intertalk wristband radio frequency identification (RFID) tag, which can simultaneously transmit and receive radio-frequency signal to perform bidirectional communication, whereby the nursed in an emergency can presses the intertalk button to communicate with the medical personnel or the nursing personnel and ask for medical rescue.
[0008] To achieve the abovementioned objective, the present invention proposes an intertalk wristband radio frequency identification tag, which can apply to any type of wristband radio frequency identification system and comprises the following components: an RFID system; a switch coupled to the RFID system; an audio-receiving system controlled by the switch to receive audio signal and modulate the audio signal into oscillation frequency, which is then transmitted out by the RFID system; and an audio-outputting system controlled by the switch to receive external audio information-bearing signal via the RFID system and demodulate the audio information-bearing signal into audio frequency and display the audio information.
[0009] The RFID system further comprises the following components: a microprocessor used to process signal; a memory storing identification information; and a radio frequency module receiving/modulating the signal output by the microprocessor or the memory, receiving/demodulating external signal and transmitting the demodulated signal to the microprocessor or the memory.
[0010] The audio-receiving system further comprises the following components: a microphone receiving audio signal; a modulator receiving the audio signal from the microphone and modulating the audio signal into oscillation frequency; and a high-frequency transceiver receiving the oscillation frequency from the modulator and transmitting the oscillation frequency via the RFID system.
[0011] The audio-outputting system further comprises the following components: a high-frequency transceiver receiving external audio information-bearing signal via the RFID system; a demodulator plus an audio frequency amplifier demodulating the audio information-bearing signal into audio frequency; and a speaker displaying audio information.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a block diagram showing the architecture of the intertalk wristband RFID tag according to the present invention.
[0013] FIG. 2 is a diagram schematically showing the application of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] The technical contents of the present invention will be described in detail with embodiments. It should be noted that the embodiments are only to exemplify the present invention but not to limit the scope of the present invention.
[0015] The present invention can apply to any type of wristband radio frequency identification system. The wristband may adopt a hook-and loop fastener design, which has the advantages of simplicity, convenience, and comfort.
[0016] Refer to FIG. 1 a block diagram showing the architecture of the intertalk wristband RFID tag according to the present invention. The present invention comprises the following components: an RFID system 100 ; a switch 200 coupled to the RFID system 100 ; an audio-receiving system 300 controlled by the switch 200 to receive audio signal and modulate the audio signal into oscillation frequency, which is then transmitted out by the RFID system 100 ; and an audio-outputting system 400 controlled by the switch 200 to receive external audio information-bearing signal via the RFID system 100 and demodulate the audio information-bearing signal into audio frequency and display the audio information.
[0017] The RFID system 100 further comprises the following components: a microprocessor 110 processing signal, decoding the signal output by an RFID reader, feedbacking data to the reader according to requirements and performing encryption and decryption if the system is an encryption system; a memory 120 storing identification information and implementing the operation of the system ; and a radio frequency module 130 coupled to the microprocessor 110 and the switch 200 , receiving and modulating the signal output by the microprocessor 110 or the memory 120 , receiving and demodulating external signal, and transmitting the demodulated signal to the microprocessor 110 or the memory 120 .
[0018] The audio-receiving system 300 further comprises the following components: a microphone 310 receiving audio signal; a modulator 320 receiving the audio signal from the microphone 310 and modulating the audio signal into oscillation frequency; and a high-frequency transceiver 330 receiving the oscillation frequency from the modulator 320 and transmitting the oscillation frequency via the RFID system 100 .
[0019] The audio-outputting system 400 further comprises the following components: a high-frequency transceiver 330 receiving external audio information-bearing signal via the RFID system 100 ; a demodulator 410 plus an audio frequency amplifier 420 demodulating the audio information-bearing signal into audio frequency; and a speaker 430 displaying audio information.
[0020] Refer to FIG. 2 a diagram schematically showing the application of the present invention. The RFID tag actively transmits signal to an RF reader. According to the locations of the RF readers, the positions of a wristband RFID tag 500 carried by the nursed 600 are detected and recorded. When the nursed 600 is in an emergency, he can press the switch 200 to turn on the microphone 310 to receive audio signal. The modulator 320 modulates the audio signal into oscillation frequency, and the high-frequency transceiver 330 transmits the oscillation frequency to the radio frequency module 130 , and then the radio frequency module 130 sends out the oscillation frequency via its transmitting and receiving antenna. The high-frequency transceiver 330 may also receives external audio information-bearing signal via the transmitting and receiving antenna of the radio frequency module 130 . The demodulator 410 plus the audio frequency amplifier 420 demodulate the audio information-bearing signal into audio frequency, and then the speaker 430 displays audio information. When the nursed 600 presses the switch 200 , the microprocessor 110 is simultaneously triggered to transmit signal to the reader via the radio frequency module 130 to further trigger the linked host computer, and the host computer further links the SMS (Short Message Service) platform of a telecommunication company via the Internet to send out an SMS 800 to the related persons. Alternatively, the nursing center 700 may also sends out an SMS or a phone call to the related persons via a telecommunication company. The RFID system 100 may also have a dual-color LED. When the voltage of the battery is lower than a predetermined value, the dual-color LED will change its color. The low energy storage status can be sent to the reader via the microprocessor 110 and the transmitting/receiving antenna of the RFID system 100 .
[0021] In the present invention, an intertalk system, an SMS platform, a 3G real-time video, a network and RFID are integrated to construct the emergency-informing system for the nursed 600 . Via RFID, the nursed 600 can be free from piles of cables of the traditional medical monitoring system and moves free. Thus, the mobility limitation of the nursed 600 can be reduced to the minimum with the monitoring function still full working. According to statistics, most of the nursed 600 still have consciousness after they have fallen over. If the nursed 600 slips or falls at home, he may inform the server database in the nursing center 700 via the wristband RFID tag 500 of the present invention when he still has consciousness, wherein the RFID system 100 transmits radio-frequency signal to the reader, and the active RFID application program informs the server database of the nursing center 700 via a communication network. Thus, the medical personnel can learn the position and status of the nursed 600 via the alarm interface of the monitoring computer, SMS, and the instant bidirectional intertalk system. Then, the nursing personnel can response and act optimally within the shortest period.
[0022] The present invention utilizes the wristband RFID tag and the intertalk system to check the status of the nursed 600 . When the system detects abnormality, the personnel of the nursing center 700 can utilize the intertalk system to talk with the nursed 600 and learn the status of the nursed 600 . Thereby, the number of using video monitoring devices can be reduced. Furthermore, the nursed 600 can express his feelings, thoughts and opinions to the personnel of the nursing center 700 via the system. Therefore, the loneliness of the nursed 600 can be reduced, and the self-respect of the nursed 600 can be protected.
[0023] Further, the present invention can cooperate with a database to record the name, age, case history, psychology, equilibrium sense, muscle strength, joint mobility, intelligence, daily habits, adopted rehabilitation aid, and time of falls within the last 3-6 months of the nursed 600 and to observe and record the meal, medicine-taking, and toileting of the nursed 600 . According to the record, the nursed 600 can be classified into a high-risk faller, a middle-risk faller or a low-risk faller.
[0024] The present invention can monitor the daily living of the nursed 600 and can instantly provide the information of the abnormal status for the family members and the medical personnel. Thereby, the family members and the medical personnel can instantly make a correct decision and provide appropriate medical care to reduce the harm on the nursed 600 and avoid an irrecoverable result. Therefore, the family members needn't pay too much attention on the nursed 600 and can do their work without worry.
[0025] Those preferred embodiments described above are only to exemplify the present invention but not to limit the scope of the present invention. Any equivalent modification or variation according to the specification or claims of the present invention is to be also included within the scope of the present invention.
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The present invention discloses an intertalk wristband RFID (Radio Frequency Identification) tag, which applies to any type of wireless automatic wristband RFID system and comprises an RFID system, an audio-receiving system, and an audio-outputting system. The present invention utilizes the RFID system to receive and transmits the audio information-bearing signal and the radio frequency signal to implement a bidirectional communication function. Via the bidirectional communication function, the nursed in an emergency can press an intertalk button to talk with the nursing personnel and ask for rescue.
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[0001] This application is the U.S. national phase application of PCT International Application No. PCT/US2011/030325, filed on Mar. 29, 2011, which claims priority to U.S. Provisional Patent Application No. 61/318,519 filed on Mar. 29, 2010, the contents of such applications being incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to the field of Positron Emission Tomography (PET). In particular, it relates to a method of synthesizing radiolabeled molecules, which can be detected with PET. The present invention also provides novel compounds that may be used in the various methods for synthesizing a radiolabeled molecule.
[0004] 2. Background of the Invention & Description of Related Art
[0005] Positron emission tomography (PET) is a diagnostic imaging technique for measuring the metabolic activity of cells in vivo. For example, PET can show images of glucose metabolism in the brain and rapid changes in activity at various time points. It can be used to show changes in physiology before any change in gross anatomy has occurred. PET has been used in detecting diseases such as cancer, heart disease, Alzheimer's disease, Parkinson's disease, and schizophrenia.
[0006] PET uses chemical compounds that are labeled with radioactive atoms that decay by emitting positrons. The most commonly used PET radioisotopes are 11 C, 13 N, 15 O, and 18 F. Typically, the labeled compound is a natural substrate, substrate analog, or drug that is labeled with a radioisotope without altering the compound's chemical or biological properties. After injection into an animal, the radiolabeled compound should follow the normal metabolic pathway of its unlabeled analog. The labeled compound emits positrons as it moves through tissues. Collisions between the positrons and electrons that are present in the tissue emit gamma rays that are detectable by a PET scanner.
[0007] Construction of radiolabeled tracers by direct labeling involves the coupling of both an activated labeling species, such as 18 F-fluoride, and a highly activated precursor molecule. Subsequent steps may be required to further elaborate the initial radiolabeled species into the final imaging agent. For example, preparation of 18 F-FLT is accomplished by reacting 18 F-fluoride with a protected nosylated precursor, which after labeling, is deprotected and purified to generate 18 F-FLT suitable for PET imaging. This example illustrates the many drawbacks associated with this method of tracer labeling. First, the very nature of labeling with 18 F-fluoride severely limits the choice of labeling precursors. Typical precursors suitable for direct labeling include the use of activated alkyl and/or aryl sulfonate esters. Secondly, acidic protons cannot be present in the labeling precursor or the labeling efficiency will suffer. This specific limitation prevents the direct labeling of compounds containing moieties such as free carboxylic acids, ammonium salts, sulfonamides and sometimes even amides. Finally, direct labeling requires high temperatures which can lead to excessive decomposition of both the precursor and product leading to purification difficulties and inefficient labeling. There is a great need for labeling protocols that are synthetically easy to perform under milder conditions and allow for the synthesis of a broader range of tracers.
[0008] A number of milder labeling methods involve the use of click chemistry, oxime condensations, reductive aminations and amide couplings with activated esters (cf. Scheme 1). While these techniques have been successfully employed to label a variety of tracers including peptides and small molecules, each technique introduces additional labeling restrictions.
[0000]
[0009] The use of click chemistry for 18 F-labeling for the introduction of a 1,2,3-triazole into the tracer, requires the simultaneous use of both an azide and alkyne coupling partner. Click chemistry is advantageous for radiolabeling since the coupling occurs quickly, cleanly and tolerates a wide array of solvents, including water.
[0010] The use of oxime condensations typically involves coupling of 18 F-labeled aldehydes with oxy-amino starting materials. Introduction of the oxy-amino group requires several synthetic steps, with the extra issue of the oxy-amino groups themselves degrading over time.
[0011] Reductive aminations using either 18 F-labeled aldehydes or 18 F-labeled amines are sensitive to reaction conditions and extensive optimization is often needed in order to obtain high radiochemical conversions. In addition, copious amounts of reducing agents, such as NaCNBH 3 , may lead to unwanted side reactions thus decreasing the overall labeling yield.
[0012] Finally, amide couplings using 18 F-labeled activated esters have been used extensively for labeling of biomacromolecules. Unfortunately, the preparation of these activated esters requires many steps and leading to a very lengthy labeling protocol. In addition, coupling yields can be severely hampered by the presence of trace amounts of water.
[0013] A milder protocol that is less sensitive to the presence of water, results in labeling with high efficiency and is compatible with wide variety of functional groups would be a vast improvement over traditional labeling methods.
[0014] The Staudinger reaction, first published in 1919, described the preparation of phosphoazo compounds from phosphine and azide coupling partners via loss of N 2 . In the presence of water, the phosphoazo complex generates an amine and a concomitant phosphine oxide. Several variants of the Staudinger reaction are known and often utilized in chemistry including the formation of amines from azides, aziridines from alpha-hydroxy azides and amides from phosphine-containing esters. The latter reaction is commonly referred to as the Staudinger ligation.
[0015] The Staudinger Ligation, an amide bond forming reaction between an azide and a phosphine containing ester, was developed by Saxon et al, “A ‘Traceless’ Staudinger Ligation for Chemoselective Synthesis of Amide Bonds”, Organic Letters, American Chemical Society, vol. 2, no. 14, pp. 2141-2143, (Jun. 20, 2000). In this reaction, the amide linkage was created by a chemoselective ligation between an azide and a triaryl phosphine. The mechanism of the reaction involves nucleophilic attack of a phosphine on an azide to form a phosphazide, which after loss of nitrogen and hydrolysis with water results in the formation of a phosphine oxide and amide. This reaction possesses several advantages over conventional amide coupling reactions that employ amines and activated acid derivatives. In conventional coupling methods, coupling yields are usually low due to competing side reactions such as the hydrolysis of activated esters by adventitious water. Additionally, racemization of the substrates and/or products can be a major problem in conventional amide coupling reactions when chiral centers are present. The Staudinger ligation does not suffer from these limitations. For example, the Staudinger ligation is widely used in carbohydrate chemistry to avoid racemization issues.
[0016] The Staudinger ligation has been used successfully for several applications including cell surface engineering, probing post-translational modifications of proteins and for coating microarrays. This reaction is highly selective and can be carried out on biomolecules in an aqueous medium, even on the surface of living cells.
[0017] Saxon et al. designed a triarylphosphine containing an aryl group which is functionalized by an ester adjacent to the phosphorous (cf. Scheme 2). The proximity of the functional groups helps to facilitate the intramolecular trapping of the aza glide intermediate and followed by an acyl transfer step.
[0000]
[0018] The aza-ylide reacts preferentially to the adjacent carbonyl, via a nucleophilic attack of the nitrogen atom onto the ester, during the hydrolysis step. This transformation was so efficient and mild that it was executed on the surface of living cells. One limitation of this method is the automatic incorporation of the bulky arylphosphine as part of the amide construct. As a consequence, any compound produced by using this method must contain a triarylphosphine oxide moiety in the final product. The presence of this phosphine oxide may not be suitable for preparing glycoconjugate vaccines or even small molecules, as the presence of the phosphine oxide could significantly deter substrate binding.
[0019] In an effort to avoid the problem of having a disruptive triarylphosphine oxide moiety, two groups (i.e., Saxon et al., and Nilsson et al., “High-Yielding Staudinger Ligation of a Phohinothioester and Azide to Form a Peptide”, Organic Letters, American Chemical Society, vol. 3, no. 1, pp. 9-10, (Dec. 19, 2000)) have independently prepared a new generation of phosphines which are released from the conjugated product, thus inventing the traceless Staudinger ligation (Scheme 3). In this method, the final product is an amide without the phosphine oxide present, thus allowing broader use of this reaction. In this new generation, the phosphine is part of the leaving group and not conjugated to the transferred acyl group. In the example given by Saxon et al., the t 1/2 for the ligation reaction was reported to be 18 hours. This long half-life is not compatible for labeling with short-lived isotopes such as 18 F-fluorine. In the example given by Nilson et al., the t 1/2 for the ligation reaction was reported to be several hours for both the oxygen and thio-phosphine derivatives. Again, this prolonged reaction kinetics makes the use of these ligands incompatible for 18 F-labeling.
[0000]
[0000]
[0020] Raines et al, “Reaction Mechanism and Kinetics of the Traceless Staudinger Ligation”, J. Am. Chem. Sc., vol. 128, no. 27, pp. 8820-8828 (Jun. 20, 2006), compared the reactivity of various phosphine ligands for the Staudinger Ligation, shown below. They observed that the phosphines 1 and 5 have similar reactivity and afforded amides as the exclusive product. No amine by-product was observed when using phosphine 5, but some amine by-product was observed when using phosphine 1.
[0000]
[0021] Despite the excellent reactivity of phosphine 1 and 5 for forming amides, these phosphines contain several inherent limitations. First, the preparation of 1 is lengthy and time consuming. Secondly, the shelf-life of 1 is very short owing to rapid air oxidation. Phosphine 5 is a more suitable moiety for Staudinger-based ligations as it appears to have a longer shelf-life. However, both 1 and 5 have long t 1/2 reaction rates that are not compatible with 18 F-labeling. New phosphines are needed which are easy to prepare, stable and can rapidly perform couplings with fast rates to accommodate the short half-lives of positron emitters. In addition, the ligation chemistry must tolerate a wide range of functional groups and reaction conditions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 shows LCMS data of phosphine 8b.
[0023] FIG. 2 shows LCMS Data for Compound 19.
SUMMARY OF THE INVENTION
[0024] A method for generating a radiolabeled tracer, the method comprising: providing a compound of the following Formula I:
[0000]
[0025] In Formula I, X is C, N, or a bond, and Y is C or N. When X is C, ring A is either aromatic or saturated. When X is N, ring A is aromatic. When X is a bond, ring A is saturated.
[0026] R 1 is H, an electron withdrawing group, or an electron donating group.
[0027] Z 1 and Z 2 , together with the phosphorus atom to which they are attached to, may form a substituted or unsubstituted, heterocyclic ring. Alternatively, Z 1 and Z 2 together may be ferrocene, with the P atom being connected to each cyclopentadiene ring. As another alternative, Z 1 and Z 2 may each independently be carbocyclic, heterocyclic, aryl, heteroaryl, or NR 2 R 3 . When either Z 1 or Z 2 is NR 2 R 3 , R 2 and R 3 are each independently H, alkyl, aryl, an electron withdrawing group, or an electron donating group.
[0028] When R 1 is H, at least one of Z 1 and Z 2 is an aryl which includes a substituent which is an electron withdrawing group or an electron donating group.
[0029] In a first step of the method for generating a radiolabeled tracer, the OH of Formula I is condensed with an acid to produce a phosphine ester. Staudinger ligation is then performed to generate the radiolabeled tracer by treating the phosphine ester produced in the first step with a radiolabeled azide having a PET radioisotope moiety Q as the radiolabel.
DETAILED DESCRIPTION OF EMBODIMENTS
[0030] It is to be understood that the figures and descriptions of the present invention have been simplified to illustrate elements that are relevant for a clear understanding of the present invention, while eliminating, for purposes of clarity, many other elements which are conventional in this art. Those of ordinary skill in the art will recognize that other elements are desirable for implementing the present invention. However, because such elements are well known in the art, and because they do not facilitate a better understanding of the present invention, a discussion of such elements is not provided herein.
[0031] The present invention will now be described in detail on the basis of exemplary embodiments.
[0032] The process describes the rapid radiolabeling of the acid via traceless Staudinger ligation to generate amide compounds.
[0033] The process involves the generation of radiolabeled tracers from a phosphine with the general formula:
wherein X is C, N, or a bond;
[0000]
wherein Y is C or N;
wherein:
ring A is either aromatic or saturated when X is C; ring A is aromatic when X is N; and ring A is saturated when X is a bond;
wherein R 1 is H, an electron withdrawing group, or an electron donating group;
wherein:
Z 1 and Z 2 , together with the phosphorus atom to which they are attached to, form a substituted or unsubstituted, heterocyclic ring; Z 1 and Z 2 together are ferrocene with the P atom being connected to each cyclopentadiene ring; or Z 1 and Z 2 are each independently carbocyclic, heterocyclic, aryl, heteroaryl, or NR 2 R 3 ; wherein R 2 and R 3 are each independently H, alkyl, aryl, an electron withdrawing group, or an electron donating group; and
wherein, when R 1 is H, at least one of Z 1 and Z 2 is an aryl which includes an electron withdrawing group substituent, or an electron donating group substituent.
[0047] Electron withdrawing groups include CN, CF 3 , F, Cl, Br, COR 4 , CONH 2 , SONH 2 , SO 3 R 5 , and NO 2 with R 4 and R 5 each being independently selected as H, alkyl, or aryl.
[0048] Electron donating groups include alkyl, aryl, O-alkyl, O-aryl, NH 2 , NHR 6 , NR 7 R 8 , and NHCOMe, with R 6 , R 7 , and R 8 each being independently selected as alkyl or aryl.
[0049] Specific examples of such phosphines include, but are not limited to, the following general formulas:
[0000]
[0000] where R 10 to R 31 are each independently H, alkyl, aryl, an electron withdrawing group, or an electron donating group; where X 1 and X 2 are each independently CH or N; where Y 1 , Y 2 , Y 4 , and Y 5 are each independently S, O, NH, or CH 2 ; and where Y 3 and Y 6 are each N or CH.
[0050] Any of the above compounds may be used in the reactions of the present invention.
[0051] The phenolic OH of the phosphine is condensed with various acids like aliphatic, aromatic, amino heterocycle, heteroaryl of the general formula:
[0000] R′—COOH;
[0000] where R′=alkyl, aryl, aminoalkyl, sugar, heterocycle, heteroaryl.
[0052] The coupling generates the phosphine esters which, in one example, are of the general formula:
[0000]
[0000] where each R is independently H, alkyl, aryl, an electron withdrawing group, or an electron donating group.
[0053] It will be understood that the use of each different compound above will generate different but analogous phosphine esters. For example, using the phosphine with two cyclohexane molecules may generate a slightly different ester from the example above.
[0054] The acylated phosphine precursor is then treated with the radiolabeled azide to generate the labeled compound of formula:
[0000] Q-B—N 3 +R′—CO—OL→Q-B—NH—CO—R′;
[0000] where Q is a PET radioisotope moiety; B is defined as alkyl, aryl, aminoalkyl, sugar, heterocycle, or heteroaryl; and the “OL” is the phosphine moiety, with the O of the “OL” coming from the OH group of the original phosphine.
[0055] Examples of appropriate PET radioisotope moieties Q for the radiolabeled azide include 11 C, 13 N, 15 O, and 18 F, with 18 F being a particularly suitable radioisotope moiety.
Examples
[0056] Synthesis of Phosphine Ligand:
[0057] Diphenylphospine was coupled with iodophenol in the presence of palladium acetate at 100° C. to give the corresponding phosphine phenol. The phenol was benzoylated at room temperature to yield the benzoyl phosphine.
[0000]
[0058] Staudinger Ligation:
[0059] The reaction conditions were optimized by changing the solvent, temperature and substituent on the phosphine.
[0060] Effect of Temperature:
[0000]
[0000]
Amide Formation
(%)
Phosphine
R
80° C.
100° C.
8a
H
13
26
8b
Cl
3
8
8c
CH 3
27
60
[0061] The Staudinger ligation was performed by treating the phosphine ester with 18 F-ethylazide. The reaction time was shortened (10 min) to accommodate the rapid the radioactivity decay of 18 F-fluoride. The phosphine as described by Saxon at al. (R═H), poorly converted the phosphine ester into the resultant amide, even at elevated temperatures. The chloro-analog performed very poorly and afforded very little conversion to the desired product. By adding a modestly electron donating group, the conversion to the desired product increased dramatically.
[0062] The reaction mixture cleanly afforded the desired production without formation of the unwanted 18 F-fluoroethyl amine. Because the conversion to product is relatively clean, the purification process is relatively simple affording a higher probability of isolating a pure product within a timeframe compatible with the half-life of 18 F-fluorine (t 1/2 =110 min).
[0000]
[0063] Effect of Solvent:
[0064] The choice of solvents for the coupling was relevant to the formation of the desired product. Water was relevant for the formation of the amide. Aqueous THF afforded the highest coupling percentage. Addition of DMF, which was reported by Nilson et al. to afford the best coupling yields, hurt the coupling yield. Addition of DMSO also hurt the coupling reaction.
[0000]
Amide
Solvent mixture
Ratio
Formation (%)
THF:H 2 O
3:1
60
DMF:THF:H 2 O
3:1:1
37
DMSO:THF:H 2 O
3:1:1
38
THF
100%
0
[0065] Stability of the Phosphines:
[0000]
[0066] Phosphines 8a and 8c exhibit excellent stability profiles at room temperature, while the chloro compound 8b found to oxidize during the isolation using column chromatography. 35% of oxidized phosphine was formed within an hour at room temperature during the isolation as shown in FIG. 1 . Oxidation was minimized by storing the compound under Ar at −20° C.
[0067] Synthesis of Heterocyclic Phosphine:
[0000]
[0068] Application of Staudinger Ligation:
[0069] 1. Application of Staudinger Ligation in Hypoxia Imaging:
[0000]
[0070] Stability of the Phosphine Esters 14 and 19:
[0000]
[0071] Phosphinemethane thiol ester 19 underwent 10% oxidation during the isolation using column chromatography ( FIG. 2 ) at room temperature within an hour, while the arylphospine ester found to be stable under the same conditions. Also the diphenylphosphino methanethiol used for the synthesis of 19 is highly air sensitive unlike the diphenylphosphinephenol.
[0072] 2. Application of Staudinger Ligation in Caspase 3 Imaging:
[0000]
[0073] 3. Application of Staudinger Ligation in Amino Acid Synthesis:
[0000]
[0074] Experimentals:
[0075] All the substituted aryl phosphines were synthesized according to the general experimental procedure given below.
[0000]
[0076] General Experimental Procedure for Phosphination:
[0077] To a round bottomed flask equipped with a magnetic stir bar, rubber septum, and argon inlet containing ACN (33 vol) was placed phenol (1 equiv). To this solution was added diphenylphosphine (1.2 equiv), Pd(OAc) 2 (0.05 equiv), triethylamine (6 equiv) and the reaction was allowed to stir at 100° C. for 15 h. The solvent was removed in vacuo. The residue was purified over silica gel using Hexanes:EtOAC as an eluent to afford the final product.
[0078] General Experimental Procedure for Benzoylation:
[0079] To a round bottomed flask equipped with a magnetic stir bar, rubber septum, and argon inlet containing DCM (100 vol) was placed diphenylphosphinophenol (1 equiv). To this solution was added benzoyl chloride (1.2 equiv), triethylamine (5 equiv) and the reaction was allowed to stir at room temperature for 15 h. The solvent was removed in vacuo. The residue was purified over silica gel using Hexanes:EtOAC as an eluent to afford the final product.
[0000]
[0080] 2-(diphenylphosphino)phenyl benzoate 8a:
[0081] 1 H NMR (400 MHz, CDCl 3 ): δ 7.82 (d, J=7.2 Hz, 2H), 7.53 (t, J=7.6 Hz, 2H), 7.43-7.30 (m, 13H), 7.17 (dd, J=7.6, 6.8 Hz, 1H), 6.86-6.83 (m, 1H); MS (ESI, Pos.) m/z (M+H) +
[0000]
[0082] 4-chloro-2-(diphenylphosphino)phenyl benzoate 8b:
[0083] 1 H NMR (400 MHz, CDCl 3 ): δ 7.79 (dd, J=8.4, 1.2 Hz, 2H), 7.55-7.49 (m, 2H), 7.40-7.29 (m, 12H), 7.24-7.21 (m, 1H), 6.76 (dd, J=3.2, 2.4 Hz, 1H); MS (ESI, Pos.) m/z 417.0 (M+H) +
[0000]
[0084] 2-(diphenylphosphino)-4-methylphenyl benzoate 8c:
[0085] 1 H NMR (400 MHz, CDCl 3 ): δ 7.81 (dd, J=8.4, 1.2 Hz, 2H). 7.53-7.49 (m, 1H), 7.35-7.29 (m, 12H), 7.22-7.14 (m, 2H), 6.64-6.62 (m, 1H) 2.22 (s, 3H); MS (ESI, Pos.) m/z 397.1 (M+H) +
[0086] General Experimental Procedure for the Synthesis of Heterocyclic Phosphines:
[0000]
[0087] General Experimental Procedure for Phosphination:
[0088] To a round bottomed flask equipped with a magnetic stir bar, rubber septum, and argon inlet containing THF (10 vol) place protected phenol (1 equiv). To this solution add n-BuLi (1.2 equiv) at −78° C. and TMEDA (0.1 Equiv), and stir the reaction for 1 h. Add the chlorophosphine (1 equiv) in THF (5 vol) to the reaction mixture and stir at RT until the reaction is complete by LCMS. Quench the reaction mixture with water, extract with DCM, wash the organic layer with water and dry over Na 2 SO 4 . Remove the solvent in vacuo and purify the residue over silica gel using Hexanes:EtOAC as an eluent affords the final product.
[0089] General Experimental Procedure for Deprotection:
[0090] To a round bottomed flask equipped with a magnetic stir bar add the protected phosphine ester (1 equiv) in MeOH (5 vol). To this solution add 1N HCl in MeOH (1 vol) and stir the reaction at rt for 1 h. After the reaction is complete, evaporate the solvent in vacuo yields the phenol.
[0091] General Experimental Procedure for Benzoylation:
[0092] To a round bottomed flask equipped with a magnetic stir bar, rubber septum, and argon inlet containing DCM (100 vol) place phosphinophenol (1 equiv). To this solution add benzoyl chloride (1.2 equiv), triethylamine (5 equiv) and stir the reaction at room temperature for 15 h. Remove the solvent in vacuo and purify the residue over silica gel using Hexanes:EtOAC as an eluent affords the final product.
[0093] Synthesis of Imidazole Phosphine Ester:
[0000]
[0094] Synthesis of Compound 13:
[0095] To a round bottomed flask equipped with a magnetic stir bar, rubber septum, and argon inlet containing t-BuOH: H 2 0 (1:1, 4 ml) was placed pegylated azide (0.05 g, 0.17 mmol, 1 equiv). To this solution was added acetylene (0.027 g, 0.18 mmol, 1.05 equiv), CuSO 4 .5H 2 O (8.6 mg, 0.034 mmol, 0.2 equiv), sodium L-ascorbate (0.014, 0.069 mmol, 0.4 equiv) and the reaction was allowed to stir at room temperature for 3 h. After the reaction was complete, the reaction mixture was diluted with water and purified HPLC to give 0.06 g (80%) of the triazole 13 as white solid. MS (ESI, Pos.) m/z: 443.1 [M+H] + .
[0096] Synthesis of Compound 14:
[0097] A 5 mL microwave tube was charged with acid (0.02 g, 0.045 mmol, 1 equiv), PS-Carbodiimide (73 mg, 0.090 mmol, 2 equiv), 1-hydroxybenzotriazole (6.0 mg, 0.044 mmol, 0.99 equiv) and phenol (0.012 g, 0.045 mmol, 1 equiv) in dichloromethane (2 mL). The suspension was irradiated in an Emrys Optimizer microwave reactor (250 W) at 100° C. for 15 min. After cooling to room temperature the reaction mixture was diluted with MeOH/H 2 O and purified by HPLC to yield the ester 14 (0.01 g, 33%).
[0098] Synthesis of Compound 15:
[0099] To a round bottomed flask equipped with a magnetic stir bar, rubber septum, and argon inlet containing THF: H 2 0 (1:0.25, 2 ml) was placed phosphine ester (0.01 g, 0.014 mmol, 1 equiv). To this solution was added fluoroethylazide (excess) and the reaction was allowed to stir at 80° C. for 10 min. After the reaction was complete, the reaction mixture was diluted with water and purified HPLC to give 0.002 g (30%) of the amide 15 as white solid. MS (ESI, Pos.) m/z: 488.1 [M+H] + .
[0100] Synthesis of Imidazole Thiol Ester 19:
[0000]
[0101] To a round bottomed flask equipped with a magnetic stir bar, rubber septum containing DMF (5 mL) was placed triazole acid (0.029 g, 0.052 mmol, 1 equiv). To this solution was added EDC (0.037 g, 0.19 mmol, 3 equiv), HOBt (0.026 g, 0.19 mmol, 3 equiv) and the reaction was allowed to stir at room temperature for 15 h. To this mixture thiol (0.15 g, 0.065 mmol, 1.5 equiv) was added and stirred at room temperature for 15 h. The solvent was removed in vacuo. The residue was purified over silica gel using Hexane:EtOAC (10:90) as an eluent to afford thiol ester 19 (0.01 g, 23%) as a white solid. MS: MS (ESI, Pos.) m/z: 657.1 [M+H] + . Oxidation of the phosphine thiol ester was observed during the isolation.
[0102] Synthesis of FETA:
[0000]
[0103] Synthesis of Compound 17:
[0104] A 5 mL microwave tube is charged with acid (0.05 g, 0.292 mmol, 1 equiv), PS-Carbodiimide (47 mg, 0.584 mmol, 2 equiv), 1-hydroxybenzotriazole (0.038 g, 0.29 mmol, 0.99 equiv) and phenol (0.081 g, 0.292 mmol, 1 equiv) in dichloromethane (1 mL) and DMF (1 mL). The suspension is irradiated in an Emrys Optimizer microwave reactor (250 W) at 100° C. for 15 min. After cooling to room temperature the reaction mixture is diluted with MeOH/H 2 O and purification by HPLC affords the phosphine ester 17.
[0105] Synthesis of Compound 18:
[0106] To a round bottomed flask equipped with a magnetic stir bar, rubber septum, and argon inlet containing THF: H 2 0 (1:0.25, 2 ml) add phosphine ester (0.01 g, 0.023 mmol, 1 equiv). To this solution add fluoroethylazide (excess) and stir the reaction at 80° C. for 10 min. After the reaction is complete, the reaction mixture is diluted with water and purified HPLC to give the amide 18.
[0107] Synthesis of Quinazolinone Amide:
[0000]
[0108] Synthesis of Compound 21:
[0109] A 5 mL microwave tube was charged with acid 20 (0.036 g, 0.105 mmol, 1 equiv), PS-Carbodiimide (17 mg, 0.209 mmol, 2 equiv), 1-hydroxybenzotriazole (0.013 g, 0.104 mmol, 0.99 equiv) and phenol (0.029 g, 0.105 mmol, 1 equiv) in dichloromethane (1 mL) and DMF (1 mL). The suspension was irradiated in an Emrys Optimizer microwave reactor (250 W) at 100° C. for 15 min. After cooling to room temperature the reaction mixture was diluted with MeOH/H 2 O and filtered to yield the phosphine ester 21 as a yellow solid (0.05 g, 83%).
[0110] Synthesis of Compound 22:
[0111] To a round bottomed flask equipped with a magnetic stir bar, rubber septum, and argon inlet containing THF: H 2 0 (1:0.25, 2 ml) add phosphine ester (1 equiv). To this solution add fluoroethylazide (excess) and stir the reaction at 80° C. for 10 min. After the reaction is complete, the reaction mixture is diluted with water and purified HPLC to give the amide 22.
[0112] Synthesis of Amino Acid Derivative:
[0000]
[0113] Synthesis of Compound 23:
[0114] A 5 mL microwave tube was charged with acid (0.115 g, 0.300 mmol, 1 equiv), PS-Carbodiimide (0.48 g, 0.593 mmol, 2 equiv), 1-hydroxybenzotriazole (0.039 g, 0.294 mmol, 0.99 equiv) and phenol (0.086 g, 0.311 mmol, 1 equiv) in dichloromethane (2 mL mL). The suspension was irradiated in an Emrys Optimizer microwave reactor (250 W) at 100° C. for 15 min. After cooling to room temperature the reaction mixture was diluted with MeOH/H 2 O and purified by HPLC to yield the phosphine ester as white solid 23 (0.1 g, 53%).
[0115] Synthesis of Compound 24:
[0116] To a round bottomed flask equipped with a magnetic stir bar, rubber septum, and argon inlet containing THF: H 2 0 (1:0.25, 2 ml) add phosphine ester (1 equiv). To this solution add fluoroethylazide (excess) and stir the reaction at 80° C. for 10 min. After the reaction is complete, the reaction mixture is diluted with water and purified HPLC to give the amide 24.
[0117] All the [F18] labeled amides were prepared using the general experimental procedure for Staudinger ligation as given below.
[0118] Synthesis of [F-18] Labeled Amide:
[0119] Aqueous [F-18]fluoride ion produced in the cyclotron target, is passed through an anion exchange resin cartridge. The [O-18]H 2 O readily passes through the anion exchange resin while [F-18]fluoride is retained. The [F-18]fluoride is eluted from the column using either a solution of potassium carbonate (7.5 mg/mL of water)/Kryptofix® 222 (20 mg/mL of anhydrous acetonitrile or tetra butyl ammonium bicarbonate (0.6 mL) or tetra ethyl ammonium bicarbonate (5 mg/mL of water) is collected in a reaction vessel. The mixture is dried by heating between 70-115° C. under reduced pressure (250 mbar) and a stream of argon. This evaporation step removes the water and to produce anhydrous [F-18], which is much more reactive than aqueous [F-18]fluoride. A solution of the precursor, (˜5 mg) dissolved in THF or DMF or ACN or DMSO (0.5 mL) is added to the reaction vessel containing the anhydrous [F-18]Fluoride. The vessel is heated to approximately 80-150° C. for 3-15 min to induce displacement of the leaving group by [F-18]fluoride. After the reaction time, the [F-18]fluoro compound is either distilled or purified by semi-prep or ion-exchange or C-18 column in to a 5 mL vial containing phosphine ester in THF/H 2 O (3:1, 0.5 mL) mixture.
[0120] If the F-18 fluorinated compound is purified by semi-prep or ion-exchange or C-18 column, then, depending on the mobile phase/solvent combination used, it is reformulated either with THF/H2O or ACN/H2O (3:1, 0.5 mL) mixture before adding to the phosphine ester mixture.
[0121] This mixture is heated in an oil bath or 2 nd reaction pot for 5-20 min at 80-100° C. The crude mixture is purified by semi-prep HPLC using appropriate mobile phase. Appropriate mobile phases for semi-preparative reverse phase HPLC include aqueous acetonitrile or methanol with an optional additive such as formic acid. After collection of the purified material, the product can either be used without reformulation or can be reformulated by diluting with water (20-50 mL), passing through C-18 and the mixture is collected onto a C-18 cartridge. The cartridge is rinsed with water (10 mL) and the product is eluted with EtOH (0.5-1.0 mL) into a vial with or without stabilizer and diluted with either 0.9% saline or water (4.5-9.0 mL).
[0122] While this invention has been described in conjunction with the specific embodiments outlined above, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, the preferred embodiments of the invention as set forth above are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the inventions as defined in the following claims.
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A method for generating a radiolabeled tracer. The method includes providing a phosphine molecule having at least one carbocyclic, aromatic, or pyrrolidinyl ring with an OH substitute. The OH of this phosphines molecule is then condensed with an acid to produce a phosphine ester. Staudinger ligation is then performed to generate the radiolabeled tracer by treating the phosphine ester with a radiolabeled azide having a PET radioisotope moiety.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims priority from U.S. Ser. No. 61/662,393 filed Jun. 21, 2012 and U.S. Ser. No. 61/663,513 filed Jun. 22, 2012; and is related to U.S. Ser. No. 13/164,456 filed Jun. 20, 2011; U.S. Ser. No. 12/968,151 filed Dec. 14, 2010; U.S. Ser. No. 13/140,029 filed Dec. 18, 2009; U.S. Ser. No. 61/500,561 filed Jun. 23, 2011; U.S. Ser. No. 61/500,560 filed Jun. 23, 2011; and U.S. Ser. No. 61/638,454 filed Apr. 25, 2012; the disclosures of which are incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] Not applicable
BACKGROUND
[0003] Many energy storage devices like batteries, capacitors and photovoltaics can utilize a binder and/or an electrolyte and separator film to provide enhanced performances in mechanical stabilization, improved electrical conduction of the powder used in cathodes or electrodes and ion transport in the electro-or photoactive material and electrolyte.
[0004] Lithium ion batteries are used extensively for portable electronic equipment and batteries such as lithium ion and lead-acid are increasingly being used to provide electrical back-up for wind and solar energy. The salts for the cathode materials in lithium ion batteries are generally known to have poor electrical conductivity and poor electrochemical stability which results in poor cycling (charge/discharge) ability. Both cathode and anode materials in many battery types such as lithium ion based batteries exhibit swelling and deswelling as the battery is charged and discharged. This spatial movement leads to further separation of some of the particles and increased electrical resistance. The high internal resistance of the batteries, particularly in large arrays of lithium ion batteries such as used in electric vehicles, can result in excessive heat generation leading to runaway chemical reactions and fires due to the organic liquid electrolyte.
[0005] Lithium primary batteries consist, for example, of lithium, poly(carbon monofluoride) and lithium tetrafluoroborate together with a solvent such as gamma-butyrolactone as an electrolyte. These lithium primary batteries have excellent storage lifetimes, but suffer from only being able to provide low current and the capacity is about one tenth of what is theoretically possible. This is ascribed to the poor electrical conductivity of the poly(carbon monofluoride). In some cases a portion manganese dioxide is added to aid in the electrical conductivity and power of the lithium battery.
[0006] Attempts to overcome the deficiencies of poor adhesion to current collectors and to prevent microcracking during expansion and contraction of rechargable batteries have included development of binders. Binders such as polyacrylic acid (PAA), for cathodes, poly(styrene butadiene), carboxymethylcellulose (CMC), styrene-butadiene (SBR), for anodes, and particularly polyvinylidene fluoride (PVDF) for cathodes and anodes, are used in lithium based batteries to hold the active material particles together and to maintain contact with the current collectors i.e., the aluminum (Al) or the copper (Cu) foil. The PAA and SBR are used as aqueous suspensions or solutions and are considered more environmentally benign than organic solvent based systems such as n-methyl 2 pyrrolidone (NMP) with PVDF.
[0007] A cathode electrode of a lithium ion battery is typically made by mixing active material powder, such as lithium iron phosphate, binder powder, i.e., high molecular weight PVDF, solvent such as NMP if using PVDF, and additives such as carbon black, into a slurry (paste) and pumping this slurry to a coating machine. An anode electrode for a lithium ion battery is made similarly by typically mixing graphite, or other materials such as silicon, as the active material, together with the binder, solvent and additives. The coating machines spread the mixed slurry (paste) on both sides of the Al foil for the cathode and Cu foil for the anode. The coated foil is subsequently calendared to make the electrode thickness more uniform, followed by a slitting operation for proper electrode sizing and drying.
[0008] For zinc-carbon batteries, the positive electrode can consist of a wet powder mix of manganese dioxide, a powdered carbon black and electrolyte such as ammonium chloride and water. The carbon black can add electrical conductivity to the manganese dioxide particles, but is needed at high weight percentages in the range about 10 to 50% by weight of manganese dioxide. These high amounts of carbon black needed for improved electrical conductivity, or reduced impedance of the battery, diminish the capacity per unit volume of the battery as less manganese dioxide can be employed per unit volume of the positive paste mix. Thus, in general, there is a need to improve the impedance of a battery while maximizing the amount of active material per unit volume.
[0009] For a lead-acid battery the anode can be made from carbon particles together with a binder to provide higher specific capacity (capacity per unit weight). The anode of a zinc-carbon battery is often a carbon rod typically made of compressed carbon particles, graphite and a binder such as pitch. The carbon particle anodes tend to have poor mechanical strength leading to fracture under conditions of vibration and mechanical shock.
[0010] The characteristics of the binder material are important for both manufacturing and performance of the battery. Some of these characteristics of relevance are electrical and ionic conductivity, tensile strength and extensibility, adhesion to particles as well as the foils, and swelling of electrolyte. Improvement of electrical and ionic conductivity is needed for improved battery capacity and power. Materials such as lithium manganese oxide for cathodes and silicon particles for anodes exhibit much lower practical specific capacity than theoretically available. A higher electrical and ionic conductivity binder material would be most beneficial to achieve specific capacities closer to their theoretical values. It is desirable to improve the tensile and adhesive strength of binders so that less binder material can be employed and also improve the battery cycling lifetime. Addition of conductive particles, such as carbon black decreases the tensile strength and extensibility of binders. Controlled swelling of the binder in electrolyte is also important. If too much swelling occurs, this separates the particles and significantly increases the inter-particle ohmic resistance. Also, since the particles of the anode or cathode are coated with binder, the layer thickness of the binder can be as thin as 50 to 100 nanometers. This layer thickness precludes uniform distributions of particles of sizes larger than the binder layer thickness. For example, multiwall carbon nanotubes as usually made in a gas phase reactor consist of bundles with diameters ranging from about 50 to 500 microns in diameter and would therefor reside only at the interstitial spaces between the particles.
[0011] Impurities, such as non-lithium salts, iron, and manganese to name a few, with the binder can also be highly deleterious to battery performance. Typically, high purity of the binder material, and other additives comprising the binder material such as carbon black to improve electrical conductivity, is an important factor to minimize unwanted side reactions in the electrochemical process. For example in alkaline-manganese dioxide batteries the total iron in the manganese dioxide is less than 100 ppm to prevent hydrogen gassing at the anode. Commercially available carbon nanotubes such as Baytubes® (Bayer AG) or Graphistrength® (Arkema) can contain as much as ten percent or more by weight of residual metal catalysts and are not considered advantageous for batteries at these levels of impurity.
[0012] For photovoltaics, lines of conductive paste ink, made from solvents, binders, metal powder and glass frit, are screen-printed onto solar panel modules. The binders are usually polymer based for improved printability, such as ETHOCEL™ (Dow Chemical Company). During the burning off of the polymer and cooling the lines can crack due to shrinkage forces and so increase impedance. It is highly desirable to have a more robust conductive paste ink to prevent cracking during heating and cooling.
[0013] Efforts to improve the safety of lithium ion batteries have included using non-flammable liquids such as ionic liquids, for example, ethyl-methyl-imidazolium bis-(trifluoromethanesulfonyl)-imide (EMI-TFSI), and solid polymer, sometimes with additional additives, for example, polyethylene oxide with titanium dioxide nanoparticles, or inorganic solid electrolytes such as a ceramic or glass of the type glass ceramics, Li 1 +x+yTi 2 -xAl x Si y P 3 -yO 12 (LTAP). The electrical conductivity values of organic liquid electrolytes are in the general range of 10 −2 to 10 −1 S/cm. Polymer electrolytes have electrical conductivity values in the range of about 10 −7 to 10 −4 S/cm, dependent on temperature, whereas inorganic solid electrolytes generally have values in the range 10 s to 10 −5 S/cm. At room temperature most polymer electrolytes have electrical conductivity values around 10 −5 S/cm. The low ionic conductivities of polymer and inorganic solid electrolytes are presently a limitation to their general use in energy storage and collection devices. It is thus highly desirable to improve the conductivity of electrolytes, and particularly with polymer and inorganic electrolytes because of their improved flammability characteristics relative to organic liquids. Also, it is desirable to improve the mechanical strength of solid electrolytes in battery applications requiring durability in high vibration or mechanical shock environments, as well as in their ease of device fabrication.
[0014] In alkaline batteries the electrolyte is typically potassium hydroxide. Alkaline batteries are known to have significantly poorer capacity on high current discharge than low current discharge. Electrolyte ion transport limitations as well as polarization of the zinc anode are known reasons for this. An increase in the electrolyte ion transport is highly desirable.
[0015] Amongst new generation thin film photovoltaic technologies, dye sensitized solar cells (DSSCs) possess one of the most promising potentials in terms of their cost-performance ratio. One of the most serious drawbacks of the present DSSCs technology is the use of liquid and corrosive electrolytes which strongly limit their commercial development. An example of an electrolyte currently used for DSSCs is potassium iodide/iodine. Replacement of the presently used electrolytes is desirable, but candidate electrolytes have poor ion transport.
[0016] Typical electrolytic capacitors are made of tantalum, aluminum, or ceramic with electrolyte systems such as boric acid, sulfuric acid or solid electrolytes such as polypyrrole. Improvements desired include higher rates of charge and discharge which is limited by ion transport of the electrolyte.
[0017] A separator film is often added in batteries or capacitors with liquid electrolytes to perform the function of electrical insulation between the electrodes yet allowing ion transport. Typically in lithium batteries the separator film is a porous polymer film, the polymer being, for example a polyethylene, polypropylene, or polyvinylidene fluoride. Porosity can be introduced, for example, by using a matt of spun fibers or by solvent and/or film stretching techniques. In lead-acid batteries, where used the separator film is conventionally a glass fiber matt. The polymer separator film comprising discrete carbon nanotubes of this invention can improve ion transport yet still provide the necessary electrical insulation between the electrodes.
[0018] The present invention comprises improved binders, electrolytes and separator films for energy storage and collection devices like batteries, capacitors and photovoltaics comprising discrete carbon nanotubes, methods for their production and products obtained therefrom.
SUMMARY
[0019] In one embodiment, the invention is a composition comprising a plurality of discrete carbon nanotube fibers, said fibers having an aspect ratio of from about 10 to about 500, and wherein at least a portion of the discrete carbon nanotube fibers are open ended, wherein the composition comprises a binder material, an electrolyte material or a separator film of an energy storage or collection device.
[0020] In another embodiment, the composition comprises a plurality of discrete carbon nanotube fibers have a portion of discrete carbon nanotubes that are open ended and ion conducting. The composition can further comprise at least one polymer. The polymer is selected from the group consisting of vinyl polymers, preferably poly(styrene-butadiene), partially or fully hydrogenated poly(styrene butadiene) containing copolymers, functionalized poly(styrene butadiene) copolymers such as carboxylated poly(styrene butadiene) and the like, poly(styrene-isoprene), poly(methacrylic acid), poly(acrylic acid), poly(vinylalcohols), and poly(vinylacetates), fluorinated polymers, preferably poly(vinylidine difluoride) and poly(vinylidene difluoride) copolymers, conductive polymers, preferably poly(acetylene), poly(phenylene), poly(pyrrole), and poly(acrylonitrile), polymers derived from natural sources, preferably alginates, polysaccharides, lignosulfonates, and cellulosic based materials, polyethers, polyolefines, polyesters, polyurethanes, and polyamides; homopolymers, graft, block or random co- or ter-polymers, and mixtures thereof.
[0021] In yet another embodiment of this invention, the plurality of discrete carbon nanotube fibers are further functionalized, preferably the functional group comprises a molecule of mass greater than 50 g/mole, and more preferably the functional group comprises carboxylate, hydroxyl, ester, ether, or amide moieties, or mixtures thereof.
[0022] A further embodiment of this invention comprising a plurality of discrete carbon nanotube fibers further comprising at least one dispersion aid.
[0023] In a yet further embodiment of this invention, the plurality of carbon nanotubes further comprise additional inorganic structures comprising of elements of the groups two through fourteen of the Periodic Table of Elements.
[0024] Another embodiment of this invention comprises a plurality of carbon wherein the composition has a flexural strength of at least about ten percent higher than a comparative composition made without the plurality of discrete carbon nanotubes.
[0025] Yet another embodiment of this invention is a binder, electrolyte or separator film composition comprising a plurality of discrete carbon nanotube fibers having a portion of discrete carbon nanotubes that are open ended and ion conducting further comprising non-fiber carbon structures. The non-fiber carbon structures comprise components selected from the group consisting of carbon black, graphite, graphene, oxidized graphene, fullerenes and mixtures thereof. Preferably the graphene or oxidized graphene have at least a portion of discrete carbon nanotubes interspersed between the graphene or oxidized graphene platelets.
[0026] A yet further embodiment of this invention is a composition comprising a plurality of discrete carbon nanotube fibers where the binder material has an impedance of less than or equal to about one billion (1×10 9 ) ohm-m and the electrolyte material has a charge transfer resistance of less than or equal to about 10 million (1×10 7 ) ohm-m.
[0027] Another embodiment of this invention comprises an electrolyte or separator film composition comprising a plurality of discrete carbon nanotube fibers wherein the carbon nanotubes are oriented. The orientation is accomplished by fabrication techniques such as in a sheet, micro-layer, micro-layer with vertical film orientation, film, molding, extrusion, or fiber spinning fabrication method. The orientation may also be made via post fabrication methods, such as tentering, uniaxial orientation, biaxial orientation and thermoforming.
[0028] A further embodiment of this invention is a composition comprising a plurality of discrete carbon nanotubes wherein the portion of open ended tubes comprise electrolyte. For an electrolyte comprising polymer, the polymer is preferred to comprise a molecular weight of the polymer less than 10,000 daltons, such that the polymer can enter within the tube. The electrolyte may contain liquids.
[0029] An additional embodiment of this invention comprises a composition including a plurality of discrete carbon nanotube fibers, said fibers having an aspect ratio of from about 10 to about 500, and wherein at least a portion of the discrete carbon nanotube fibers are open ended, preferably wherein 40% to 90% by number of the carbon nanotubes have an aspect ratio of 30-70, and more preferably aspect ratio of 40-60, and 1% to 30% by number of aspect ratio 80-140, most preferably an aspect ratio of 90 to 120. In statistics, a bimodal distribution is a continuous probability distribution with two different modes. These appear as distinct peaks (local maxima) in the probability density function. More generally, a multimodal distribution is a continuous probability distribution with two or more modes. The discrete carbon nanotubes can have a unimodal, bimodal or multimodal distribution of diameters and/or lengths. For example, the discrete carbon nanotubes can have a bimodal distribution of diameters wherein one of the peak values of diameter is in the range 2 to 7 nanometers and the other peak value is in the range 10 to 40 nanometers. Likewise, the lengths of the discrete carbon nanotubes can have a bimodal distribution such that one peak has a maximum value in the range of 150 to 800 nanometers and the second peak has a maximum value in the range 1000 to 3000 nanometers. That composition is useful in binders and electrolytes of the invention.
[0030] In yet another embodiment, the invention is an electrode paste, preferably an anode paste, for a lead acid battery, the paste comprising discrete carbon nanotubes having an average length from about 400 to about 1400 nm, polyvinyl alcohol, water, lead oxide and sulfuric acid. Preferably, the carbon nanotubes, polyvinyl alcohol and water form a dispersion, and the dispersion is then contacted with lead oxide followed by sulfuric acid to form the electrode paste.
BRIEF DESCRIPTION OF FIGURES
[0031] The following drawings form part of the present specification and are included to further demonstrate certain aspects of the present invention. The invention may be better understood by reference to one or more of these drawings in combination with the detailed description of specific embodiments presented herein.
[0032] FIG. 1 shows discrete carbon nanotubes of this invention with a bimodal length distribution where the maximum of one peak is about 700 nanometers and the maximum of the second peak is about 1600 nanometers. The lengths were determined by deposition of the discrete carbon nanotubes on a silicon wafer and by using scanning electron microscopy.
DETAILED DESCRIPTION
[0033] In the following description, certain details are set forth such as specific quantities, sizes, etc., so as to provide a thorough understanding of the present embodiments disclosed herein. However, it will be evident to those of ordinary skill in the art that the present disclosure may be practiced without such specific details. In many cases, details concerning such considerations and the like have been omitted inasmuch as such details are not necessary to obtain a complete understanding of the present disclosure and are within the skills of persons of ordinary skill in the relevant art.
[0034] While most of the terms used herein will be recognizable to those of ordinary skill in the art, it should be understood, that when not explicitly defined, terms should be interpreted as adopting a meaning presently accepted by those of ordinary skill in the art. In cases where the construction of a term would render it meaningless or essentially meaningless, the definition should be taken from Webster's Dictionary, 3rd Edition, 2009. Definitions and/or interpretations should not be incorporated from other patent applications, patents, or publications, related or not, unless specifically stated in this specification.
[0035] In the present invention, discrete oxidized carbon nanotubes, alternatively termed exfoliated carbon nanotubes, are obtained from as-made bundled carbon nanotubes by methods such as oxidation using a combination of concentrated sulfuric and nitric acids and sonication. The bundled carbon nanotubes can be made from any known means such as, for example, chemical vapor deposition, laser ablation, and high pressure carbon monoxide synthesis. The bundled carbon nanotubes can be present in a variety of forms including, for example, soot, powder, fibers, and bucky paper. Furthermore, the bundled carbon nanotubes may be of any length, diameter, or chirality. Carbon nanotubes may be metallic, semi-metallic, semi-conducting, or non-metallic based on their chirality and number of walls. They may also include amounts of nitrogen within the carbon wall structure. The discrete oxidized carbon nanotubes may include, for example, single-wall, double-wall carbon nanotubes, or multi-wall carbon nanotubes and combinations thereof. The diameters and lengths of the discrete carbon nanotubes can be determined by deposition of the discrete carbon nanotubes from dilute solution on a silicon wafer and by using scanning electron microscopy.
[0036] One of ordinary skill in the art will recognize that many of the specific aspects of this invention illustrated utilizing a particular type of carbon nanotube may be practiced equivalently within the spirit and scope of the disclosure utilizing other types of carbon nanotubes.
[0037] Functionalized carbon nanotubes of the present disclosure generally refer to the chemical modification of any of the carbon nanotube types described hereinabove. Such modifications can involve the nanotube ends, sidewalls, or both. Chemical modifications may include, but are not limited to covalent bonding, ionic bonding, chemisorption, intercalation, surfactant interactions, polymer wrapping, cutting, solvation, and combinations thereof.
[0038] Any of the aspects disclosed in this invention with discrete carbon nanotubes may also be modified within the spirit and scope of the disclosure to substitute other tubular nanostructures, including, for example, inorganic or mineral nanotubes. Inorganic or mineral nanotubes include, for example, silicon nanotubes, boron nitride nanotubes and carbon nanotubes having heteroatom substitution in the nanotube structure, such as nitrogen. The nanotubes may include or be associated with organic or inorganic elements or compounds from elements such as, for example, carbon, silicon, boron and nitrogen. The inorganic elements can comprise of elements of the groups two through fourteen of the Periodic Table of Elements, singly or in combination. Association may be on the interior or exterior of the inorganic or mineral nanotubes via Van der Waals, ionic or covalent bonding to the nanotube surfaces.
[0039] Dispersing agents to aid in the dispersion of discrete carbon nanotubes or other components of this invention are, for example, anionic, cationic or non-ionic surfactants, such as sodium dodecylsulfonate, cetyltrimethyl bromide or polyethers such as the Pluronic made by BASF. They can be physically or chemically attached to the discrete carbon nanotubes. In some cases the dispersing aid can also act as a binder. For example, with lead-acid batteries polyvinylalcohol can be used to disperse discrete carbon nanotubes of this invention in water among the paste particles then on addition of sulfuric acid the polyvinylalcohol is considered to deposit on the paste particle and act as a binder, The polyvinylalcohol is preferred to have an average molecular weight less than about 100,000 daltons.
[0040] In some embodiments, the present invention comprises a composition for use as a binder material, an electrolyte material or a separator film material of an energy storage or collection device, comprising a plurality of discrete carbon nanotube fibers The nanotube fibers may have an aspect ratio of from about 10 to about 500, and at least a portion of the discrete carbon nanotube fibers may be open ended. The portion of discrete carbon nanotubes that are open ended may be conducting.
[0041] In some embodiments of the present invention, the composition may further comprise at least one polymer. The polymer may be selected from the group consisting of vinyl polymers, such as poly(styrene-butadiene), partially or fully hydrogenated poly(styrene butadiene) containing copolymers, functionalized poly(styrene butadiene) copolymers such as carboxylated poly(styrene butadiene), poly(styrene-isoprene), poly(methacrylic acid), poly(methylmethacrylate), poly(acrylic acid), poly(vinylalcohols), poly(vinylacetates), fluorinated polymers, polyvinylpyrrolidone, conductive polymers, polymers derived from natural sources, polyethers, polyesters, polyurethanes, and polyamides; homopolymers, graft, block or random co- or ter-polymers, and mixtures thereof.
[0042] In further embodiments, the composition of the present invention may comprise carbon nanotubes which are further functionalized. The composition of the present invention may comprise additional inorganic structures comprising elements of the groups two through fourteen of the Periodic Table of Elements. The composition of the present invention may further comprise at least one dispersion aid.
[0043] The composition of the present invention may further comprise an alcohol, such as polyvinyl alcohol.
[0044] In some embodiments, the present invention comprises a binder material further comprise non-fiber carbon structures, for example carbon black, graphite, graphene, oxidized graphene, fullerenes, and mixtures thereof. In some embodiments, at least a portion of discrete carbon nanotubes are interspersed between graphene and/or oxidized graphene plates. In this embodiment, the binder material may have an impedance of less than or equal to about one billion ohm-m.
[0045] In further embodiments, the composition of the present invention comprises an electrolyte material or separator film. The composition may have a charge transfer resistance of less than or equal to about 10 million ohm-m.
[0046] In further embodiments, the carbon nanotubes of the present invention are oriented, for example in a sheet, micro-layer, micro-layer with vertical film orientation, film, molding, extrusion, or fiber spinning fabrication method. Orientation may be accomplished using post fabrication methods, such as tentering, uniaxial orientation, biaxial orientation and thermoforming.
[0047] In some embodiments of the present invention, a portion of open ended tubes comprise electrolyte. The electrolyte may comprise a polymer or a liquid.
[0048] In further embodiments of the invention, 40% to 90% by number of the discrete carbon nanotubes have an aspect ratio of 30-70. In other embodiments, 1% to 30% by number of carbon nanotubes have an average aspect ratio 80-140.
[0049] In some embodiments, the present invention comprises an electrode paste for a lead-acid battery comprising discrete carbon nanotubes having an average length from about 400 to about 1400 nm. The electrode paste may further comprise an alcohol, for example polyvinyl alcohol.
[0050] The present invention also comprises a method for making a composition for use as a binder material, an electrolyte material or a separator film material for an energy storage or collection device. The method comprises the steps of a) adding carbon nanotubes to a liquid, solvent or polymer melt b) vigorous mixing such as with a sonicator or high shear mixer for a period of time; and c) optionally adding further materials, such as PVDF, and inorganic fillers such as carbon black and continued mixing until a homogenous dispersion is obtained. The mixture can then be further fabricated into shapes by such methods as film extrusion, fiber extrusion, solvent casting, and thermoforming. The method may further comprise adding a polymer, a dispersion aid, additional inorganic structures, or an alcohol, such a polyvinyl alcohol.
Electrolytes
[0051] The term electrolyte is defined as a solution able to carry an electric current. An ionic salt is dissolved in a medium which allows ion transport. Ion transport is defined as the movement of ions through the electrolyte. The ions are preferably a single type of ion, but can be a mixture of types of ions. The medium can be solid, liquid or semi-solid, for example gelatinous. For example, in a lead-acid battery the electrolyte medium is preferred to be liquid or gelatinous. For a lithium based battery the electrolyte medium is preferred to be gelatinous and more preferably a solid at use temperature to prevent high concentrations of flammable organic liquids which could escape on battery failure by shorting or penetration. The electrolyte has to be sufficiently non-electrically conductive to prevent poor storage stability or shorting.
[0052] A separator film is often added in batteries with liquid electrolytes to perform the function of electrical insulation between the electrodes yet allowing ion transport. Typically in lithium batteries the separator film is a porous polymer film, the polymer being, for example a polyethylene, polypropylene, or polyvinylidene fluoride. Porosity can be introduced, for example, by using a matt of spun fibers or by solvent and/or film stretching techniques. In lead-acid batteries, where used the separator film is conventionally a glass fiber matt. The separator film comprising discrete carbon nanotubes of this invention can improve ion transport yet still provide the necessary electrical resistivity. The degree of electrical conductivity can be controlled by the amount of discrete carbon nanotubes within the binder or separator film medium. In a binder it may be advantageous to use higher levels of discrete carbon nanotubes, for example in the range 10 to 50% by weight of the binder medium, for the optimum balance of low electrical resistivity, for example, less than 1×10 7 ohm-m, with strength, than for the electrolyte medium or separator film where it may be advantageous to use less than 10% weight of discrete carbon nanotubes to maintain electrical resistivity greater than about 1×10 7 ohm-m. The use of discrete carbon nanotubes to improve the strength and ease of battery assembly of the thin electrolyte or separator films is also considered valuable.
[0053] The flexural strength or resistance to cracking of the solid electrolytes can be determined by flexural bending of a film or sheet of the solid electrolyte on a thin aluminum or copper film in a 3-point bending fixture and an Instron Tensile Testing machine. The test is analogous to standard test procedures given in ASTM D-790. The resistance to deformation and stress to crack the solid electrolyte through the solid electrolyte film thickness is recorded. Units are in MPa.
[0054] Ionic salts can be added to a polymeric medium such as polyethylene oxide to produce electrolytes. For example, for lithium ion batteries ionic salts, such as lithium perchlorate, lithium tetrafluoroborate, lithium trifluoromethanesulfate, lithium bistrifluoromethanesulfonimide, lithium bisoxalatoborate can be added to the polymer, by solvent or to the polymer melt. Solvents can be those that are retained as an electrolyte medium, for example, ethylene carbonate, propylene carbonate, or solvents which are then removed by drying such as acetonitrile.
[0055] The electrolyte or separator film containing polymeric material may have a polymer, or a combination of polymers that are dissimilar by molecular weight and or by type. For example, in an electrolyte containing polyethylene oxide a portion of the polyethylene oxide can be of molecular weight above about 200,000 daltons and a portion less than about 10,000 daltons. As another example, the polyethylene oxide can be partially replaced by another polymer, such as polyvinylidene fluoride, polyvinylpyrrolidone, or polymethylmethacrylate.
Procedure for Impedance and Swelling Evaluation of Binder Materials
[0056] Each dried sample film is obtained using a 22 mm diameter punch. Films are also obtained saturated with neat electrolyte (a 50/50 composition of ethylene carbonate and propylene carbonate) and electrolyte and 50% by weight of lithium perchlorate by immersing the films for 1-20 days at room temperature. The films are evaluated for swelling by weight increase and tested for impedance using an LCR meter, (Agilent 4263B) at 25 degrees centigrade and under about 70 psi, (0.483 MPa) pressure at 1 Khz. The units of impedance are usually given as ohm-meter.
[0057] The flexural strength or resistance to cracking of the pastes can be determined by flexural bending of the paste on a thin aluminum or copper film in a 3-point bending fixture and an Instron Tensile Testing machine. The test is analogous to standard test procedures given in ASTM D-790. The stress to crack the paste through the paste thickness is recorded. Units are in MPa.
[0058] The adhesive strength of the pastes can be determined by using lap shear strength procedures and the Instron Tensile Testing Machine. The test is analogous to EN 1465. The specimen consists of two rigid substrates, for example aluminum sheets or copper sheets, bonded together by the paste in a lapped joint. This causes the two ends of the specimen to be offset from the vertical load line of the test. The paste is placed between two strip of material, The stress to failure on pulling the lapped specimen is recorded. Units are in MPa.
Procedure for Charge Transfer Resistance Evaluation of Electrolyte Materials
[0059] Electrolyte films are placed between two electrodes the resistance and reactance determined at frequencies of 100 Hz, 120 Hz, 1 KHz, 10 KHz and 100 KHz using an LCR meter, (Agilent 4263B) at 25 degrees centigrade and a 2 volt dc bias with a sinusoidal test level of 20 mv. A Nyquist plot is constructed of the real and imaginary components of the impedance from which the charge transfer resistance is obtained.
Examples 1-3
Compositions Consisting of Discrete Carbon Nanotubes in Poly(Vinylidene Fluoride) for Binders and Separator Films.
[0060] General Procedure.
[0061] A dispersion of discrete carbon nanotubes in n-methyl-2-pyrrolidone (NMP) is first made by adding carbon nanotubes of about 2% weight of oxidized moieties and average aspect ratio about 60 to NMP under vigorous stirring. Following addition, sonication is applied for about 15 minutes to exfoliate the carbon nanotubes. An amount of PVDF is slowly added to the system over a period of 30 minutes to obtain the desired weight fraction of carbon nanotube to PVDF. Vigorous stirring and sonication is continued until a homogenous dispersion was obtained. A uniform black colored film of PVDF is obtained by removing the NMP in vacuo to constant weight.
[0062] Examples 1-3 are dried PVDF films containing discrete carbon nanotubes in the weight percentage 2.5, 7.5 and 10%, respectively, and are shown in Table 1.
[0063] Control 1 is made in a similar manner as Example 1 except that no discrete carbon nanotubes are added. The resultant dried film is a pale yellow. The impedance measurements of the dry films and films swollen for 20 days in a mixture of ethylene carbonate and propylene carbonate 50/50 and 50% by weight of lithium perchlorate are provided in Table 1.
[0064] The results shown in Table 1 demonstrate that Examples 1-3 with discrete oxidized carbon nanotubes of this invention in PVDF gave significantly lower values of impedance than the control 1 of PVDF film alone. Furthermore, inclusion of carbon nanotubes of this invention in PVDF demonstrate higher mass uptake of the LiClO 4 solvent mixture which enables improved ion transport. These improved properties on addition of discrete carbon nanotubes of this invention should lead to much enhanced performance as a binder or separator film.
[0000]
TABLE 1
Volume resistivity
% mass
Volume
swollen with
% wt
uptake in
resistivity
ECO/PCO &
Carbon
ECO/PCO
Dry
LiClO 4 ,
PVDF
nanotubes
and LiClO 4
Ohm-m
ohm-m
Control 1
0
6
1.579 × 10 12
3.035 × 10 11
Example 1
2.5
7
1.315 × 10 11
1.403 × 10 10
Example 2
7.5
9
3.326 × 10 7
1.239 × 10 9
Example 3
10
14
1.216 × 10 8
3.694 × 10 8
Examples 4 and 5
[0065] Binder Composition of Discrete Carbon Nanotubes (w/w) in SBR Latex
[0066] A polyether (BASF, Pluronic F-127) as a dispersing aid for the discrete carbon nanotubes is dissolved in water cleaned by reverse osmosis at a weight ratio of 1.5 to 1 of the polyether to dry oxidized carbon nanotubes, then oxidized carbon nanotubes are added at a concentration of 1.5 weight/volume carbon nanotubes to water and sonicated for a period of 30 minutes to disperse the oxidized carbon nanotubes. SBR latex (Dow Chemical Company, grade CP 615 NA, 50% solids content) is added directly to the exfoliated carbon nanotubes at the desired carbon nanotube to SBR weight ratio and stirred vigorously until homogenous. A black film is obtained on drying the mixture in air, followed by drying in vacuo until constant weight of the film is obtained.
[0067] Example 4 is made with five weight percent of discrete carbon nanotubes to dry SBR.
[0068] Example 5 is made with seven point five weight percent of discrete carbon nanotubes to dry SBR.
[0069] Control 2 is made as example 4 and 5 except no discrete carbon nanotubes are added. The film is clear.
[0070] The impedance measurements of the dry films and films swollen for 2 days in a mixture of ethylene carbonate, ECO, and propylene carbonate, PCO, 50/50 and 50% by weight of lithium perchlorate are provided in table 2. The results demonstrate inclusion of discrete carbon nanotubes of this invention with SBR provide a significant reduction in impedance.
[0000]
TABLE 2
% mass
% weight
uptake*
Volume
carbon
ECO/PCO
resistivity
SBR
nanotubes
LiClO 4
Ohm-m
Control 2
0
−3
9.99 × 10 11
Example 4
5
−2
4.241 × 10 11
Example 5
7.5
−2
1.073 × 10 11
*2 day swell
Example 6
[0071] Formation of a Solid Electrolyte Contained Discrete Carbon Nanotubes Wherein the Tubes are Further Functionalized with Polyethylene Oxide.
[0072] Oxidized carbon nanotube fibers are made by first sonicating the carbon nanotube fiber bundles (CNano, grade 9000) at 1% w/v in a mixture of concentrated sulfuric acid/nitric acid for 2 hours or more at about 30° C. After filtering and washing with water the pH of the final washing is about 4. The oxidized carbon nanotube fibers are dried in vacuo for 4 hours at about 80° C. The resultant oxidized tubes generally contain about 1.5-6% by weight of oxygenated species as determined by thermogravimetric analysis in nitrogen between 200 and 600° C. and at least a portion of the tubes are open ended as determined by secondary electron microscopy. The residual ash after burning the oxidized carbon nanotubes in air to 800° C. is about 0.5 to 2% w/w. Monohydroxy poly(ethylene glycol), PEG-MH, of molecular weight about 1900 daltons (Sigma Aldridge) is added in excess to the dried oxidized nanotubes together with a small amount of sulfuric acid as a catalyst and the mixture heated to 100° C. while sonicating for about 1 hour. After cooling and addition of water the functionalized carbon nanotubes are filtered followed by washings to remove excess PEG-MH and sulfuric acid. The functionalized carbon nanotubes are dried in vacuo at 40° C. overnight. 0.5% w/w of the carbon nanotubes reacted with PEG-MH are added to PEG-MH, heated to 60° C. and sonicated for 30 minutes. A uniform black liquid is obtained which on examination while in the liquid state by optical microscopy up to 150× magnification revealed no discernible aggregates of carbon nanotubes, i.e. the tubes are discrete and dispersed On cooling, the PEG-MH with discrete carbon nanotubes the PEG-MH is observed to crystallize and carbon nanotubes are observed to be between crystal lamellae, i.e., in the amorphous regions of the solid polymer. This is considered very advantageous as ions are recognized to travel preferentially in the amorphous regions.
Examples 7-15
[0073] Solid Electrolyte Compositions with Discrete Carbon Nanotubes
[0074] Discrete carbon nanotubes of oxidation about 2% and an average aspect ratio of 60, with a portion of the carbon nanotubes being open-ended are dried in vacuo at 80° C. for four hours. Compositions are made up as detailed in table 3 by first making solutions of the components using acetonitrile (Sigma Aldridge, 99.8% anhydrous) as a solvent; a 1% w/v solution of the discrete carbon nanotubes, a 2.5% w/v of polyethylene oxide, PEOG, (Alfa Aesar) consisting of a ratio of two PEO's, one of molecular weight 300,000 daltons and the other molecular weight 4000 daltons in the weight ratio 1:0.23, respectively, and 5% w/v solution of lithium trifluoromethanesulfate (Aldrich). The dried discrete carbon nanotubes are first sonicated in acetonitrile for 30 minutes using a sonicator bath. The solutions are made to the various compositions (parts per hundred of PEO) given in Table 3, then sonicated for 30 minutes at around 30° C. in a sonicator bath (Ultrasonics). The mixtures are then transferred to a glass dish and the acetonitrile evaporated for 4 hours to give films. The films are dried in vacuo at 50° C. for 2 hours followed by compression molded at 120° C. for 3 minutes and 20 tons platen pressure between polyethylene terephthalate sheets, cooled to room temperature and stored in a dessicator before testing.
[0075] The results in Table 3 show that significant improvements are gained in the conductivity of the solid electrolyte films with addition of discrete carbon nanotubes of this invention compared to the controls. The electrolyte films made with discrete carbon nanotubes are also seen to have higher strength than the controls as judged by their ability to be handled without tearing.
[0000]
TABLE 3
LiCF 3 SO 3
PEO
Discrete Carbon
Conductivity at 10
phr
phr
nanotubes phr
KHz, 25° C., S/cm
Control 3
15
100
0.0
3.89 × 10 −5
Control 4
20
100
0.0
1.49 × 10 −5
Control 5
30
100
0.0
4.90 × 10 −6
Example 7
15
100
1.5
6.21 × 10 −4
Example 8
20
100
1.5
5.74 × 10 −4
Example 9
30
100
1.5
4.32 × 10 −4
Example 10
15
100
2.0
1.27 × 10 −4
Example 11
20
100
2.0
2.27 × 10 −4
Example 12
30
100
2.0
2.67 × 10 −4
Example 13
15
100
3.0
3.62 × 10 −4
Example 14
20
100
3.0
1.11 × 10 −4
Example 15
30
100
3.0
2.89 × 10 −4
Example 16
Paste Composition Containing Discrete Carbon Nanotubes for Lead-Acid Battery
[0076] The compositions for making an anode paste for a lead acid battery for control 6 and example 16 is shown in Table 4. The expander (Hammond) is a composition of lignin sulfonate, barium sulfate and carbon black in the weight ratio 1:1:0.5, respectively. The expander is added to the dry powder of lead oxide, then water is added and mixed, followed by slow addition and mixing of acid (sulfuric acid, 1.4 specific gravity) while maintaining the temperature below 55° C. In example 16, discrete carbon nanotubes of average length 700 nanometers and oxidation level about 2% and polyvinyl alcohol, PVA, (Sigma Aldridge, average molecular weight 30,000 to 70,000 daltons, 87 to 90% hydrolyzed) are admixed with water and sonicated to give a dispersion of discrete carbon nanotubes of 2.25% by weight and PVA of 3.375% by weight. The discrete carbon nanotube solution is added together with the water to the lead oxide followed by slow addition of the sulfuric acid. The anode material is pasted to a lead grid and assembled into a battery with a lead oxide cathode, followed by standard battery formation as recorded elsewhere, i.e., Lead-Acid Batteries: Science and Technology: Science and Technology, Elsevier 2011. Author: D. Pavlov. The weight % of discrete carbon nanotubes to dry lead oxide in the anode paste is 0.16.
[0077] Relative to Control 6, Example 16 showed a higher charge efficiency of at least 30% at 14.2v charging voltage, an increase rate of charge of at least 200% and at least 50% lower polarization between 14 and 15 volts. Polarization is the difference between the voltage of the battery under equilibrium and that with a current flow.
[0000]
TABLE 4
Control 6
Example 16
Kg
Kg
Lead Oxide
230
230
Fiber flock
0.15
0.15
Expander
1.4
1.4
Discrete carbon nanotubes
0
0.368
Polyvinylalcohol
0
0.552
Water
27
27
Sulfuric acid 1.4 sg
23.1
23.1
|
In various embodiments an improved binder composition, electrolyte composition and a separator film composition using discrete carbon nanotubes, their methods of production and utility for energy storage and collection devices, like batteries, capacitors and photovoltaics, is described. The binder, electrolyte, or separator composition can further comprise polymers. The discrete carbon nanotubes further comprise at least a portion of the tubes being open ended and/or functionalized. The utility of the binder, electrolyte or separator film composition includes improved capacity, power or durability in energy storage and collection devices. The utility of the electrolyte and or separator film compositions includes improved ion transport in energy storage and collection devices.
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BACKGROUND
[0001] The invention relates to a machine, particularly a machine tool, having an error recognition and/or information unit and at least one output, wherein the error recognition and/or information unit is set up to output an information code at the output on the occurrence of an error or other information requirement during operation of the machine.
[0002] Machines of this kind are known and are used in production installations in order to allow or facilitate error recognition for machines during operation. In this context, it is known that in the event of an error or other information requirement the machine provides at the output a numerical code that the user needs to translate into an error description and/or action instruction in a handbook. Since the machines are very complex and have a wealth of functions, these error descriptions and action instructions normally fill several volumes of a handbook. It has become customary for machines, for example component fitting machines, joining machines or machine tools such as reshaping machines, lathes, grinding machines, milling machines or other machines for cutting and/or non-cutting machining of workpieces, to be monitored in production installations by operators, with one operator monitoring multiple machines. Frequently, it is desirable to allow monitoring of this kind by semi-skilled personnel too.
[0003] The invention additionally relates to a method for diagnosis, particularly error diagnosis, for a machine, particularly a machine tool, wherein an information code is automatically generated on the occurrence of an error or other information requirement.
SUMMARY
[0004] The invention is based on the object of simplifying the involvement for monitoring the operation of machines and of reducing the demands on required personnel for operating the machines.
[0005] The invention achieves this object by providing the features. In particular, for a machine of the type described at the outset, it is therefore provided that an output unit is produced that is set up to output a prescribed number of pictographic and/or audible information items, that an actuation unit is set up to actuate the output unit to output a desired pictographic and/or audible information item from the prescribed number of pictographic and/or audible information items on the basis of an actuation command, that an association between the information codes and actuation commands is provided in a database that can be read by the actuation unit and that the actuation unit is set up to read an information code from the output and to execute an actuation command associated with a read information code. In this case, it is advantageous that there is the possibility of reducing the wealth of information for error recognition. By stipulating a prescribed number of pictographic information items that are actually possible, it is possible for the error recognition and error handling and/or a reaction to information generated by a machine to be performed on the machine even by personnel who have relatively low qualifications. In many cases, a detailed understanding of the internal functional sequence of the machine is no longer necessary. Instead, it is sufficient, for many cases, to internalize action instructions that pertain to the output pictographic information items. The use of pictographic information items in contrast to written instructions affords the advantage that a user can derive the associated action instruction himself, regardless of language, just from the pictographic symbol. By way of example, the information code may be an error code or another pointer, for example a maintenance pointer. The output may therefore be an error output or may at least be able to be used as such. In this case, the output unit may be in the form of a display unit if pictographic information items are output. The output unit may also be set up to output audible signals, however.
[0006] The pictographic symbols may be formed by a characteristic shaping and/or coloration. By way of example, it is possible to use color areas or shapes that, in a highly simplified form, denote an activity, a tool belonging to or required for an activity and/or a portion of a machine that belongs to an activity, or combinations of these. The pictographic information items may also be represented in a form that is coded by dot and/or bar patterns, for example in the form of a binary coding in the manner of the binary coding for binary clock displays or in the form of a dot pattern for the spots on a dice.
[0007] By way of example, provision may be made for the output unit to have a display. Hence, the output unit can be produced as a display unit. It is advantageous in this case that great flexibility is provided for displaying a wide variety of pictographic information items in the form of pictographic symbols. Hence, a multiplicity of pictographic information items can be displayed in a small space, with the respectively displayed pictographic information items, for example a symbol or a plurality of symbols, being able to be display able, and being able to be displayed, in a manner that fills or takes advantage of the display unit.
[0008] Alternatively or additionally, provision may be made for the output unit to have a number of luminous fields that each reproduce a pictographic information item. Hence, the output unit can be produced as a display unit. It is advantageous in this case that the pictographic information items are each associated with a luminous field that can be activated by switching on. The user can therefore recognize what pictographic information item is involved even remotely at the physical position of the respectively lit luminous field. This allows the user, who is responsible for monitoring a plurality of machines, for example, to make preparations for the necessary action measures even remotely.
[0009] In one embodiment of the invention, provision may be made for the luminous fields of the output unit to be in flat form. It is advantageous in this case that a space-saving output unit is provided that can be fitted to a housing portion of the machine, for example.
[0010] Alternatively or additionally, provision may be made for the luminous fields of the output unit to radiate in a full circle. It is advantageous in this case that recognition of the respectively displayed pictographic information item is possible from different directions. Hence, a user who is responsible for monitoring can read the pictographic information item remotely from his current position.
[0011] By way of example, the aforementioned luminous fields may be embodied such that the pictographic information item to be output is printed or permanently produced in another way in order to allow the pictographic information item to be displayed when the associated luminous field is illuminated. The luminous fields may alternatively or additionally be in the form of color areas in different colors.
[0012] In one embodiment of the invention, provision may be made for the output unit to be in the form of a shadow board having at least one tool or spare part holder and a signaling element associated with the tool or spare part holder. It is advantageous in this case that the pictographic information item, which is displayed in the form of an activated signaling element pertaining to the respective contour of the tool or spare part, additionally provides the associated tool for the action measure or the associated spare part for this action measure in response to the recognized error. In this context, a shadow board is understood to mean an arrangement of holders for tools and/or spare parts in which the respective holders have such contours as denote the respective tool or spare part that is to be held when filled correctly as explicitly as possible for the user. In comparison with other organization principles, a shadow board therefore has the advantage that correct filling of the shadow board can be recognized just from the fact that the respective tools and/or spare parts placed into the holders match the contours linked to the holders. The use of a shadow board supports the user process for the machine, since the user can recognize the correct tool or spare part for correcting the displayed error from the displayed pictographic information item, that is to say the contour of a holder that is displayed by means of the signaling element.
[0013] In one embodiment of the invention, provision may be made for the database to have at least one actuation command that can be used to output at least two separately outputtable, in particular display able, pictographic and/or audible information items on the output unit, particularly the display unit, simultaneously. It is advantageous in this case that this allows the conveyance of a meaning that is simple to grasp, in particular that can be grasped regardless of language. This allows units of meaning to be compiled from elementary commands, the content of which is comprehensible even to users who have only little understanding of the actual technical sequence of a machine. By way of example, this allows the information about an imminent oil change in a particular portion of the machine to be output by virtue of a pictographic information item for “oil change” and a particular pictographic information item for the relevant portion on the machine being displayed. It is also possible for pictographic information items that refer to a particular portion of the machine, for example, to be outputtable in combination with audible information items, for example for an imminent oil and/or tool change.
[0014] In this case or in the case of a further exemplary embodiment, provision may be made for at least one actuation command to be provided in a manner compiled from at least two elementary commands that can each be used to output a pictographic and/or audible information item on the output unit. It is advantageous in this case that the aforementioned composition of a more complex meaning can be stored in the database. By way of example, elementary commands may be the aforementioned oil change or even a tool change or cleaning of a waste chamber or refilling of a chamber with consumables. Other elementary commands can denote machine parts or provide other clarification of what addition is meant to apply for an output elementary command.
[0015] In one embodiment of the invention, provision may be made for a log device to be present that can be used to record the pictographic and/or audible information items that are output in one period. It is advantageous in this case that inspection of the use of the machine is possible. In comparison with the mere recording of information codes that are output at the output, the recording of the output or displayed pictographic and/or acoustic information items affords the advantage that it is possible to check a conversion of the complex information codes into the pictographic and/or audible information items by means of inspection of the recording. This allows erroneous links in the database to be identified and removed, for example.
[0016] In one embodiment of the invention, provision may be made for the output unit, particularly the display unit, to be mounted immovably on the machine or to be set up immovably next to the machine. It is advantageous in this case that it is possible to ensure that the output unit can always be read from a preferred position, for example the regular whereabouts of the user. Hence, in comparison with the swivelable arrangement of control panels and the like that has been customary to date for operation in situ, the fixed, non-swivelable arrangement of the output unit affords the advantage that the output unit is not by chance unreadable in the event of an error due to its having been unintentionally or inadvertently swiveled into an unreadable position. Valuable time up to error recognition and up to the beginning of error correction can therefore be saved.
[0017] To achieve the stated object, the invention provides that a method of the type described at the outset involves the information code being automatically converted into an actuation command for an actuation unit using an association between information codes and actuation commands that is kept in an electronically readable database, and the actuation unit using the actuation command to output, particularly to display, a pictographic information item and/or audible information item from a prescribed number of pictographic and/or audible information items. It is advantageous in this case that the complexity of the possible information codes is reduced to an easily comprehensible, in particular comprehensible regardless of language, number of pictographic and/or audible information items. It is therefore possible to dispense with in-depth technical understanding of the machines for recognition of important actions in response to output errors or other pointers.
[0018] In one embodiment of the invention, provision may be made for the pictographic information item to be output, particularly displayed, by actuating a display. It is advantageous in this case that great design latitude is available for the design of the pictographic information items. Alternatively or additionally, provision may be made for the pictographic information item to be displayed by activating at least one luminous field that represents the pictographic information item. This makes it possible to achieve a high recognition value for the displayed pictographic information item. The combination of the fixed position of a luminous field with the fixed outer design of the luminous field by virtue of the pictographic information item allows a quick reminder of the true semantic content of the displayed pictographic information item and the correct choice of the associated action instructions.
[0019] Alternatively or additionally, the output unit may be set up to output audible information items, particularly sound signals. By way of example, the output unit may have a tone generator, and/or a loudspeaker.
[0020] In one embodiment of the invention, provision may be made for the pictographic information item to be output by activating at least one signaling element of a shadow board. It is advantageous in this case that the pictographic information item can be displayed by the contour of the portion of the shadow board that is denoted by the signaling element. It is also advantageous that the display simultaneously also refers to the correct tool or the correct spare part for executing the associated action instructions. Hence, a user can use the output pictographic and/or audible information item to immediately inspect whether the action instructions may be correct or whether they have been memorized incorrectly. A risk of confusion between the associated action instructions can therefore be decreased.
[0021] In one embodiment of the invention, provision may be made for the actuation command to be compiled from elementary commands that are used to output individual pictographic and/or audible information items. It is advantageous in this case that a rudimentary image and/or sound language can be used in which components of the pictographic and/or audible information items that are each associated with the elementary commands carry a semantic meaning of their own. By way of example, elementary commands of this kind may be an oil change, a tool change, cleaning of a machine part, the provision of new consumables, a disruption in the flow of materials or generally the statement that it is time for a particular action. By way of example, further elementary commands can denote particular machine parts for which the respective other elementary command is meant to apply. It is also possible for pictographic and/or audible information items to be compiled from more than two elementary commands.
[0022] It is particularly beneficial if the actuation commands used are concomitantly logged or electronically recorded. This allows an inspection of whether pictographic and/or audible information items are ambiguous or information codes are incorrectly assigned, for example when an incorrect action instruction is executed for an output information code.
[0023] In the case of the invention, that is to say in the case of the method according to the invention and/or in the case of the machine according to the invention, the machine may be in the form of a machine tool, particularly a lathe, a grinding machine, a milling machine and/or another machine for the cutting and/or non-cutting machining of workpieces, for example.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The invention will now be described in more detail using an exemplary embodiment but is not limited to this exemplary embodiment. Further exemplary embodiments will emerge through a combination of the features of individual or multiple claims with one another or with individual or multiple features of the exemplary embodiment.
[0025] The single
[0026] FIG. 1 shows a schematic illustration of a machine according to the invention to explain the method according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] A machine that is denoted as a whole by 1 has an inherently known error recognition and/or information unit 2 , which is not shown further, that can be used to automatically recognize errors in the sequence of the operation of the machine 1 in a manner that is known per se. The machine 1 is shown as a machine tool for the purposes of explaining the invention. Details of the machine 1 are not shown in more detail in order to simplify the illustration, and are known from commercially available machines. In further exemplary embodiments, the machine is set up for other workpiece machining and/or workpiece processing steps, for example joining, particularly adhesive bonding and/or welding, component fitting, sorting, assembly and/or other handling.
[0028] By way of example, the machine 1 may be a lathe, a grinding machine, a milling machine, or set up in another way for cutting and/or non-cutting machining of a workpiece.
[0029] The error recognition and/or information unit 2 is connected to an output 3 to which an information code, for example an error code, is applied when an error or another pointer, for example a maintenance pointer, is recognized during operation of the machine 1 .
[0030] The machine 1 has an output unit 4 , which is described even more accurately, produced on it that can be used to output a prescribed number of pictographic and/or audible information items.
[0031] An actuation unit 5 generates actuation commands 6 on the basis of information codes 7 that are applied to the output 3 .
[0032] To this end, the actuation unit 5 reads the output 3 at recurrent times or even continuously and accesses a database 8 in order to convert the respectively read information code 7 into an associated actuation command 6 .
[0033] For this purpose, the database 8 stores an association between outputtable information codes 7 and associated actuation commands 6 .
[0034] The sum total of the stored associations provides a prescribed number of pictographic and/or audible information items that can actually be output.
[0035] The output unit 4 may be in the form of a display unit and, by way of example, may have a display 9 on which the pictographic information item, which is not shown further in this case, can be displayed. In this case, the actuation command 6 comprises, in a manner which is known per se, the measures for appropriate actuation of the output of the display 9 . The display 9 may be produced on a smartphone, a tablet PC, a preferably portable PC, a smart watch, smart glasses, a smart reading and/or visual aid and/or another mobile computation unit.
[0036] Alternatively or additionally, the output unit 4 may have luminous fields 10 , each luminous field 10 being associated with a respective outputtable pictographic information item by virtue of the pictographic information item being permanently reproduced on the luminous field 10 . The output is made in the form of display through activation, that is to say switching on, for example, of the luminous fields 10 .
[0037] In this case, the luminous fields 10 may be in the form of flat luminous fields 10 on a panel 11 or may be produced on a luminous column 12 for the purpose of radiation in a full circle. In further exemplary embodiments, other arrangements and embodiments of the luminous fields 10 , including other shapes, are implemented.
[0038] The output unit 4 may also have a shadow board 13 , with the pictographic information items being displayed by contours of the respective associated tools 14 or spare parts. These contours each define a tool or spare part holder 17 for the respective tool 14 or spare part. For the purpose of display, the relevant signaling element 15 , for example an LED or another illuminant or a tone generator, is activated. The tool or spare part holder 17 pertaining to the activated signaling element 15 is the pictographic information item that is displayed by the activation.
[0039] The database 8 stores actuation commands that can be used to output not only a single pictographic and/or audible information item but also a plurality of pictographic information items simultaneously. By way of example, actuation commands 6 may be stored that can be used to activate a plurality of luminous fields 10 simultaneously and/or that can be used to output additional sound signals.
[0040] In this way, the actuation commands 6 can be compiled from elementary commands that each relate to a pictographic and/or audible information item and that, by way of example, lead to the activation of a single luminous field 10 or to the output of a sound sequence or at least a chord.
[0041] The actuation unit 5 contains a log device that is used to record the output pictographic and/or audible information items in the form of the transmitted actuation commands 6 .
[0042] In this way, it is possible to comprehend which information item has been output in each case. Hence, it is possible to perform an inspection of the user instructions for the users in response to the respective pictographic and/or audible information item.
[0043] In further exemplary embodiments, the output unit 4 may alternatively or additionally be set up to output audible information items, for example stipulated sound sequences and/or chords. To this end, the output unit 4 can have a tone generator that is connected to a loudspeaker.
[0044] The aforementioned output units 4 are each immovably, that is to say particularly non-swivelably, mounted on the machine 1 or immovably set up next to the machine 1 . Hence, the output unit 4 cannot be taken out of the field of view of the user by unintentional or inadvertent swiveling.
[0045] During operation, the information code applied to the output 3 is therefore automatically recognized by means of cyclic or even continuous reading and automatically converted into an actuation command 6 by means of the database 8 . This conversion is carried out by the actuation unit 5 , which accesses the database 8 and may have a CPU.
[0046] The actuation command 6 is then output to the respectively present output unit 4 so as there to output the pictographic and/or audible information item that is denoted by the actuation command 6 .
[0047] This can be accomplished by actuating the display 9 or by activating the associated luminous field 10 and/or by activating the associated signaling element 15 .
[0048] The actuation commands 6 can be compiled from elementary commands such that a plurality of pictographic and/or audible information items, which can be output or displayed independently of one another, are output simultaneously. To this end, the actuation command 6 contains commands that lead to the activation of a plurality of luminous fields 10 or a plurality of signaling elements 15 simultaneously.
[0049] The respectively output actuation commands 6 are recorded in the actuation unit 5 in a log device 16 .
[0050] In further exemplary embodiments, the output unit 4 may be in the form of a combination of the examples shown, for example in the form of a combination of a display 9 and/or a luminous column 12 with a shadow board 13 .
[0051] In the case of the machine 1 with an output 3 that is actuated by an error recognition and/or information unit 2 , it is proposed that the output information codes 7 be converted by means of an actuation unit 5 into actuation commands 6 that output a pictographic and/or audible information item associated with the respective information code 7 on an output unit 4 .
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The invention relates to a machine ( 1 ) comprising an output ( 3 ) that is controlled by an error detection and/or information unit ( 2 ). According to the invention, the output information codes ( 7 ) are converted to control commands ( 6 ) with the aid of a control unit ( 5 ), by which commands pictorial information associated with the respective information code ( 7 ) is output by an output unit ( 4 ).
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FIELD OF THE INVENTION
This invention relates broadly to apparatus for making organic fertilizer from organic waste material, sometimes referred to as compost, and more particularly to an improved humidifying and air-supply system for use in connection with such apparatus.
BACKGROUND OF THE INVENTION
Prior art systems for achieving composting of solid waste and sewage sludge typically employ one or more multi-stage digesters in which material being treated undergoes staged microbial decomposition. The conventional digester is divided into two or more compartments or stages and during material processing is rotated while air is circulated through the digester at controlled rates under predetermined conditions in a flow direction counter to the material flow. The climate in each stage is maintained to achieve the optimum development of the type and species of microorganism predominant in that stage. Spent air is vented from the digester to the atmosphere and water vapor added, as needed. To maintain optimum climatic conditions in each of the operating stages temperatures are kept below 150 degrees F. to ensure the maximum rate of composting. Typical of such prior art systems and methodology of operation are those set out and described in U.S. Pat. Nos. 3,245,759 and 3,138,447 assigned to the assignee of the present invention, the teachings of which are hereby incorporated by reference.
The method and apparatus for manufacture of compost described in those patents is designed to produce aerobic decomposition of organic waste materials by maintaining within the apparatus in which the method is carried out, conditions suitable for optimum propagation of the different types of aerobic bacteria on which such decomposition depends. The apparatus comprises a digester in the form of a cylindrical drum mounted for rotation on an axis which is slightly declined towards the discharge end relative to the horizontal. The interior of the digester is divided into a series of compartments or chambers by a plurality of transverse partitions spaced along the axis of rotation. Each partition is provided with transfer buckets which are selectively opened and which when opened, transfer material from compartment to compartment from the higher to the lower end of the drum, the raw waste organic material being fed into the digester at the higher end and partially cured compost being withdrawn at the lower end.
The co-composting technology to which the present invention has particular application embodies a fermentation reactor which is employed to accelerate the microbial conversion of solid waste and sewage sludge into a high quality compost. The process has the ability to compost municipal solid waste and sewage together hence the term co-composting, thereby addressing the two principal waste management problems communities will face in the next few decades.
An important step in the overall composting process is the maintenance in each of the operating stages of the process of proper humidity conditions to insure optimal microbial growth.
Prior art techniques for maintaining proper moisture content of the entrained mass within the various compartments of the rotating digester drum were to stop the rotation of the drum and to spray water on the compost through open manways or sampling ports.
I have discovered that by installing a water manifold system fixedly secured to the drum with multiple spray nozzles communicating with each compartment and by providing the manifold with a rotating connection concentric with the rotational axis of the drum it is possible to provide for water additions to the entrained compost mass without stopping the digester or impairing the ongoing biological process. Furthermore, each spray nozzle that directs water into an associated composting compartment has its own shut-off valve making it possible to selectively direct water only to that section of the system where additional water is needed.
An alternative embodiment of the invention is one in which the dual functions of providing process air and of humidifying the entrained mass undergoing composting are combined into a composite feed system utilizing concentric conduits aligned with the rotational axis of the digester drum. One section of the air conduit feeds directly into and is attached to the discharge end of the digester at its center line. A second section of the air conduit is stationary and interconnects with the first section through an air-tight rotating joint. The section of the water manifold system aligned with the rotational axis of the drum is concentric with and disposed within the air conduit. This construction permits both of these critical functions to be carried out in a confined area with minimal space requirements.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purpose of illustrating the invention, there is shown in the drawings forms which are presently preferred; it being understood, however, that this invention is not limited to the precise arrangements and instrumentalities shown.
FIG. 1 is an isometric overview of a composting facility depicting a rotating multi-compartment digester drum system for the fermentation of natural organic material;
FIG. 2 is an elevational view showing details of the digester drum and water manifold system comprising the present invention;
FIG. 3 is a detailed layout of the composite air and water piping system comprising an alternative embodiment of the subject invention;
FIG. 4 is a partially sectioned isometric view of the water piping and cylinder injection points of the water manifold system.
FIG. 5 illustrates alternative means for effecting valve control of the water injection system.
FIG. 6 is a detail of the water-line construction for bypassing the drum tires and girth gears.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings and more particularly to FIG. 1 thereof, there is shown a composting facility comprised of three major areas, the tipping area 10, a processing area 12, and an aeration or curing area 14. The tipping area floor is where the solid waste is dumped and sorted. Unacceptable waste, for example, white goods, car batteries, tires, large pieces of wood, etc., is rejected and sent to a landfill. The acceptable waste is then moved by means of an end loader 16 from the tipping floor into ram pits 18 positioned at the entry of the digesters 20. Waste is loaded directly into the digester drum by means of an hydraulic loading ram. Sewage sludge delivered to the plant is stored in a liquid sludge tank where it is pumped by liquid sludge pumps directly into the digesters 20 as needed to maintain the proper carbon/nitrogen ratio essential to efficient composting. The material is processed through the digester for a period of three days. The digester is typically divided internally into three fermentation chambers or stages by means of internal partitions. Material is discharged from the digester after approximately three days of residence time.
Essential to this stage of the process is the maintenance of proper humidity conditions for optimal microbial activity. It is to this phase of the process to which the present invention is directed. The various fermentation stages each require different degrees of aeration and have different temperatures and carbon dioxide concentrations. By controlling these parameters of operation the entire process can be conducted and controlled. It is important also that in the parts of the digester where maximum microbic activity is desired that the air supply consists of not fresh air from the atmosphere but of air similar to the kind found in fertile soil, which is saturated with moisture and contains from ten to fifty times as much carbon dioxide as does atmospheric air. Such air becomes available in the process through the microbic activities and can be distributed as required. With moisture the carbon dioxide forms carbonic acid, which aids in rendering the organic wastes assimilable to the microorganisms in the decomposing mass, just as happens in fertile soil.
The microbic developments in the process are caused by aerobic and facultative aerobic fungi, bacteria, and actinomycetes. The exact sequence of these various activities in composting varies considerably depending on slight changes in materials processed, moisture, and pH conditions.
As seen in FIG. 2, the process is carried out in a rotating digester which is supported on two approximately 20" wide ×14' diameter cast steel tires 22 and one 216 tooth, approximately 21" wide, spring mounted girth gear 24. Each tire rolls over two thrust rollers 26 and two forged steel trunnion rollers 28 (only one of which can be seen for each tire in FIG. 2) all mounted on a fabricated steel trunnion base 29. The girth gear, is engaged by a steel pinion gear 30.
The digester is rotated clockwise by means of a 150-200 horsepower, variable speed high efficiency electric motor 32 coupled to a pinion gear reducer 34. The speed is maintained at approximately 20 revolutions per hour during normal operating conditions and increased to approximately 30 to 40 rph during the unloading and transfer period.
FIG. 2 is an elevational view showing details of the digester drum and attached water manifold and air supply system. As seen in that Figure and in
FIG. 3, the water manifold system, which resides internally of the air conduit 35, comprises a first section 36 disposed concentrically with the rotational axis 38 of the digester drum 20. A second section 40 of the manifold system is secured to the drum for rotation therewith. The first section is connected to a stationary water supply conduit 42 through a swivel or universal joint 44, as best seen in FIG. 3. This arrangement permits relative movement between the stationary and rotating parts of the system.
Water is fed to the water manifold system by means of a hose connection 45 secured to adapter 46. The water is fed through pipes 36, 50, and 52 to spray nozzles 54. As seen in FIG. 4, each spray nozzle has its own shut off valve 56. This valve can be controlled manually by means of lever 58 or, for example, by electronically operated solenoids 59 as seen in FIG. 5. Water is injected into the fermentation chamber as needed through the spray nozzle or capped pipe 54 the internally disposed end of which is provided with 3/8" holes 60 spaced 120 degrees apart.
Referring again to FIG. 3, the detailed structure of the manifold system which is aligned concentric with the rotational axis of the drum, as viewed from left to right in that Figure, consists of a series of galvanized pipe sections comprising "L" section 62 and pipe 36, 24" long threaded at both ends. One end of the pipe is secured to the "L" section 62 and the other end to a low pressure swivel joint 44. The swivel joint in turn is connected to threaded pipe 42 to which is secured the hose adapter 46. This part of the manifold system is supported by a ball bearing 64 mounted on a necked-down, machined surface of pipe 36. The ball bearing is secured to "T" element 66 by pipe plug 68, the "T" being threadably connected to the stationary air input pipe section 70.
As previously noted, the first section of the water manifold system for a multistage digester resides within the air conduit system. The air conduit system is comprised of threaded pipe sections 72 connected at their outer ends to T-sections 74 and 66 and interconnected at their inner ends through swivel joint 78. Pipe section 35 is fixedly secured to the discharge end of digester drum 20. The radially extending section 50 of the water conduit system is connected to the air conduit through a water tight connection 84 comprised of "O" ring 86 interposed between collar 88 and pipe plug 89. The pipe plug is secured in position by collar 90.
As seen in FIG. 4, water flows through pipes 50, 52 to the various spray heads or nozzles 54, each of which is controlled by its own shut off valve 56. The valves are operated either manually by levers 58 or electronically through computer programmed solenoids 96 as seen diagrammatically in FIG. 5. For convenience the computer 97 can be located at a remote control station.
FIG. 6 illustrates one constructional technique for shutting the water line around the tires and girth gear. As illustrated in that Figure a triangular shaped plate 98 is secured to the undersurface of drum 20 as by welding, the ends of which are sealed by triangular end plates 100. The cavity defined by this arrangement is interconnected to the externally located water pipe 52 through "L" connectors 102 and 104.
By means of this composite air/water system the moisture and oxygen content of the composting mass is accurately and efficiently controlled resulting in reduced processing time and an improved end product.
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A water manifold and air supply system for use with a multi-compartment rotating drum apparatus for the fermentation of natural organic material which provides for selective injection of air and predetermined amounts of water into compartments of the drum during its rotation which system includes an air supply conduit concentrically aligned with the rotational axis of the drum, a first water-conduit section fixedly secured to the rotating drum, a second water-conduit section concentric with the rotational axis of the drum residing within the air supply conduit and connected to the first section through a water-tight seal, the two water-conduit sections and air supply conduit being respectively connected to stationary water-supply and air-supply means by swivel joints.
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RELATED APPLICATIONS
The present application is a U.S. National application of PCT/IL98/00111, filed on Mar. 8, 1998, which is a continuation-in-part of PCT/IL97/00160 filed on May 15, 1997.
FIELD OF THE INVENTION
The present invention relates to knitting machines and in particular to means and methods for activating latch needles in knitting machines and monitoring latch needle positions.
BACKGROUND OF THE INVENTION
Automatic knitting machines use banks of large numbers of closely spaced latch needles to interlock threads in a series of connected loops to produce a knitted fabric. The latch needle is a long flat needle having, at one end, a small hook and a latch that swivels to open and close the hook. The hook ends of the latch needles are moved forwards and backwards towards and away from the threads being knitted into the fabric. As a latch needle is moved, its latch alternately opens and closes so that the hook catches a thread close to it, pulls it to create a loop of fabric, and then releases the thread to start the cycle over again and produce another loop of fabric.
Latch needles are arranged parallel to each other, in arrays of many hundreds to thousands of latch needles in modern knitting machines. The latch needles are placed into narrow latch needle slots that are machined into a planar surface, hereafter referred to as a “needle bed surface”, of a large rectangular metal plate, hereafter referred to as a “needle bed”. The latch needle slots hold the latch needles in position and confine their motion to linear displacements along the lengths of the latch needle slots. The latch needle slots are parallel to each other and equally spaced one from the other with spacing that varies depending upon the quality and type of fabric being produced. Spacing of two to three millimeters is typical, but spacing significantly less than and greater than two millimeters are also common.
The latch needle slots in a needle bed are sufficiently deep so that all or most of the body of a latch needle lies completely in the latch needle slot in which it is placed and below the needle bed surface into which the latch needle slots are machined. A small square fin that sticks out from one side of the shaft of the latch needle protrudes above the needle bed surface. The fins of all latch needles in a needle bed are accurately aligned in a single straight row perpendicular to the latch needle slots.
The latch needles are moved, hereafter referred to as “activated”, back and forth in their respective latch needle slots in order to form loops in a fabric being knitted, by a shuttle that travels back and forth along the length of the needle bed surface parallel to the row of aligned latch needle fins. The shuttle has a flat planar surface facing and parallel to the needle bed surface that extends the full length of the shuttle along the direction of travel of the shuttle. The surface has a channel extending the full length of the shuttle along the direction of travel of the shuttle. The channel is open at both of its two ends, and both ends are aligned with the row of aligned fins. As the shuttle moves along the row of latch needle fins, the fins of the latch needles sequentially enter the channel at one end of the channel, travel along the channel length and exit the channel at the other end of the channel. For most of its length the channel is parallel to the row of aligned fins, i.e. the direction of travel of the shuttle, however towards its middle it has a bend. A latch needle is activated when its fin encounters the bend and moves along the direction of the bend. In moving along the direction of the bend, the fin and its latch needle are moved back and forth along the direction of the latch needle slot in which the latch needle is placed, i.e. perpendicular to the row of aligned fins.
The conventional method for moving latch needles in a knitting machine as described above has a number of drawbacks.
For one, the sequential activation of latch needles by a shuttle as the shuttle moves along a needle bed limits the production rates of fabrics. Production rates of fabric produced by knitting machines could be increased if latch needles were individually activated and different combinations of latch needles could be moved simultaneously. Some shuttles in fact have more than one channel in order to simultaneously activate more than one latch needle and increase production rate.
In addition, in the process of knitting a fabric, dust and dirt accumulate in the slots in which latch needles of a knitting machine move. As the dust and dirt accumulate, more force is required to move the latch needles. At some point, dust and dirt accumulate to such an extent that a latch needle jams in its slot. The shuttle is too massive and moves too quickly for it to be practical for the shuttle to be sensitive to, or respond to, changes in the force needed to move a particular latch needle. As the shuttle rushes along the needle bed and encounters a jammed latch needle it breaks the fin or some other part of the jammed latch needle. When this happens physical damage to the knitting machine is often considerably more extensive than the damage to the single latch needle that jammed and knitting machine down time as a result of the damage is prolonged.
In order to prevent damage to knitting machines from jammed latch needles it would be advantageous to have a system for moving latch needles in a knitting machine that activates latch needles individually and is responsive to changes in the forces required to move individual latch needles.
Prior art direct needle drive systems exist that provide for individual activation of latch needles in a knitting machine. These systems, hereafter referred to as “DND” systems, generally provide an actuator for each latch needle and a system for monitoring the position of each latch needle. However, the prior art systems have not been completely satisfactory. The dimensions of actuators used in the prior art systems are large compared to the spacing between latch needles. Complicated spatial configurations are therefore required to pack large numbers of the actuators in a convenient volume of space near to the latch needles in order to couple the actuators to the latch needles.
Additionally, the response times of prior art DND systems are slow. This is the result of slow response times of actuators and of latch needle position monitoring systems used in these systems. The advantages in production rate and decreased knitting machine down time that should be provided by prior art DND systems are at least partly neutralized by the slow response times of these systems.
SUMMARY OF THE INVENTION
It is an object of one aspect of the present invention to provide a knitting machine comprising a fast response time DND system for activating latch needles in the knitting machine.
It is an object of another aspect of the present invention to provide a DND system in which each latch needle of a knitting machine is activated exclusively by at least one piezoelectric micromotor which activates only that latch needle.
An object of another aspect of the present invention is to provide a piezoelectric micromotor suitable for use in a fast response time DND system.
An additional aspect of the present invention is to provide a transmission for coupling each latch needle in a DND system, in accordance with a preferred embodiment of the present invention, to an at least one piezoelectric micromotor, which at least one piezoelectric micromotor, hereafter referred to as “at least one exclusive piezoelectric micromotor”, is not coupled to any other latch needle.
Piezoelectric micromotors can be made small and powerful and response times of piezoelectric micromotors can satisfy the fast response time requirements of modern knitting machines. The dynamic range of motion available from piezoelectric micromotors and the energy that can be transmitted in short periods of time from piezoelectric micromotors to moveable elements are also consistent with the requirements of modem knitting machines. A piezoelectric micromotor and transmission, in accordance with preferred embodiments of the present invention, can therefore be used to provide fast response time activation of individual latch needles in a knitting machine.
It is an object of yet another aspect of the present invention to provide a DND system comprising a fast response time system for monitoring the position of latch needles activated by the DND system.
It is a further object of another aspect of the present invention to provide an electro-optical latch needle position monitoring system, hereafter referred to as an “OPM”, that operates with a fast response time.
DND systems by their nature require fast response time position monitoring systems for monitoring the positions of latch needles that they activate. The positions of the latch needles are controlled in knitting machines to accuracy on the order of 25-50 micrometers (μm). A DND system that moves latch needles with a velocity “V” must therefore sample the position of each latch needle it activates with a frequency of between ˜2×(Vm/sec÷25 μm) to 2×(Vm/sec÷50 μm), in order to control the position the latch needle to an accuracy of 25 μm-50 μm. It therefore requires a position monitoring system with a response time on the order of (25 μm-50 μm)/2V. In many conventional knitting machines V is on the order of 1.5 m/sec. A DND system that moves latch needles with this velocity therefore requires a system that samples the position of latch needles with a frequency, or sampling rate, of between 50-100 kHz and a response time between 10 μsec and 20 μsec.
Electro-optical systems inherently operate at frequencies that are much faster than typical mechanical cycle frequencies of motion of knitting machine components. In particular an electro-optical OPM, in accordance with a preferred embodiment of the present invention, can provide the fast response time and accuracy of measurement required for monitoring latch needle positions in DND systems.
A piezoelectric micromotor for operating individual latch needles in a DND, in accordance with a preferred embodiment of the present invention, comprises a ceramic vibrator formed in the shape of a thin flat plate having two large planar surfaces and narrow edge surfaces. Piezoelectric vibrators of this type are described in U.S. Pat. No. 5,453,653, which is incorporated herein by reference. The thickness of the vibrator preferably ranges from one to a few millimeters. The thickness of the vibrator thus has dimensions on the order of the size of the spacing between latch needles in a needle bed. It is therefore possible to pack large numbers of these vibrators close to each other with their large planar surfaces parallel and with a thin edge of each vibrator aligned with a single latch needle in the needle bed. Each latch needle is activated (i.e. moved back and forth in its latch needle slot in order to form a loop in a fabric being knitted) by coupling to the latch needle vibratory motion of at least one exclusive piezoelectric micromotor having a thin edge aligned with the latch needle. Coupling of the latch needle and the vibratory motion of the at least one exclusive piezoelectric motor may be accomplished by means of a transmission, in accordance with a preferred embodiment of the present invention.
In a DND, in accordance with a preferred embodiment of the present invention, latch needles in a knitting machine needle bed and piezoelectric micromotors are coupled by a rotary transmission comprising a bearing shaft on which a plurality of annuli is stacked. The annuli rotate freely on the bearing shaft. Each latch needle in the knitting machine needle bed is coupled to vibratory motion of a different at least one exclusive piezoelectric motor via one of the plurality of annuli.
The bearing shaft is mounted over the needle bed, preferably close to the needle bed and with its axis parallel to the needle bed and perpendicular to the latch needle slots in the needle bed. The spacing between the annuli on the shaft is such that the fin of each latch needle in the needle bed is aligned with a different annulus on the bearing shaft. A preferably rigid connecting arm connects the fin of each latch needle in the needle bed to the annulus with which the latch needle fin is aligned. The connecting arm is attached to the fin, preferably by a slideable or flexible joint, formed using methods known in the art.
Each annulus on the bearing shaft is coupled to its own at least one exclusive piezoelectric micromotor, in accordance with a preferred embodiment of the present invention by resiliently pressing the at least one exclusive piezoelectric micromotor against the annulus. Activation of the piezoelectric micromotors coupled to an annulus causes the annulus to rotate. The rotation of the annulus is transmitted to the fin of the latch needle to which the annulus is connected, by the connecting arm. The joint connecting the fin and the connecting arm translates the rotational motion of the connecting arm to a linear motion of the latch needle forwards and backwards in its latch needle slot parallel to the length of the latch needle slot, thereby activating the needle.
In a DND system, in accordance with an alternative preferred embodiment of the present invention latch needles in a knitting machine needle bed and piezoelectric micromotors are coupled by a linear transmission. With the linear transmission each latch needle in a knitting machine needle bed has at least one exclusive piezoelectric micromotor pressed, preferably by resilient force, directly onto the shaft of the latch needle or onto a suitable extension of the shaft of the latch needle. The latch needle slots in which the latch needles are placed, and/or, the surfaces of the needles in contact with the latch needle slots are preferably provided with bearings or nonstick surfaces. This reduces the possibility of a latch needle jamming or sticking in its latch needle slot under the application of the resilient force pressing the at least one exclusive piezoelectric micromotor to the latch needle shaft or suitable extension thereof. Coupled in this way, vibratory motion of the at least one exclusive micromotor pressed to a latch needle shaft or extension thereof activates the latch needle by causing the latch needle to move back and forth in its latch needle slot.
In another form of linear transmission, in accordance with a preferred embodiment of the present invention, piezoelectric micromotors are coupled directly to a “coupling” fin of a latch needle in order to transmit motion to the latch needle. The coupling fin, except for its dimensions, is preferably similar in shape and construction to conventional latch needle fins. The coupling fin is a planar extension of the body of the latch needle having first and second parallel planar sides and thin edges. Preferably, the coupling fin is formed as an integral part of the latch needle and lies in the plane of the body of the latch needle (the latch needle is flat). A rectangular region of the first side and a rectangular region of the second side, hereafter referred to as first and second “coupling regions” respectively, are preferably clad in wear resistant material suitable for friction coupling with piezoelectric micromotors, such as for example, alumina. Preferably, the first and second coupling regions are congruent and directly opposite each other.
In one configuration for coupling piezoelectric micromotors to the coupling fin, in accordance with a preferred embodiment of the present invention, at least one micromotor is resiliently pressed to each of the first and second coupling regions so that a surface region of the micromotor used for transmitting motion from the micromotor to a moveable element, or a hard wear resistant friction nub on the surface region, contacts the coupling region. Preferably, the same number of piezoelectric micromotors is resiliently pressed to each of the first and second coupling regions. Preferably the at least one micromotor pressed to the first coupling region is identical to the at least one micromotor pressed to the second coupling region. Preferably, points at which the at least one micromotor pressed to the first coupling region contacts the first coupling region and points at which the at least one micromotor pressed to the second coupling region contacts the second coupling region are directly opposite each other. Preferably, the magnitude of the forces exerted on the coupling fin perpendicular to the plane of the coupling fin by the at least one micromotor pressed to the first and second coupling regions are equal. Preferably, the at least one piezoelectric micromotor pressed to each coupling region comprises one micromotor.
The latch needle is driven back and forth in its latch needle slot when the at least one piezoelectric micromotor pressed to the first and second coupling regions are activated so as to transmit linear motion in the same direction to the coupling fin. Preferably, the at least one piezoelectric micromotor pressed to the first and second coupling regions are activated in phase. This substantially prevents a torque that tends to twist the latch needle in its latch needle slot from developing.
In another configuration for coupling piezoelectric micromotors to the coupling fin, accordance with a preferred embodiment of the present invention, a piezoelectric micromotor coupled to a coupling fin is mounted in a transmission bracket. The transmission bracket comprises a bearing or a non-stick surface area against which a surface region of the micromotor used for transmitting motion to a moveable element, or preferably, a wear resistant friction nub on the surface region of the micromotor, is resiliently pressed. In order to couple the piezoelectric micromotor to the coupling fin, the coupling fin is inserted between the friction nub and the bearing or the non-stick surface. With this coupling configuration a single piezoelectric micromotor can be used to activate a latch needle without causing unwanted torque that twists the latch needle in its latch needle slot. Force exerted by the piezoelectric micromotor perpendicular to the plane of the coupling fin is opposed by an equal and opposite force exerted on the coupling fin by the bearing or the non-stick surface.
In order to couple adjacent latch needles in a needle bed to piezoelectric micromotors using coupling fins, in accordance with a preferred embodiment of the present invention, coupling fins of adjacent latch needles are preferably displaced with respect to each other in the direction of motion of the latch needles and/or protrude different distances above the latch needle bed. This provides sufficient space between piezoelectric micromotors coupled to coupling fins of adjacent latch needles so that the piezoelectric micromotors do not interfere with the motion of the latch needles
A DND system controls latch needle actuators responsive to the position of the particular latch needle to which the actuators are coupled. In a DND system, in accordance with a preferred embodiment of the present invention, latch needle positions are monitored by an OPM.
An OPM, in accordance with a preferred embodiment of the present invention, monitors the position of a latch needle by optically tracking the position of a small light reflecting region, or a region comprising areas of substantially different reflectivity, such as a light reflecting region with a black line, hereafter referred to as a “fiducial”, located at a known fixed position on the latch needle. The fiducial is illuminated by light from an appropriately located light source, hereafter referred to as a “fiducial illuminator”. The fiducial reflects a portion of the light from the fiducial illuminator with which it is illuminated into an optical device, hereafter referred to as a “fiducial imager”, comprising a detector having a light sensitive surface. The fiducial imager uses the reflected light to form an image of the fiducial on the light sensitive surface of its detector. A change in the position of the fiducial causes a change in the image of the fiducial on the light sensitive surface, which change is used to determine the change in position of the fiducial.
There are a number of other ways in which the latch needle can be provided with a fiducial, in accordance with preferred embodiments of the present invention. For example, a small retro-reflector can be fixed to a point on the body of the latch needle or an appropriate reflecting discontinuity, such as a scratch or dimple, can be formed on a region of the surface of the latch needle. Preferably, the fiducial reflects incident light diffusely within a cone of half energy angle on the order of 10°-20°. The detector and fiducial illuminator comprised in a fiducial imager, in accordance with a preferred embodiment of the present invention, are located so that at any position occupied by the latch needle in its operating range of motion, substantially all the light reflected by the latch needle fiducial into the half energy cone is incident on the detector.
In order to provide position measurements for a plurality of latch needles in a needle bed of a knitting machine, an OPM, in accordance with a preferred embodiment of the present invention, comprises a plurality of fiducial imagers arranged in an array. Preferably, the fiducial imagers are aligned collinearly in a line array defined by an axis that is a straight line. Preferably, the axis is parallel to the needle bed surface of the needle bed and perpendicular to the directions of the needle bed slots.
The number of the plurality of fiducial imagers in the array in a preferred embodiment of the present invention is preferably equal to the number of the plurality of latch needles. Each fiducial imager is aligned with a different one of the plurality of latch needles and provides position data for the latch needle with which it is aligned. The positions of all latch needles in the plurality of latch needles are thus, preferably, simultaneously measurable by the OPM. Preferably, the number of the plurality of latch needles is equal to the number of latch needles in the knitting machine.
In some preferred embodiments of the present invention, the number of the plurality of fiducial imagers in the array of fiducial imagers of an OPM is less than the number of the plurality of latch needles whose positions are to be determined using the OPM. In order to provide position measurements for all the latch needles of the plurality of latch needles, the array of fiducial imagers in the OPM is moved along the needle bed in which the latch needles are held. Preferably, the array of fiducial imagers is moved over the needle bed in a direction collinear with the axis of the array.
In one preferred embodiment of the present invention the fiducial imager comprises a lens and a detector having a light sensitive surface that is divided into first and second regions. The areas of the two regions are preferably equal and preferably abut each other along a straight line. The straight line is preferably oriented substantially perpendicular to the direction of motion of the latch needle. The detector sends first and second signals that are functions of the amounts of reflected light from the fiducial incident on the first and second regions respectively to a controller. The lens focuses reflected light from the fiducial to form an image of the fiducial on the light sensitive surface of the detector. The portions of the image, and thereby the amounts of reflected light, that fall on the first and second regions are different for different positions of the fiducial. The first and second signals, are therefore functions of the position of the fiducial and thereby of the position of the latch needle on which the fiducial is located. The controller uses the first and second signals to determine the position of the latch needle.
In another preferred embodiment of the present invention the fiducial imager comprises a lens, a detector and a light filter. The detector comprises a light sensitive surface sensitive to light in first and second non-overlapping wavelength bands of light. The light filter has first and second filter regions. Each of the filter regions transmits light in a different one of the wavelength bands and does not transmit light in the other wavelength band. The areas of the two filter regions are preferably equal and preferably abut each other along a straight dividing line.
The lens focuses light from the fiducial illuminator that is reflected from the fiducial to form an image of the fiducial on the light sensitive surface of the detector. The filter is positioned with respect to the detector and lens so that the dividing line of the filter and the optic axis of the lens intersect and so that all light from the fiducial focused on the light sensitive surface of the detector passes through the filter. (The filter can also be comprised in an appropriate coating on the lens.) As a result reflected light from the fiducial incident on a first one half of the lens is filtered by the first filter region and reflected light from the fiducial incident on the other half of the lens, a “second half”, is filtered by the second filter region. Therefore the amounts of light in the image of the fiducial in the first and second wavelength bands are proportional to the amounts of light incident on the first and second halves of the lens respectively.
Preferably, the fiducial illuminator illuminates the fiducial with substantially equal intensities of light in the first and second wavelength bands and the fiducial has substantially the same reflectivity for light in both wavelength bands. Preferably, the transmittance of the first filter region for light in the first wavelength band is substantially equal to the transmittance of the second filter region for light in the second wavelength band. Preferably, intensities registered by the light sensitive surface in the first and second wavelength bands are normalized to the intensities of light radiated by the fiducial illuminator in the first and second wavelength bands. The intensities are preferably corrected for differences in reflectivity of the fiducial in the two wavelength bands. Preferably, the intensities are corrected for differences between the transmittance of the first filter region for light in the first wavelength band and the transmittance of the second filter region for light in the second wavelength band. The intensities are preferably corrected for differences in sensitivity of the light sensitive surface to light in the two wavelength bands.
Hereinafter, when intensities, integrated intensities or amounts of light on light sensitive surfaces are compared, it is understood that they are appropriately normalized to the intensity of light radiated by the fiducial illuminator and corrected for biases introduced by various optical components.
The amounts of light incident on the first and second halves of the lens are functions of the position of the fiducial. When the fiducial is located on the optic axis of the lens the first and second halves of the lens receive the same amounts of reflected light. When the fiducial is displaced from the optic axis in the direction of one or the other halves of the lens, the half towards which the fiducial is displaced gets more light and the other half gets less light. Preferably, the dividing line of the filter is substantially perpendicular to the motion of the latch needle and thereby to the fiducial in order to maximize change in the amounts of light incident on the first and second halves of the lens with change of position of the fiducial. The first and second signals sent by the detector to the controller are therefore functions of the position of the fiducial. These signals are used by the controller to determine the position of the fiducial and the latch needle on which the fiducial is located.
In an alternate preferred embodiment of the present invention, the fiducial imager comprises two preferably identical light detectors, each having its own lens that focuses an image of the fiducial onto the detector's light sensitive surface. The two light detectors are displaced from each other by a short distance. The line between the two detectors is aligned parallel with and in the plane of the latch needle slot of the latch needle whose position the detectors are used to determine. The difference between the amounts of light from the fiducial illuminator that is reflected into each of the two detectors is different for different positions of the latch needle along the latch needles range of motion. For example, assume the fiducial illuminator is equidistant from both detectors. When the fiducial is equidistant from both detectors each detector receives the same amount of reflected light from the fiducial and the difference between the amounts of light received by the detectors is substantially zero. If the fiducial is displaced along the direction of motion of the latch needle towards one of the detectors, the detector towards which it is displaced receives an increased amount of reflected light and the other detector receives a decreased amount of light. The difference between the amounts of reflected light received by the detectors from the fiducial is a function of the displacement of the fiducial from the position of the fiducial at which both detectors receive the same amount of reflected light. This difference, and thereby the location of the fiducial and the latch needle, is determined by a Circuit that receives an input signal from each detector that is a function of the intensity of light incident on the detector.
In another preferred embodiment of the present invention the fiducial imager comprises one light detector and two lenses. The light sensitive surface of the light detector is sensitive to light in two non-overlapping wavelength bands of light. The fiducial illuminator illuminates the fiducial with preferably equal intensities of light from both wavelength bands. Each of the lenses transmits light in only one of the two different wavelength bands. Both lenses focus light reflected from the fiducial onto the light sensitive surface of the detector. The lenses are displaced a short distance from each other and the line connecting the centers of the lenses is aligned parallel with and in the plane of the latch needle slot of the latch needle whose position the fiducial imager is used to determine. As in the previous fiducial imager, when the fiducial is equidistant from both lenses the detector registers equal intensity (appropriately normalized as discussed above) of light in both of the wavelength bands for which it is sensitive. As the fiducial is displaced towards one or the other of the lenses, the difference between the intensities of light registered by the detector in the two wavelength bands changes as a function of the amount of the displacement.
In a yet another preferred embodiment of the present invention, the fiducial imager comprises one light detector and a lens. The light sensitive surface of the light detector is sensitive to light in two non-overlapping wavelength bands of light. The lens transmits light in both of the two wavelength bands. The latch needle whose position is measured using the fiducial imager is provided with two fiducials displaced from each other by a short distance along the length of the latch needle. Each of the fiducials reflects light in a different one of the wavelength bands to which the detector is sensitive and absorbs light in the other wavelength band. The lens focuses both fiducials on the light sensitive surface of the light detector. The difference between the light intensity registered by the detector in the two different wavelength bands is used to determine the position of the two fiducials and thereby of the latch needle.
In still yet another preferred embodiment of the present invention, the fiducial imager comprises a monochromatic light detector having a pixelated light sensitive surface, such as a CCD, and a lens that focuses an image of the fiducial on the pixelated surface. The location of the fiducial image on the pixelated surface is determined to be the center of gravity of the illumination pattern on the surface that is caused by the fiducial image. The location of the center of gravity is determined to sub-pixel resolution from the locations of pixels illuminated by the fiducial image and the intensities with which these pixels are illuminated using techniques known in the art. The position of the fiducial and its latch needle is determined from the location of the fiducial image on the pixelated surface by techniques that are well-known in the art.
It should be realized that an OPM, in accordance with a preferred embodiment of the present invention, is useable for any application requiring position monitoring of latch needles and its use is not restricted for use only in cooperation with a DND system. It should also be realized that an OPM, in accordance with a preferred embodiment of the present invention, is useable for providing latch needle position measurements for a DND system irrespective of the type of actuators used to activate latch needles in the DND system, and is not limited to use with DND systems that use piezoelectric micromotors or actuators.
There is therefore provided in accordance with a preferred embodiment of the present invention an optical position monitor for determining the position of a latch needle in a knitting machine comprising: at least one fiducial at a known fixed location on the body of the latch needle; a fiducial imager that produces at least one optical image of the at least one fiducial on at least one light sensitive surface, wherein the at least one optical image changes with changes in position of the at least one fiducial; and a controller that receives at least one signal responsive to the changes in the at least one image and uses the at least one signal to determine the position of the at least one fiducial and thereby of the latch needle.
Preferably, the optical position monitor comprises at least one fiducial illuminator that illuminates the at least one fiducial. Additionally or alternatively, the changes in the at least one image comprise changes in integrated intensity of the at least one image. Alternatively or additionally, the at least one fiducial comprises a single fiducial.
In some preferred embodiments of the present invention the at least one light sensitive surface comprises first and second light sensitive surfaces and the at least one signal comprises first and second signals responsive to the intensity of light reflected by the at least one fiducial imaged on the first and second light sensitive surfaces respectively.
Preferably, the first and second light sensitive surfaces comprise first and second contiguous light sensitive surfaces. The at least one image preferably comprises a single image having first and second portions on the first and second light sensitive surfaces respectively and the ratio between the first and second portions depends upon the position of the at least one fiducial.
Alternatively, the first and second light sensitive surfaces comprise first and second light sensitive surfaces that are preferably displaced from each other by a distance. Preferably, the optical position monitor comprises first and second lenses and the at least one image comprises first and second images, wherein the first and second light sensitive surfaces are optically aligned with the first and second lenses respectively, and the first lens produces the first image on the first light sensitive surface and the second lens produces the second image on the second light sensitive surface and wherein the ratio between the integrated intensities of the first and second images depends upon the position of the at least one fiducial.
In still other preferred embodiments of the present invention the at least one light sensitive surface comprises a single light sensitive surface sensitive to light in first and second non-overlapping wavelength bands of light and the at least one signal comprises first and second signals responsive to the integrated intensity of light incident on the single light sensitive surface in the first and second wavelength bands respectively.
Preferably, the optical position monitor comprises a light filter having first and second filter regions wherein the first region transmits light only in the first wavelength band and the second filter region transmits light only in the second wavelength band and light reflected from the single fiducial that is imaged on the light sensitive surface, passes through either the first filter region or the second filter region.
Preferably, the at least one image comprises a single image, wherein a first portion of light in the single image reflected from the fiducial passes through the first filter region and a second portion of light in the single image reflected from the fiducial passes through the second filter region, and wherein the ratio between first and second portions depends upon the position of the fiducial.
Alternatively, the optical position monitor comprises a first lens and a second lens displaced from each other by a distance, wherein the first lens transmits light only in the first wavelength band and the second lens transmits light only in the second wavelength band, wherein the first and second lenses produce first and second images of the fiducial on the light sensitive surface respectively, and the relative integrated intensity of light in the first and second images is a function of the position of the fiducial.
In some preferred embodiments of the present invention the at least one fiducial comprises at least a first and a second fiducial. Preferably, the at least one light sensitive surface comprises a single light sensitive surface sensitive to light in first and second non-overlapping wavelength bands of light and wherein the at least one signal comprises first and second signals responsive to the integrated intensity of light incident on the single light sensitive surface in the first and second wavelength bands respectively. Preferably, the first fiducial reflects light only in the first wavelength band and the second fiducial reflects light only in the second wavelength band, and the optical position monitor comprises: a lens that produces a first image of the first fiducial and a second image of the second fiducial on the light sensitive surface using light reflected from the first and second fiducials respectively; wherein the integrated intensity of light in the first and second images depends upon the position of the first and second fiducials.
In an optical position monitor in accordance with some preferred embodiments of the present invention, changes in the at least one image comprise changes in the location of the at least one image on the at least one light sensitive surface. Preferably, the at least one light sensitive surface comprises at least one pixelated surface. Preferably, the at least one signal comprises signals responsive to the intensity of light incident on each pixel of the at least one pixelated surface. The at least one image preferably comprises a single image on each of the at least one pixelated surface. In some preferred embodiments of the present invention the at least one pixelated surface comprises a single pixelated surface.
In some preferred embodiments of the present invention a location for each of the at least one image is defined as the location of an optical center of gravity of the at least one image, which location is determined from the signals responsive to the intensity of light incident on each pixel of the at least one pixelated surface, and wherein the location of the optical center of gravity is responsive to the position of the at least one fiducial.
In some preferred embodiments of the present invention wherein changes in the at least one image comprise changes in the location of the at least one image on the at least one light sensitive surface, the at least one fiducial comprises a single fiducial.
In some preferred embodiments of the present invention the single fiducial of a plurality of latch needles is imaged on different regions of the at least one pixelated surface, and the optical position monitor is used to determine the positions of a plurality of latch needles. Preferably, the number of the plurality of latch needles is greater than 5. Alternatively, the number of the plurality of latch needles is preferably greater than 10. Alternatively, the number of the plurality of latch needles is preferably greater than 20.
In some preferred embodiments of the present invention an optical position monitor comprises a means for selectively aligning the optical position monitor with different latch needles in the needle bed.
There is further provided an optical position monitor for simultaneously monitoring the position of a plurality of latch needles in a knitting machine needle bed, which needle bed has a plane surface having latch needle slots that are parallel to each other, comprising a plurality of optical position monitors in accordance with a preferred embodiment of the present invention.
Preferably, each of the plurality of the optical position monitors is aligned with a different latch needle and is used to determine the position of at least the latch needle with which it is aligned.
The optical position monitors in the plurality of optical position monitors are preferably aligned in a line array along a straight line. Preferably, the line array is parallel to the needle bed surface and perpendicular to the latch needle slots. Alternatively or additionally, the spacing between an optical position monitor in the line array and an adjacent optical position monitor is the same for any optical position monitor in the line array. Preferably, the spacing is equal to the spacing between adjacent latch needles of the plurality of latch needles.
In some preferred embodiments of the present invention, the number of the plurality of needles is equal to the number of needles in the needle bed.
In other preferred embodiments of the present invention the number of the plurality of latch needles is less than the number of needles in the needle bed and the optical position monitor includes a means for selectively aligning the optical position monitor with different groups of latch needles in the needle bed. Preferably the means for aligning the optical position monitor with different groups of latch needles comprises means for translating the optical position monitor in a direction parallel to the needle bed and perpendicular to the latch needle slots.
In some preferred embodiments of the present invention the optically reflective fiducial comprises at least two regions on the surface of the latch needle having different reflectivities. Preferably, at least one of the at least two regions comprises a retroreflector. Alternatively or additionally, at least one of the at least two regions comprises at least one discontinuity in the surface of the latch needle. Preferably, the at least one discontinuity comprises at least one straight line groove on the surface of the latch needle. Alternatively or additionally, the discontinuity preferably comprises at least one dimple depressed into the surface of the latch needle. Alternatively or additionally, at least one of the at least two regions is preferably substantially non-reflecting.
Additionally or alternatively, light reflected from the fiducial is substantially confined within a cone of half energy angle less than 20°. Additionally or alternatively light reflected from the fiducial is substantially confined within a cone of half energy angle less than 15°.
Additionally or alternatively, light reflected from the fiducial is substantially confined within a cone of half energy angle less than 10°.
There is further provided an actuator system for activating a latch needle, which latch needle has a shaft, comprising: a flat planar extension of the shaft having first and second parallel planar surfaces; at least one piezoelectric micromotor having a first surface region for transmitting motion to a moveable element, which first surface region is resiliently pressed to the first surface and at least one additional piezoelectric motor having a second surface region for transmitting motion to a moveable element which second surface region is resiliently pressed to the second surface; and wherein vibratory motions of the first and second surface regions apply forces to the flat extension that cause motion in the latch needle.
There is also provided an actuator system for activating a latch needle, which latch needle has a thin flat shaft comprising: a flat planar extension of the shaft having first and second planar surfaces; a piezoelectric micromotor having a surface region for transmitting motion to a moveable element; a transmission bracket for holding the piezoelectric micromotor, the transmission bracket comprising a bearing surface and a means for resiliently urging the surface region of the piezoelectric micromotor towards the bearing surface; and wherein the flat extension is inserted between the surface region of the piezoelectric micromotor and the bearing or the non-stick surface and wherein vibratory motion of the surface region applies force to the flat extension causing motion in the latch needle.
Preferably, the bearing surface is the surface of a rotatable roller or ball. Alternatively or additionally, the bearing surface is a surface having a low friction coating.
In an actuator system for activating a latch needle according to some preferred embodiments of the present invention, the surface region for transmitting motion to a moveable element comprises a wear resistant nub that makes contact with a surface of the moveable element towards which the surface region for transmitting motion is resiliently pressed in order to transmit motion to the moveable element.
In an actuator system for activating a latch needle according to some preferred embodiments of the present invention, points on surfaces of the flat extension at which said surface regions of the piezoelectric micromotors make contact are clad in wear resistant material.
BRIEF DESCRIPTION OF FIGURES
The invention will be more clearly understood by reference to the following description of preferred embodiments thereof read in conjunction with the attached figures listed below, wherein identical structures, elements or parts that appear in more than one of the figures are labeled with the same numeral in all the figures in which they appear, and in which:
FIG. 1 shows the basic structure of a latch needle;
FIG. 2 is a schematic illustration of a conventional system for activating latch needles in a knitting machine;
FIG. 3 is a schematic illustration of a system for coupling piezoelectric micromotors to latch needles in a needle bed by rotary transmission, in accordance with a preferred embodiment of the present invention;
FIG. 4 shows a schematic of a system for coupling piezoelectric micromotors to latch needles in a needle bed by linear transmission in accordance with an alternative preferred embodiment of the present invention;
FIG. 5 illustrates schematically the coupling of a latch needle with a coupling fin to two piezoelectric micromotors in accordance with a preferred embodiment of the present invention;
FIG. 6 illustrates schematically the coupling of a latch needle with a coupling fin to a single piezoelectric micromotor mounted to a transmission bracket in accordance with yet another preferred embodiment of the present invention;
FIGS. 7A-7C schematically illustrate an OPM comprising a single fiducial imager, imaging a latch needle fiducial, in accordance with a preferred embodiment of the present invention;
FIG. 8 schematically illustrates an OPM comprising a linear array of a plurality of imaging fiducials shown in FIGS. 7A-7C, imaging an equal plurality of latch needle fiducials in accordance with a preferred embodiment of the present invention;
FIGS. 9A-9C schematically illustrate an OPM comprising a single fiducial imager, imaging a latch needle fiducial, in accordance with an alternative preferred embodiment of the -present invention;
FIGS. 10A-10C schematically illustrate an OPM comprising a single fiducial imager, imaging a latch needle fiducial, in accordance with another preferred embodiment of the present invention;
FIGS. 11A-11C schematically illustrate an OPM comprising a single fiducial imager, imaging a latch needle fiducial, in accordance with yet another preferred embodiment of the present invention;
FIGS. 12A-12C schematically illustrate an OPM comprising a single fiducial imager, imaging a latch needle fiducial, in accordance with still another preferred embodiment of the present invention; and
FIGS. 13A-13C schematically illustrate an OPM comprising a single fiducial imager, imaging a latch needle fiducial, in accordance with another alternative preferred embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows a profile of a latch needle 20 . Latch needle 20 is a thin metallic structure with a long shaft 22 having a hook 24 and a tip 30 formed on one of its ends. A latch 26 is rotatable about a pivot 28 and is shown in the figure in the position where it caps tip 30 to close hook 24 and prevents hook 24 from hooking a thread. In an open position latch 26 is rotated clockwise almost to a position where it is parallel to shaft 22 . A fin 32 extends out from shaft 22 , generally on the same side of shaft 22 as hook 24 .
FIG. 2 is a schematic illustration of the arrangement of needle beds in a conventional knitting machine and a shuttle which transmits motion to latch needles in the needle beds.
Two needle beds 36 and 38 are rigidly joined at an angle to each other so that an edge 39 of needle bed 36 is close to and parallel to an edge 40 of needle bed 38 . A long narrow space 44 separates edge 39 and edge 40 . Needle beds 36 and 38 are identical or very similar and detailed discussion will be confined to needle bed 36 with the understanding that details and structures described for needle bed 36 apply equally to needle bed 38 .
Threads to be woven into fabric (not shown) are held under tension close to and parallel to edges 39 and 40 . Fabric (not shown), as it is produced moves downwardly from edges 39 and 40 into space 44 . As the fabric moves down it exits the knitting machine.
Needle bed 36 is provided with an array of equally spaced parallel latch needle slots 42 that are perpendicular to edge 39 . A latch needle 20 is placed in each latch needle slot 42 . The bodies of latch needles 20 are completely inside latch needle slots 42 and are not visible. Only fins 32 of latch needles 20 protrude above the surface of needle bed 36 and are visible. Fins 32 of all latch needles 20 that are at rest in slots 42 are aligned along a straight row which is perpendicular to latch needle slots 42 . Each needle 20 is moveable back and forth in its latch needle slot 42 .
A shuttle 46 , having ends 52 and 54 , moves back and forth parallel to edges 39 and 40 along the length of needle bed 36 . An interior face 48 of shuttle 46 is parallel to needle bed 36 and has a channel 50 formed in the face. Channel 50 is open on both ends 52 and 54 of shuttle 46 . The two open ends of channel 50 are in line with the row of fins 32 . A section 56 of channel 50 is not-collinear with the ends of channel 50 . Channel 50 is just wide enough and deep enough so that fins 32 can pass into and move through it.
As shuttle 46 moves back and forth with interior face 48 parallel to latch needle bed 36 , fins 32 of latch needles 20 enter channel 50 at one end and move along the length of channel 50 . When a fin 32 of a latch needle 20 encounters non-collinear section 56 of channel 50 the fin 32 and the latch needle 20 to which fin 32 is attached are displaced parallel to latch needle slot 42 in which the latch needle 20 is found. In FIG. 2, for clarity of presentation, only a few of latch needles 20 that are moving in channel 50 are shown.
FIG. 3 shows a system for exclusively coupling each of the latch needles in a needle bed to at least one exclusive piezoelectric micromotor using a rotary transmission, according to a preferred embodiment of the present invention. A long bearing shaft 58 is mounted over a needle bed 60 that is provided with slots 62 into which have been placed latch needles 63 . Bearing shaft 58 is mounted with a multiplicity of thin annuli 64 , one annulus for each latch needle (for clarity only three are shown). The annuli rotate freely on bearing shaft 58 . Each annulus is positioned opposite a fin 65 of a particular latch needle 63 . A connecting arm 66 connects each annulus 64 to a point 68 on fin 65 , to which annulus 64 is opposite. The connection at point 68 is a flexible or slideable connection produced by methods known in the art. One or more piezoelectric micromotors 70 , 72 , and 74 , are resiliently pressed against each annulus 64 by methods known in the art. When piezoelectric micromotors 70 , 72 , and 74 , are activated they cause annulus 64 and connecting arm 66 to rotate, which in turn moves latch needle 63 linearly in its slot 62 . The flexible connection at point 68 translates rotational motion of arm 66 to linear motion of latch needle 63 . It should be understood that this arrangement allows for a much higher speed of the latch needle than that available from the motor itself.
While three exclusive piezoelectric micromotors are shown coupled to annulus 64 in FIG. 3, a greater or lesser number of micromotors can be used depending on the speed or torque required for motion of the needle. Also, other types of piezoelectric micromotors constructed differently than the ones shown in FIG. 3 and described above may be used to rotate annulus 64 and are advantageous. U.S. Pat. No. 4,562,374 and the publication by Hiroshi et al., IEEE Transactions on Ultrasonics, Ferroelectrics, and Frequency Control, Vol. 42, No. 2, March 1995, incorporated herein by reference, describe rotary piezoelectric micromotors. These rotary piezoelectric micromotors comprise a cylindrical, annular or disc shaped rotor that is caused to rotate by coupling to a stator that is a cylindrical, annular or disc shaped vibrator. The rotor and stator are concentric. A vibrating surface of the stator is coupled to an inside edge surface or an outside edge surface of the rotor to impart a rotary motion to it Alternatively, a vibrating surface of the stator may be coupled to a face surface of the rotor to impart rotational motion to the rotor. Annulus 64 can be rotated by the use of stators similar to those described in the above references. Annulus 64 is coupled to the stators in similar fashion to the way that the rotors are coupled to the stators in the described rotary piezoelectric micromotors.
FIG. 4 shows another system for coupling each of the latch needles in a needle bed to at least one exclusive piezoelectric micromotor using a linear transmission, according to an alternative preferred embodiment of the present invention.
A latch needle bed 76 is provided with latch needle slots 78 in which are placed latch needles 80 . One or more thin piezoelectric micromotor 82 is resiliently pressed against the shaft 84 of each latch needle 80 (only one is shown for each latch needle for simplicity). Piezoelectric micromotors 82 on adjacent latch needles 80 are in line with each other so that they form a straight row. Alternatively, piezoelectric micromotors 82 may be staggered with respect to each other so that they are arrayed in two or more parallel rows. FIG. 4 shows an embodiment according to the present invention in which piezoelectric micromotors are aligned in two parallel rows. Staggered configurations allow for more space between closely packed vibrators 82 than would be available if vibrators 82 were arrayed in a single row and thus allow for thicker more powerful piezoelectric micromotors to be coupled to latch needles 63 .
Vibrations of piezoelectric micromotors 82 are directly translated into linear motion of latch needles 80 . Slots 78 are fitted with bearings (not shown) or with a non-stick surface so that the resilient force which presses a vibrator 82 to a shaft 84 of a needle 80 does not result in excessive friction between needle 80 and the bottom or sides of latch needle slot 78 in which needle 80 is placed.
Rotary piezoelectric micromotors similar to those described in U.S. Pat. No. 4,562,374 and the publication by Hiroshi et al. cited above may also be used to drive latch needles 80 . The edge surface of a rotor of a rotary piezoelectric micromotor is resiliently pressed against shaft 84 of each latch needle 80 . The axes of the rotors are perpendicular to latch needle slots 78 in which latch needles 80 are placed. Frictional forces at the area of contact between the edge surface of a rotor and the surface of shaft 84 of a needle 80 acts to prevent the edge surface of the rotor from slipping on the surface of shaft 84 when the rotor rotates. As the rotor rotates it therefore causes shaft 84 of latch needle 80 to displace linearly in latch needle slot 78 in which latch needle 80 is placed in the direction of motion of the mass points of the edge surface of the rotor which are in contact with the surface of shaft 84 .
FIG. 5 shows a latch needle 300 coupled to two identical piezoelectric micromotors 302 and 304 , in accordance with yet another preferred embodiment of the present invention. Latch needle 300 comprises a latch needle shaft 301 and a coupling fin 306 . Coupling, fin 306 has two parallel planar surfaces 308 and 310 . A coupling region 312 of each surface 308 and 310 (coupling region 312 of surface 308 is not seen in the perspective of FIG. 5) is preferably clad with a wear resistant material suitable for friction coupling with piezoelectric micromotors.
Piezoelectric micromotors 302 and 304 preferably comprise friction nubs 314 and 316 respectively. Piezoelectric micromotors 302 and 304 are resiliently pressed to coupling fin 306 so that friction nubs 314 and 316 contact coupling regions 312 of surfaces 308 and 310 respectively at points that are directly opposite each other. In order to move latch needle 300 back and forth in its latch needle slot (not shown) piezoelectric micromotors 302 and 304 are preferably simultaneously activated in phase to transmit motion to coupling fin 306 .
FIG. 6 shows latch needle 300 coupled to a single piezoelectric micromotor 320 , in accordance with still another preferred embodiment of the present invention. Piezoelectric micromotor 320 is mounted to a transmission bracket 322 preferably comprising a bearing 324 and a biasing means 326 such as a spring or resilient pad. Dashed lines indicate parts of piezoelectric micromotor 320 hidden by transmission bracket 322 . Piezoelectric micromotor 320 preferably comprises a friction nub 328 (shown in dashed lines). Biasing means 326 resiliently presses piezoelectric micromotor 320 in a direction so that friction nub 328 is urged towards bearing 324 . Transmission bracket 322 is held by an appropriate mechanical structure (not shown) so that coupling fin 306 is located between friction nub 328 and bearing 324 .
As a result of the action of biasing means 326 bearing 324 presses resiliently on coupling region 312 of surface 310 and friction nub 328 presses resiliently on coupling region 312 of surface 308 . Transmission bracket 322 is oriented so that the direction in which friction nub 328 is urged by biasing means 326 is substantially perpendicular to the plane of coupling fin 306 . Bearing 324 and friction nub 328 exert equal and opposite forces on coupling fin 306 perpendicular to the plane of coupling fin 306 . As a result piezoelectric micromotor 320 does not produce a torque on latch needle 300 that tends to rotate latch needle 300 in its latch needle slot (not shown).
Coupling fin 306 can be located at different positions along shaft 301 of different latch needles 300 . In addition coupling fin 306 can be formed so that it extends different distances from shaft 301 of different latch needles 300 . Adjacent latch needles in a needle bed can therefore preferably, have coupling fins that protrude different heights above the needle bed and/or are displaced with respect to each other in a direction parallel to their shafts in order to provide space for piezoelectric micromotors that are coupled to the coupling fins.
It is clear from the above discussion that piezoelectric micromotors in accordance with preferred embodiments of the present invention can be conveniently coupled to latch needles in a latch needle bed of a knitting machine so that each latch needle is exclusively coupled to at least one piezoelectric micromotor.
FIGS. 7A-7C schematically illustrate an OPM 98 comprising a fiducial imager 100 and a fiducial illuminator 101 imaging a latch needle fiducial 102 located on a latch needle 104 , in accordance with a preferred embodiment of the present invention. Fiducial imager 100 comprises a lens 106 and a detector 108 . Detector 108 has a light sensitive surface 10 (shown greatly exaggerated in thickness for convenience and clarity of presentation) that is divided into a first detector region 112 and a second detector region 114 . A region of Light sensitive region 110 is schematically shown from “underneath”, in a ventral view, as seen from fiducial 102 , in views 116 , 118 and 120 to the left of detector 108 in each of FIGS. 7A-7C respectively. The areas of detector regions 112 and 114 preferably have the same shape, are equal and abut each other along a straight dividing line 122 . Detector 108 registers the intensity of light incident on first detector region 112 and second detector region 114 separately. Detector 108 sends a first signal to a controller (not shown) that is a function of the intensity of light registered on first detector region 112 and a second signal to the controller that is a function of the intensity of light registered by second detector region 114 .
Detector 108 is oriented with respect to latch needle 104 so that dividing line 122 is substantially perpendicular to the plane (the same as the plane of FIGS. 7A-7C) of the latch needle slot (not shown,) in which latch needle 104 is held, and perpendicular to the direction of the back and forth motion of latch needle 104 indicated by doubled headed arrow 124 .
Fiducial 102 is illuminated by light from fiducial illuminator 101 and reflects some of the light, indicated by dotted line 128 , onto lens 106 . Fiducial 102 preferably reflects light from fiducial illuminator 101 diffusely in a cone (not shown) of half energy angle on the order of 10°-15°. Fiducial illuminator 101 and fiducial imager 100 are located with respect to each other so that for any position of latch needle 104 in the operating range of motion of latch needle 104 , fiducial 102 reflects light from fiducial illuminator 101 into fiducial imager 100 .
Lens 106 forms an image 130 of fiducial 102 on light sensitive surface 110 from the light reflected by fiducial 102 . A first image portion 132 of image 130 falls on first detector region 112 and a second image portion 134 of image 130 falls on second detector region 114 (views 116 , 118 and 120 ). First detector region 112 registers an intensity of light on its surface that is a function of the size of first image portion 130 and second detector region 114 registers an intensity of light that is a function of the size of second image portion 134 . Detector 108 therefore sends a first signal to the controller that is as function of the size of first image portion 130 and a second signal to the controller that is a function of the size of second image portion 134 . The relative sizes of first image portion 132 and second image portion 134 are a function of the position of fiducial 102 and first and second signals are used by the controller to determine the position of fiducial 102 and thereby of latch needle 104 .
The dependence of the sizes of first image portion 132 and second image portion 134 on the position of fiducial 102 is shown schematically in ventral views (seen from “beneath”, from the perspective of fiducial 102 ) 116 , 118 and 120 in FIGS. 7A-7C respectively. In FIG. 7A fiducial 102 is located along the axis of fiducial imager 100 , which is coincident with the direction of line 128 that indicates the direction of reflected light from fiducial 102 . First image portion 132 and second image portion 134 are equal. In FIG. 7B fiducial 102 is shown displaced far to the right of the axis of fiducial imager 100 and first image portion 132 is much larger than second image portion 134 . In FIG. 7C fiducial 102 is shown displaced far to the left of the axis of fiducial imager 102 and second image portion 134 is much larger than first image portion 132 .
FIG. 8 shows an OPM 138 , in accordance with a preferred embodiment of the present invention, that comprises a plurality of fiducial imagers 100 shown in FIGS. 7A-7C. Fiducial imagers 100 are fixed with respect to each other by an appropriate mechanical structure (not shown) in a collinear line array 140 having an axis 142 . Line array 140 is mounted over a needle bed (not shown) of a knitting machine (not shown) in which a plurality of latch needles 104 are placed. Each latch needle 104 has a fiducial 102 . Axis 142 of line array 140 is preferably parallel to the surface of the needle bed and perpendicular to latch needles 104 (and thereby perpendicular to the directions of motion of latch needles 104 ). Dividing lines 122 (not shown) of light sensitive surfaces 110 of fiducial imagers 100 are preferably parallel to axis 142 . Each of fiducial imagers 100 in line array 140 is aligned over a different one of latch needles 104 and is used to measure the position of latch needle 104 over which it is aligned.
In OPM 138 , each fiducial 102 is illuminated with light from a fiducial illuminator 101 and reflects some of this light into the fiducial imager 100 that is aligned over and images the fiducial 102 . A central ray of light from each fiducial 102 reflected into the fiducial imager 100 that images the fiducial 102 is indicated by a dotted line 128 . Each dotted line 128 starts at a fiducial 102 , and ends on the image 130 of the fiducial 102 in the fiducial imager 100 that is used to measure the position of fiducial 102 . The positions of the first and second leftmost latch needles 104 and their fiducials 102 in FIG. 8 correspond to the positions of latch needles 104 and fiducials 102 shown in FIGS. 7C and 7A respectively. The positions of the rest of latch needles 104 shown in FIG. 8 correspond to the position of latch needle 104 shown in FIG. 7 B.
OPM 138 can be used to determine positions only for those latch needles 104 that are aligned with a fiducial imager 100 of line array 140 . At any one time therefore, the number of latch needles 104 in a knitting machine whose positions can be determined by OPM 138 is equal to the number of fiducial imagers in line array 140 . Preferably, the number of fiducial imagers 100 in line array 140 is equal to the number of latch needles in the knitting machine. If the number of the fiducial imagers in line array 140 is less than the number of latch needles in the knitting machine, OPM 138 must be moved in order to provide position measurements for all latch needles 104 in the knitting machine. Preferably, OPM 138 is moved parallel to axis 142 along the knitting machine needle bed in order to provide position measurements for all the latch needles 104 in the knitting machine.
In FIG. 8 each fiducial 102 is shown illuminated by its own fiducial illuminator 101 . This is not a necessity and some OPMs, in accordance with preferred embodiments of the present invention, comprise fiducial illuminators that illuminate groups of more than one fiducial 102 . Additionally, in some preferred embodiments of the present invention, lenses 106 , each of which is used to image one fiducial 102 , are replaced by lenses, such as extended cylindrical lenses, each of which is used to image more than one fiducial 102 .
FIGS. 9A-9C schematically illustrate an OPM 270 imaging fiducial 102 of latch needle 104 , in accordance with an alternate preferred embodiment of the present invention. OPM 270 comprises a fiducial imager 272 and a fiducial illuminator 274 . Fiducial imager 272 comprises a lens 276 having an optic axis indicated by line 278 , a detector 280 and a light filter 282 . Detector 280 comprises a light sensitive surface 282 , sensitive to light in first and second non-overlapping wavelength bands of light. Detector 280 sends a first signal to a controller (not shown) that is a function of the intensity of light registered on light sensitive surface 280 in the first wavelength band and a second signal to the controller that is a function of the intensity registered by light sensitive surface 282 in the second wavelength band.
Light filter 282 has a first filter region 284 and a second filter region 286 . First filter region 284 transmits light only in the first wavelength band and second filter region 286 transmits light only in the second wavelength band. First and second filter regions 284 and 286 are preferably equal and abut each other along a straight dividing line (not shown in fiducial imager 272 ). Filter 282 is oriented with respect to lens 276 so that reflected light from fiducial 102 incident on lens 276 passes through filter 282 . A central ray of reflected light from fiducial 102 is indicated by dotted line 288 in FIGS. 9B and 9C. In FIG. 9A the central ray is coincident with optic axis 278 . The dividing line of filter 282 and optic axis 278 of lens 276 intersect. Preferably, the dividing line is perpendicular to the direction of motion of latch needle 104 and the plane (the plane of the Fig.) of the latch needle slot (not shown) that holds latch needle 104 . As a result, light incident on a first half 290 of lens 276 is filtered by first filter region 284 and light incident on a second half 292 of lens 276 is filtered by second filter region 286 . Lens 276 focuses reflected light from fiducial 102 to form an image 130 of fiducial 102 on light sensitive surface 282 of detector 280 . A first portion of the intensity of image 130 results from light incident on first half 290 of lens 276 and a second portion of the intensity of image 130 results from light incident on second half 292 of lens 276 . Since first half 290 of lens 276 is filtered by first filter region 284 , the first portion of the intensity of image 130 results from light in the first wavelength band. Similarly, the second portion of the intensity of image 130 results from light in the second wavelength band. The first and second portions of the intensity of image 130 are proportional to the amounts of light from fiducial 102 that are incident on first and second halves 290 and 292 of lens 276 respectively. As a result, the intensities of light registered by light sensitive surface 282 in the first and second wavelength bands are proportional to the amounts of reflected light from fiducial 102 incident on first and second halves 290 and 292 of lens 276 respectively.
However, the amounts of light incident on first half 290 and second half 292 are functions of the location of fiducial 102 with respect to optic axis 278 of lens 276 . When fiducial 102 is on optic axis 278 , halves 290 and 292 of lens 276 receive the same amounts of reflected light. When fiducial 102 is displaced along the direction of motion of latch needle 104 (along the direction of double headed arrow 124 in FIGS. 9A-9C) towards one or the other of halves 290 and 292 , the half towards which fiducial 102 is displaced receives more light and the other half less light. This is because the distance from fiducial 102 to the half of lens 276 towards which fiducial 102 is displaced decreases and the distance towards the other half increases. The first and second signals that detector 280 sends to the controller are therefore functions of the position of fiducial 102 . These signals are used by the controller to determine the position of fiducial 102 and latch needle 104 on which fiducial 102 is located.
FIGS. 9A-9C show schematically the relationship between positions of fiducial 102 and the intensities of image 130 in the first and second wavelength bands A region of light sensitive surface 282 is shown schematically with image 130 , in ventral view, in a view 294 in each of FIGS. 9A-9C. The dividing line of filter 282 is shown as line 296 in view 294 . The relative intensities of image 130 in the first and second wavelength bands are represented schematically in greatly exaggerated scale and only qualitatively in proportion to the actual intensities of light in image 130 in the first and second wavelength bands by the size of arrows 298 and 300 respectively.
In FIG. 9A fiducial 102 is located on optic axis 278 and image 130 has the same (appropriately normalized and corrected) integrated intensity (i.e. integrated over the area of image 130 ) in both wavelength bands. Arrows 298 and 300 are shown the same size. In FIG. 9B fiducial 102 is displaced away from optic axis 278 towards first half 290 of lens 276 . Image 130 is displaced from optic axis 278 in the opposite direction and the integrated intensity of image 130 increases in the first wavelength band and decreases in the second wavelength band. Arrow 300 is shown much larger than arrow 298 . Similarly, in FIG. 9C, fiducial 102 is shown displaced away from optic axis 278 towards second half 292 of lens 276 . The integrated intensity of image 130 increases in the second wavelength band and decreases in the first wavelength band.
FIGS. 10A-10C schematically illustrate an OPM 150 , in accordance with another preferred embodiment of the present invention, imaging fiducial 102 of latch needle 104 . OPM 150 comprises a fiducial illuminator 152 and a fiducial imager 154 comprising two, preferably identical, detectors 156 and 158 . Fiducial illuminator 152 illuminates fiducial 102 of latch needle 104 . Fiducial 102 reflects some of the light incident on fiducial 102 towards each of detectors 156 and 158 .
Detectors 156 and 158 have light sensitive surfaces 160 and 162 (shown greatly exaggerated in thickness for convenience and clarity of presentation) and lenses 164 and 166 respectively. Lens 160 focuses reflected light from fiducial 102 to provide an image 168 of fiducial 102 on light sensitive surface 160 . Similarly, lens 166 provides an image 170 of fiducial 102 on light sensitive surface 162 . Light sensitive surface 160 with image 168 , and light sensitive surface 162 with image 170 , are shown schematically, in ventral view, in views 172 and 174 respectively in each of Figs. FIGS. 10A-10C. The intensities of images 168 and 170 are schematically represented in each of views 172 and 174 by the length of arrows 169 and 171 respectively. The relative sizes of arrows 169 and 171 are greatly exaggerated for clarity and ease of presentation in comparison to the actual relative intensities of images 168 and 170 . Each of detectors 156 and 158 provides a signal to a controller (not shown) that is a function of the intensity of reflected light imaged on its light sensitive surface.
Detectors 156 and 158 are displaced from each other a small distance, “d”, and both are located at a height, “r”, directly above latch needle 104 . OPM 150 is oriented with respect to latch needle 104 so that a line between the centers of lenses 164 and 166 is parallel to latch needle 104 . Dashed lines 176 and 178 represent central rays of light reflected from fiducial 102 into detectors 156 and 158 respectively.
In FIG. 10A fiducial 102 is located at a point 180 that is equidistant from detectors 156 and 158 . Both detectors receive substantially the same amounts of reflected light from fiducial 102 . Arrows 169 and 171 in views 172 and 174 respectively are therefore shown the same size. The difference between the intensities of light reaching detectors 156 and 158 is zero.
In FIG. 10B fiducial 102 is displaced from point 180 to the right. As a result of the displacement the distance from fiducial 102 to detector 158 decreases and the distance from fiducial 102 to detector 156 increases. This increases the amount of reflected light reaching detector 158 from fiducial 102 and decreases the amount of reflected light reaching detector 156 from fiducial 102 . The size of arrow 171 in view 174 is therefore shown much larger than the size of arrow 169 in view 172 . The difference between the intensities of light reaching detectors 156 and 158 , defined as the amount of light reaching detector 156 minus the amount of light reaching detector 156 , is negative.
In FIG. 10C fiducial 102 is displaced from point 180 to the left. This increases the amount of reflected light reaching detector 156 from fiducial 102 and decreases the amount of reflected light reaching detector 158 from fiducial 102 . In this case, the size of arrow 171 in view 174 is therefore shown much smaller than the size of image 169 in view 172 . The difference between the intensities of light reaching detectors 156 and 158 , as defined above, is positive.
From considerations of geometry it can readily be shown that when r>>d, if the displacement of fiducial 102 from point 180 is represented by “Δx”, the difference between the intensities of light reaching detectors 156 and 158 is proportional to Δxd/r 4 . The difference between the signals sent by detectors 156 and 158 to the controller, which are functions of the intensities of reflected light registered by detectors 156 and 158 respectively, can therefore be used to determine Ax and the position of fiducial 102 .
FIGS. 11A-11C schematically show an OPM 190 , in accordance with yet another preferred embodiment of the present invention, imaging fiducial 102 of latch needle 104 . OPM 190 comprises a fiducial illuminator 192 and a fiducial imager 194 . Fiducial imager 194 comprises a single detector 196 and two lenses 198 and 200 . Fiducial illuminator 192 illuminates fiducial 102 of latch needle 104 . Fiducial 102 reflects some of the light incident on it from fiducial illuminator 192 towards each of lenses 198 and 200 . A central ray of reflected light from fiducial 102 to lens 198 is represented by dashed line 202 and dashed line 204 represents a central ray from fiducial 102 to lens 200 .
Detector 196 comprises a light sensitive surface 206 (shown greatly exaggerated in thickness for convenience and clarity of presentation) that is sensitive to light in two non-overlapping wavelength bands of light. Fiducial illuminator 192 illuminates fiducial 102 with preferably equal intensities of light from both wavelength bands. Each of lenses 198 and 200 transmits light in only one of the two different wavelength bands. Lens 198 focuses reflected light in one of the two wavelength bands to form an image 214 on light sensitive surface 206 . Lens 200 focuses reflected light in the other of the two wavelength bands to form an image 216 on light sensitive surface 206 . Detector 196 sends a first signal to a controller (not shown) that is a function of the amount of light in image 214 and a second signal to the controller that is a function of the amount of light in image 216 .
Lenses 198 and 200 are displaced a short distance from each other and the line connecting the centers of lenses 198 and 200 is aligned parallel with and directly above latch needle 104 . Assume that fiducial illuminator 192 is either located equidistant from lenses 198 and 200 , or that any biases in the relative amounts of light reflected by fiducial 102 onto lenses 198 and 200 resulting from an asymmetric location of fiducial illuminator 192 with respect to lenses 198 and 200 are corrected for. Then, when fiducial 102 is equidistant from lenses 198 and 200 , detector 196 registers equal intensities of light for both images 214 and 216 (i.e. surface 206 registers the same intensity of light in both of the wavelength bands to which it is sensitive). As fiducial 102 is displaced towards one or the other of lenses 198 and 200 , the relative intensities of light registered for images 214 and 216 changes.
FIG. 11A shows fiducial light 102 located at a point 208 equidistant from lens 198 and 200 . FIGS. 11B and 11C show fiducial 102 displaced right and left respectively of point 208 . View 210 each of FIGS. 11A-11C is a ventral view of light sensitive surface 206 . View 210 shows schematically images 214 and 216 of fiducial 102 that are formed on light sensitive surface 206 by lenses 198 and 200 respectively. The sizes of arrows 215 and 217 in view 210 represent schematically with greatly exaggerated scale the relative amounts of light in images 214 and 216 respectively for the different positions of fiducial 102 shown in FIGS. 11A-11C.
From considerations of geometry it can readily be shown, as in the case of OPM 150 shown in FIGS. 10A-10C, that for a displacement Δx of fiducial 102 from point 208 , the difference between the intensities of light registered by detector 196 for images 214 and 216 is substantially proportional to Δx. The signals sent by detector 206 to the controller, which are functions of the intensities of light registered by detector 206 for images 214 and 216 can therefore be used to determine Δx and thereby the position of fiducial 102 .
FIGS. 12A-12C schematically show an OPM 220 , in accordance with yet another preferred embodiment of the present invention that is used to measure the position of a latch needle provided with two fiducials. In FIGS. 12A-12C, OPM, 220 is shown imaging a latch needle 222 provided with a fiducial 224 and a fiducial 226 .
OPM 220 comprises a fiducial illuminator 228 and a fiducial imager 230 . Fiducial imager 230 comprises a single detector 232 and a single lens 234 having a lens axis 235 . Detector 232 comprises a light sensitive surface 233 (shown greatly exaggerated in thickness for convenience and clarity of presentation) that is sensitive to light in two non-overlapping wavelength bands of light. Fiducial illuminator 228 illuminates fiducials 224 and 226 preferably with light having equal intensities in both wavelength bands. Fiducial 224 reflects light in only one of the two wavelength bands and fiducial 226 reflects light in only the other of the two wavelength bands. Lens 234 images the reflected light from fiducials 224 and 226 to form an image 236 of fiducial 224 on surface 233 in one of the two wavelength bands and an image 238 of fiducial 226 on surface 233 in the other of the two wavelength bands. Detector 232 sends a signal to a controller (not shown) for each of images 236 and 238 that is a function of the intensity of light in the image.
Images 236 and 238 have the same intensities, in their respective wavelength bands, only when fiducials 224 and 226 are substantially equidistant from axis 235 of lens 234 . For different positions of latch needle 222 , one or the other of fiducials 224 and 226 is closer to axis 235 . The image of the fiducial closer to axis 235 is more intense than the image of the fiducial farther from axis 235 . Differences in intensities of images 236 and 238 registered by detector 232 are used to determine the position of fiducials 224 and 226 and thereby of latch needle 222 .
FIG. 12A shows latch needle 222 in a position for which fiducials 224 and 226 are equidistant from axis 235 . FIG. 12B shows latch needle 222 in a position in which fiducials 224 and 226 are displaced to the right of their respective positions shown in FIG. 12A, and FIG. 12C shows latch needle 222 in a position in which fiducials 224 and 226 are displaced to the left of their respective positions shown in FIG. 12 A. In each of FIGS. 12A-12C, view 240 is a ventral view of light sensitive surface 234 schematically showing images 236 and 238 . The sizes of arrows 237 and 239 shown in ventral view 240 represent schematically and in greatly exaggerated scale, the relative intensities of images 236 and 238 for the position of latch needle 222 shown in the FIG.
FIGS. 13A-13C show an OPM 250 imaging fiducial 102 , in accordance with yet another preferred embodiment of the present invention. OPM 250 comprises a fiducial illuminator 252 and a fiducial imager 254 . Fiducial imager 254 comprises a lens 256 having an optic axis 257 and a detector 258 , such as a CCD, having a pixelated light sensitive surface 260 (shown greatly exaggerated in thickness for convenience and clarity of presentation). Lens 256 focuses reflected light from fiducial 102 to form an image 262 of fiducial 102 on pixelated surface 260 .
In OPM 250 the position of fiducial 102 is determined using the rules of basic optics from the location of image 262 on pixelated surface 260 . FIGS. 13A-13C show schematically the spatial relationship between the position of fiducial 102 and image 262 of fiducial 102 on pixelated surface 260 . Image 262 and pixels 264 of pixelated surface 260 are shown schematically in a ventral view 266 of pixelated surface 260 in each of FIGS. 13A-13C. In FIG. 13A fiducial 102 is located on optic axis 257 and image 262 is located at the center of pixelated surface 260 shown in view 264 (assuming lens 256 and detector 258 are aligned). In FIGS. 13B and 13C, fiducial 102 is displaced to the right and to the left of optic axis 257 respectively. Image 262 on pixelated surface 260 moves accordingly to the left and the right of the point at which image 262 is located when fiducial 102 is on optic axis 257 .
Image 262 is preferably focused by lens 256 so that it covers a plurality of pixels on light sensitive surface 260 . Using methods well known in the art, an optical center of gravity of image 262 can be defined and located on pixelated surface 260 to sub-pixel accuracy. Using the location of the optical center of gravity of image 262 , the position of fiducial 102 and latch needle 104 are determined by OPM 250 with an accuracy sufficient for controlling latch needle actuators in a DDM.
FIGS. 13A-13C show OPM 250 being used to determine the position of a single latch needle 104 , by imaging a fiducial 102 located on the latch needle 104 . However, a single OPM of the form of OPM 250 , in accordance with a preferred embodiment of the present invention, can be used to determine the position of a plurality of latch needles 104 . This is accomplished by providing the detector 258 of the OPM with a field of view that includes the fiducial 102 of each of the plurality of latch needles 104 . Each fiducial 102 of a latch needle of the plurality of latch needles is imaged on a different rectangular region of pixelated surface 260 of the OPM. As the latch needle 104 on which the fiducial 102 is located moves back and forth in its operational range of motion, (indicated schematically by double headed arrow 124 ) the image of its fiducial 102 moves back and forth along the length of the rectangular region of pixelated surface 260 on which it is imaged.
For example, in one preferred embodiment of the present invention, detector 258 is provided with a field of view that focuses an area of a needle bed having a dimension perpendicular to latch needles 104 that is on the order of 5 cm. The dimension of the field of view in the direction parallel to latch needles 104 is on the order of the operational range of motion of latch needles 104 . If the spacing between latch needles 104 in the needle bed is 2 mm the fiducials 102 of 25 latch needles 104 will be in the field of view of the OPM. Assuming that pixelated surface 260 of detector 258 comprises a square matrix, 5 mm on a side, comprising 512 rows and 512 columns of pixels fiducials 102 of the 25 latch needles 104 in the field of view of detector 258 are imaged on parallel rectangular regions of pixelated surface 260 that are approximately 20 pixels wide and 512 pixels long. If the operational range of motion of a latch needle 104 is on the order of 5 cm, and the optical center of gravity of the image of a fiducial is located with a resolution of 0.4 pixels, the position of fiducial 102 and its latch needle 104 are located with an accuracy of about 40 micrometers.
Variations of the above-described preferred embodiments will occur to persons of the art. The above detailed descriptions are provided by way of example and are not meant to limit the scope of the invention, which is limited only by the following claims.
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An optical position monitor for determining the position of a latch needle ( 104 ) in a knitting machine is provided that comprises: at least one fiducial ( 102 ) at a known fixed cation on the body of the latch needle; a fiducial imager that produces at least one optical image ( 262 ) of the at least one fiducial on at least one light sensitive surface ( 260 ) wherein the at least one optical image changes with changes in position of said at least one fiducial; and a controller that receives at least one signal responsive to the changes in the at least one image and uses the at least one signal to determine the position of the at least one fiducial ( 102 ) and thereby of the latch needle ( 104 ).
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FIELD OF THE INVENTION
[0001] The field of the invention is boating construction.
BACKGROUND
[0002] Many different types of sliding doors are known. Such doors are very commonly supported by an overhead track and roller system, and can also have a guiding track underneath. The bottom track usually runs the length of the path of the door, and constrains undesired lateral movement of the door.
[0003] Pocket doors are sliding doors in which at least a portion of the door is withdrawn into an enclosure. Such doors are well-known in residential housing and offices, and have also been used in boats where a swinging door is undesirable, and space is at a premium. Pocket doors are usually straight, but it is known to use curved pocket doors in corner cabinets, furniture and the like.
[0004] A transom is a transverse panel forming the aft end of a boat's hull. Transoms commonly extend up above the boat's deck by a meter or more, and often have an opening through which a person can enter or exit the boat. Such openings can be blocked off with a solid door, chain, or other deterrent, but the known devices for accomplishing that function are sometimes undesirable. Regular swinging doors, for example, require adequate space for movement. And, when swung open unexpectedly, such doors can injure a person standing in its way.
[0005] Known pocket doors could theoretically be used for a boat transom, or in some other external positions on a boat, but they would not work properly. For one thing known pocket doors are usually hung from above, and therefore require some sort of stabilizing track running the length of the path of the door. But a track crossing the opening of a boat transom would be undesirable because it would be unsightly, it would tend to fill with water and other debris, and it could even comprise a danger because it could catch clothing or other objects. Problems are exacerbated for boats having a door in a curved transom. Such doors would have to be curved as well, which would be especially hard to implement without a track running across the opening.
[0006] It should be possible to support a pocket door without using a bottom track running the length of the path of the door. But one of ordinary skill in the art would reject the idea of using a pocket door in a boat because, unlike the usual housing, cabinet or furniture implementations, there will almost certainly be very significant lateral forces placed upon the boat door from time to time. Without the underlying track, the door would very likely be pushed side to side, out from its intended path.
[0007] Thus, there is still a need for a boat with a transom having an exterior portion, which includes a pocket door that opens to provide a passageway large enough for a person to pass.
SUMMARY OF THE INVENTION
[0008] The present invention provides apparatus, systems and methods in which a boat has an exterior portion, which includes a pocket door that opens to provide a passageway large enough for a person to pass.
[0009] The door can be anywhere on the exterior of the boat; for example along the transom, along a side of the boat, or leading into the cabin. Of particular interest are sliding doors that utilize a traveler and a guide, each positioned on one of the door and the housing, and having tolerances that restrict side to side movement of a distal edge of the door under normal operating conditions to 5 cm or less, more preferably to 2 cm or less, and most preferably to 5 mm or less. In a particularly preferred embodiment, the guide comprises a track and rollers, and the traveler comprises a foot disposed to travel between opposite rollers. In such embodiments the rollers can advantageously be mounted in spaced apart opposing pairs on a guide, and appropriate tolerances can be set using off-center axes in the rollers.
[0010] Travelers and guides can be made of any suitably rigid material or materials, including for example, steel or other metal alloy. Preferred travelers extend beyond the inside edge (the trailing edge that remains within the housing) of the door by at least 5 cm, and more preferably at least 20 cm. Since a major function of the traveler is to prevent side to side movement of the sliding door, preferred travelers also have a width of at least 2 cm, and more preferably at least 4 cm. Travelers can be in the form of a foot, a piston ram, or any other suitable shape, but as used herein the term traveler means a separate element from the body of the door. Thus, the term traveler excludes an unmodified bottom portion of the door, such as one would find in a typical home closet. The guide is also preferably not visible from outside the housing.
[0011] Contemplated sliding doors can be virtually any size or shape, and can include any suitable material or combination of materials. Preferred doors are at least one meter long, 5-10 cm side, and 0.5 to 1.5 meters tall. For boats, sliding doors are preferably manufactured from fiberglass or other waterproof polymeric material(s). Sliding doors can be used in pairs, where the sliding doors approximate one another at their leading edges. One or more detents can be placed on a leading edge of one or more doors, possibly with corresponding indentations in an approximating surface. Sliding doors are contemplated to be straight or curved.
[0012] Sliding doors can be operated in-any suitable manner, manually or otherwise, and it is especially contemplated that sliding doors can be operated using a pneumatic ram.
[0013] Various objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the invention, along with the accompanying drawings in which like numerals represent like components.
BRIEF DESCRIPTION OF THE DRAWING
[0014] FIG. 1 is an aerial aft perspective view of a boat having a three pocket doors.
[0015] FIG. 2 is a top view of the boat of FIG. 1 .
[0016] FIG. 3 is a view of a transom with double sliding doors.
[0017] FIG. 4 is schematic illustration of a transom door with sliding mechanism.
[0018] FIG. 5 is a view of the track and rollers assembly.
[0019] FIG. 6 is a view of a roller with off-center axis.
[0020] FIG. 7 is a view of rollers with off-center axes allowing positional adjustment during installation.
[0021] FIG. 8 is a partially transparent side view of a sliding door having a ram type traveler.
DETAILED DESCRIPTION
[0022] In FIGS. 1 and 2 , a boat 1 generally has a bow 2 , a stem 3 , a deck 4 , a cabin or cockpit 5 , and a transom 10 . Here, boat 1 has an opening 20 and a curved sliding transom door 30 . A second, flat, sliding door 230 is shown on the starboard side of the boat, and a third sliding door 330 , having an extremely slight curvature, is shown at the entrance to the cabin of the boat.
[0023] Boat 1 can be made of any suitable materials, including especially fiberglass, wood, metal, or combinations of such materials. All types of boats are contemplated, including, for example, those propelled by a motor, a sail, or both, as well as commercial, recreational, fishing/gaming, or any other type of boat.
[0024] A boat can have one or any realistic plural number of pocket doors, and such doors can be positioned anywhere on the boat, inside or outside the cabin. Nevertheless, it is especially contemplated that pocket doors can advantageously be positioned external to the cabin or at an entrance to the cabin. All suitable widths are contemplated for the openings created by the pocket door(s), including anywhere from about 50 cm to up to two meters or more. It is especially contemplated that openings can be large enough for a normal 70 kg adult person to pass through.
[0025] FIG. 3 depicts two sliding doors 30 , 40 . Sliding doors 30 and 40 cooperate to open and close an opening (i.e. a passageway) between them, are together can comprise sliding door designated 330 . Sliding door 30 generally includes top 31 A, bottom 31 B, proximal side 31 C, distal side 31 D, an inside edge 31 E, and an outside edge 31 F. Distal side 31 D has elongated detents 32 , 33 and corresponding indentations 43 , 42 in an opposing surface. Detent 32 and indentation 33 can be constructed as part of the distal side 31 D, or they can be constructed separately as attachments to distal side 31 D. Detents 32 , 33 can be made of any suitable materials, including, for example, rubber, fiberglass, plastic, metal, wood and so forth.
[0026] Use of two elongated detents in the approximate orientations shown is considered to be especially desirable because they can block light from passing in a space between the sliding door and the abutting surface, which in this instance is sliding door 40 . As used herein, the term “approximates” includes all situations where the approximating surfaces come to within 1 cm of one another, and specifically includes situations where the approximating surfaces touch one another. Those skilled in the art will, of course, appreciate that alternative detents can be different in number, configuration and orientation from that shown, including for example one or more finger-like projections extending normally from, rather than vertically to, the outside edge.
[0027] Sliding door 30 (and also 230 , 330 ) can be made of any suitable material, including for example, fiberglass, wood, metal, and so forth. Sliding doors can be solid or hollow, and can have any suitable configuration. Sliding doors can be flat, or alternatively bowed horizontally, vertically or in some other manner. They can also be curved or non-curved. All practical curvatures are contemplated, including especially those having a radius of curvature less than 10 meters, between 10 and 20 meters, and greater than 20 meters. Contemplated doors can also be curved in some manner that is inconsistent with a single radius.
[0028] Opening 20 is closed off by a single-door panel unit as shown in FIGS. 1 and 2 . In the alternative, an opening can be closed by two transom sliding doors, as shown in FIG. 3 . The two doors would usually be mirrors of one another, but they can alternatively have different configurations.
[0029] FIGS. 4-7 illustrate schematically the sliding door assembly 100 , which generally comprises a sliding door 110 , a traveler 120 , a guide 130 . Here, the traveler 120 comprises a foot, and the guide 130 comprises a race.
[0030] Sliding door 110 can be similar to door 30 , 230 or 330 , and generally includes a top 111 A, a bottom 111 B, a side 111 C, a leading edge 111 D, and a trailing edge 111 E. The door 110 can be solid, hollow, have internally molded baffles, or have any other suitable configuration. Leading edge 111 D is shown as having a detent 132 and an indentation 133 , which mate with opposing structures (not shown). The detent 132 can be constructed using any suitable materials.
[0031] Sliding mechanism 101 comprises a foot 120 and a guide 130 . In FIG. 4 a series of roller pairs constrains movement of the foot 120 within the guide 130 , but it should be appreciated that any other suitable system can be used, including for example one or more rails disposed on the guide, upon which travels the foot or a channel formed underside of the door. It is especially contemplated that the weight of the sliding door 110 can be entirely supported by the traveler, which in this case is the single foot 120 . To that end the traveler is preferably screwed to the bottom and/or one or both sides of the sliding door. To provide adequate support when the door is in a closed position, the traveler preferably extends outward beyond the inside edge of the sliding door by at least 10 cm, and more preferably by 20 cm, 40 cm, or more. This extended portion of the traveler provides continued engagement with a corresponding guide even when the sliding door is fully extended.
[0032] The sliding mechanism 101 can have any suitable position or orientation. In FIG. 4 the mechanism 101 is positioned at the bottom of the sliding door 110 . But it should be appreciated that a sliding mechanism could be additionally or alternatively positioned on the top or one or both sides of the door. It is also contemplated that instead of a foot and a race, the sliding mechanism can comprise a piston and ram, or even a hanger arrangement, so long as the tolerances of the mechanism restrict the side to side movement of the distal (i.e. leading) edge of the door under normal operating conditions to less than 5 cm, more preferably to less than 2 cm, still more to preferably less than 1 cm, and most preferably to less than 5 mm.
[0033] In more general terms it is contemplated that the traveler and guide can each be positioned on one of the door and the housing. Thus, the traveler could be on the door and the guide on the housing, or visa versa. Indeed, there could even one or more travelers on each of the door and the housing, and one or more mating guides on each of the door and housing. It should also be appreciated that different sliding mechanisms can be used for different doors of a pair.
[0034] The traveler and/or guide can be made with any suitable material, but preferably stainless steel or other corrosion resistant alloy, or a reinforced synthetic material that provides sufficient strength.
[0035] Optional actuator 112 automatically closes and opens sliding door 110 . A pneumatically operated ram is preferred because it eliminates electrical connections in a potentially moist area, and can take advantage of pressurized air which is commonly available on larger boats. It is, however, contemplated that an electric, hydraulic or other type of ram could be used. Of course, door 110 could also be operated manually.
[0036] In FIG. 5 , race 130 generally includes a frame 132 upon which are disposed rollers 134 A-L. Frame 132 can be made of suitably strong and durable material such as metal, synthetic material, and wood. Rollers 134 A-L constrain lateral movement of foot 120 while allowing for longitudinal movement. Rollers can be arranged in any suitable arrangement, but to provide greater stability when the door is closed, more proximal pairs of rollers 134 D-F and 134 J-L are spaced closer together on frame 132 than more distal pairs of rollers 134 A-L. Although FIG. 5 shows that individual members of a given pair of rollers as always positioned opposite one another, the rollers can be staggered such that there are no pairs, or so that the rollers are positioned in some other configuration. Rollers are preferably rotatable, usually about an inner guide with bearings, but could have any other suitable design, including being non-rotatable.
[0037] In FIGS. 5-7 , the rollers advantageously have a bodies with off-center holes. In FIG. 6 , for example, roller 134 has off-center hole 135 , which receives a bolt or other fastener 150 . By turning the body about the fastener, and then tightening the roller to the frame 132 , an installer can make minor adjustments to the relative position of the various rollers to the foot. As illustrated in FIG. 7 , positional movement of roller 134 not only allows adjustment and readjustment to provide desired tollerances between foot 120 and guide 130 , it also allows more convenient placement of foot 120 between the two rows of rollers 134 A-L. As discussed above, roller 134 preferably includes bearings 136 .
[0038] In FIG. 8 , a door 430 slides into and out from a housing 410 . There are two cylindrically shaped travelers 415 that cooperate with cylinders 425 to support the weight of door 430 , while allowing door 410 to move laterally in either direction without excessive side to side movement. In this particular instances, detents 432 , 433 are finger like projections that have a long axis extending horizontally, in contrast to the detents 32 , 33 of FIG. 3 that have a long axis extending more or less vertically.
[0039] Thus, specific embodiments and applications of pocket sliding door have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps can be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C . . . and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.
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A boat has an outside pocket door that opens to provide a passageway large enough for a person to pass. Of particular interest are sliding doors that utilize a traveler and a guide, each positioned on one of the door and the housing, having tolerances that severely restrict side to side movement of a distal edge of the door under normal operating conditions. The guide can advantageously comprise a track and rollers, and the traveler can comprises a foot disposed to travel between opposing ones of the rollers. In such embodiments the rollers can advantageously be mounted in spaced apart opposing pairs on a guide, using off-set centers to adjust the tolerances. Sliding doors can be operated in any suitable manner, manually or otherwise, and it is especially contemplated that sliding doors can be operated using a pneumatic ram.
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This application is a division of Ser. No. 08/003,899, filed on Jan. 13, 1993, and now U.S. Pat. No. 5,309,232.
TECHNICAL FIELD
This invention relates to the operation of vertical shaft furnaces so as to melt metal. The invention is particularly concerned with the operation of cupolas to melt ferrous metal.
BACKGROUND OF THE PRIOR ART
Cupolas are widely used in foundries to melt pig iron, iron scrap and steel scrap or mixtures thereof. In order to operate a conventional cupola, a red hot bed of coke is established at its bottom. The coke bed is maintained at the desired temperature by supplying an air blast through tuyeres that direct the air at relatively low velocity into the bed. A charge comprising alternate layers of metal to be melted and coke is fed into the shaft of the cupola. Hot gases created by the exothermic reaction of the air blast with the coke bed flow upwards through the shaft of the cupola and heat the metal by convection sufficiently for a region of molten metal to be created immediately above the coke bed. The molten metal percolates through the coke bed and is superheated by radiation from the coke. From time to time molten metal is tapped off from the bottom of the cupola into a ladle for use in the foundry. Alternatively, the molten metal may be continuously tapped and collected in a suitable receiver. Although the coke in the bed is progressively consumed by the reaction with the oxygen component of the air blast, the coke layers in the charge will replenish the bed and the coke bed is maintained at adequate depths throughout the operation of the cupola. It is also conventional to include within the charge limestone or other slag-forming agent, ferrosilicon or other suitable ferroalloys so as to improve the metallurgical properties of the metal during the melting operation.
A wide range of different variants of this basic method of operating a cupola are Known. For example, the air blast can be provided without being pre-heated. Cupolas that operate in this way are Known as cold-blast cupolas. Alternatively, the air blast can be pre-heated. Such cupolas are Known as "hot blast" cupolas. If desired, the air blast may be enriched with oxygen so as typically to raise the oxygen concentration of the air by from 2 to 4% by volume. More preferably, the oxygen may be introduced into the coke bed in the form of high velocity jets through lances. The lances may be located below the tuyeres (see GB-A-914 904) or may project through the tuyeres themselves. (See GB-A-1 006 274). As disclosed in EP-A-56 644 the oxygen jets may each enter the cupola at above sonic velocity. All the variants described above that make use of oxygen offer two main advantages. First, they enable higher temperatures to be created wi thin the cupola and thus enable the molten metal to be discharged at a higher temperature. Second, they enable the rate of melting metal to be increased.
It has been proposed in GB-A-1 500 511 to modify a conventional air blast cupola by adding to it oxy-fuel burners so as to provide additional heating to melt the metal. Accordingly, there is a reduced need for heat to be generated by the reaction between the air blast and the coke bed. As a result, the amount of coke in the charge can be reduced.
All the methods of operating cupolas described above suffer from a common disadvantage, namely that there is emitted from the top of the cupola a visible smoke or fume which is heavily laden with particles. Although it is possible to treat such smoke or fume to reduce its content of particles so as to render it less unsuitable for discharge to the atmosphere, the cost of so doing is high. There is therefore a growing demand for methods of operating cupolas which do not inevitably have associated therewith the production of a visible, particulate-laden fume.
In order to meet this demand there has been developed a cupola which uses neither an air blast nor coke. Instead, it employs air-fuel burners to melt the ferrous metal by convection heating, and a bed of ceramic balls to superheat the molten metal by radiant heat. The bed of ceramic balls is supported on a water-cooled grid. Immediately below the grid is a cavity into which the burners fire. The hot combustion gases ascend the furnace, heating the ceramic balls and melting the ferrous metal. The resulting molten metal falls through the ceramic balls and is superheated by heat radiated therefrom. There is thus no need to include any coke in the charge to the cupola, and provided that the ferrous metal in the charge is free of oil or other such contaminants, no visible fume is emitted. In practice, there have found to be a number of disadvantages associated with the operation of such cupolas. First, difficulties arise in producing molten metal at an adequate temperature. Moreover, the water-cooled grid tends to be damaged if excessive temperatures are created within the cupola. It has also been found that increased additions of ferrosilicon are required in order to ensure that a molten ferrous metal having a desired silicon content is given. Similarly, it is necessary to add carbon, typically in the form of graphite, to the molten metal to give a desired carbon content now that coke is no longer employed in the charge. Furthermore, the ceramic balls have a limited life as they tend to be eroded by the molten metal. There is therefore a need continuously to replace the balls, much in the same way as it is required in a conventional air blast cupola to include coke in the charge so as to replace the coke that is consumed by reaction with oxygen in the bed at the bottom of the cupola.
There is therefore a need for an alternative method of operating a cupola which does not of necessity entail the emission of large quantities of visible, particle-laden, fume from the furnace yet which facilitates the production of metal, particularly ferrous metal, at a temperature suitable for the direct casting of engineering iron without the need for an additional heating facility such as an electric duplexing furnace.
SUMMARY OF THE INVENTION
According to the present invention there is provided a method of operating a vertical shaft furnace comprising, establishing a hot coke bed in a bottom region of the furnace; charging the furnace with metal to be melted and with coke; burning at least one stream of fuel with a stoichiometric excess of oxygen over that required for complete combustion of the fuel and thereby forming a hot gas mixture Including oxygen; introducing the hot gas mixture into the shaft furnace and allowing it to pass upwardly through the charge in the furnace, oxygen in the hot gas mixture thereby reacting with the coke charge such that a part of the coke charge is consumed, heat being provided to the metal by the hot gas mixture and by the said reaction between the oxygen and the coke being sufficient to melt the metal without there being an air blast supplied to the furnace, and the molten metal so formed flowing downwardly under gravity through the hot coke bed; introducing at least one jet of oxygen or oxygen-enriched air into the said hot coke bed so as to maintain the bed at a temperature sufficient to superheat the molten metal as the molten metal passes through the hot coke bed; and discharging superheated molten metal from the furnace.
The invention also provides a vertical shaft furnace having associated therewith means operable to inject at least one jet of pure oxygen or oxygen-enriched air into a coke bed maintained in operation of the furnace at a bottom region thereof; at least one fuel burner operable with a stoichiometric excess of oxygen over that required for complete combustion of the fuel to form a hot gas mixture comprising combustion products and oxygen, said at least one burner being positioned so as, in use, to direct the hot gas mixture into the furnace shaft and thereby to enable it to pass upwardly through the charge in the furnace such that oxygen in the hot gas mixture is able to react with the coke charge to consume a part of the coke charge to be consumed and thereby generate an amount of heat which with the heat available from the hot gas mixture is able to melt the metal, molten metal so formed being able to flow downwardly through the hot coke bed and to be superheated by the coke in said bed; and means for discharging molten metal from the furnace, wherein the furnace has no means for supplying an air blast to it.
We have surprisingly found that when employing the method and apparatus according to the invention to melt ferrous metal in a cupola, there is surprisingly little visible fume emitted in comparison with conventional hot blast and cold blast cupolas. Although we do not fully understand why this result is obtained, we attribute it to an ability through the combustion of said at least one stream of fuel to generate a high temperature stream of oxygen-containing gas mixture. This gas mixture is typically produced at a temperature of from 900° to 1100° C. Such temperatures are well in excess of those at which the air enters the shaft of a conventional hot-blast or cold-blast cupola. The high temperature oxygen-containing gas mixture is, we believe, conducive to the creation in the shaft of the cupola of conditions in which gas-borne particles of coke are more readily oxidized to gaseous products than in conventional hot-blast or cold-blast cupolas with the result that the amount of visible fume emitted from the cupola shaft is kept down. We obtain our best results when diluting with air (or other oxygen-containing gas) the hot gas mixture at a level above the charge (so as to promote combustion of carbon monoxide and any carbon particles in the hot gas) and when operating the burner or burners not only with excess air but also with oxygen-enrichment of the combustion air.
The method and apparatus according to the invention are able to be operated so as to create in the furnace shaft a regime of a sufficiently high temperature for the molten metal to be produced with a sufficient degree of superheat, that is at a temperature sufficiently above the melting point of the metal, for the metal to be readily transferable to other vessels for immediate use in a foundry to make castings or the like. In particular, we have found it possible when melting ferrous metal to tap the metal at temperatures of 1500° C. or above. Such temperatures are generally recognized with the art to be adequate for most uses of molten ferrous metal within a foundry.
A third major advantage of the method and apparatus according to the invention is that the temperature of the molten metal being tapped is to a large extent able to be controlled independently of the melting rate: there is considerable flexibility of operation such that the production of molten metal can be adjusted within a broad range of production rates independently of the tap temperature.
The advantages and preferred features of the invention are discussed further hereinbelow.
The fuel is preferably a liquid or gaseous hydrocarbon. For example, the fuel may be propane or a fuel oil. Combustion of the fuel preferably takes place with a relatively large amount of excess air, typically from 20 to 100%, and thereby provides sufficient oxygen in the hot gas mixture to oxidize coke at a desired rate. The melting rate of the metal is determined by the rate of transfer of heat from the combustion gases to the metallic charge and the rate at which the oxygen in the combustion gases burns out the coke. Hence, for a given coke charge and rate of fuel supply, the melting rate is determined by the amount of oxygen in the hot gas mixture leaving the burner or burners. Accordingly, the rate of melting may be increased by increasing the amount of excess air employed, and decreased by decreasing this amount. The tap temperature of the molten metal may be independently controlled by the rate at which the jet or jets of oxygen or oxygen-enriched air are injected into the coke bed. Such independent control of the melting rate and tap temperature is facilitated by arranging for the burner or burners to direct hot gases into the furnace at a level appreciably above that of the injection of the or each jet of oxygen or oxygen-enriched air. The difference in height between such levels is typically in the order of 0.5 m or more. Typically, the ratio by weight of coke to metal in the charge is in a range of from 4 to 8% when melting ferrous metal. This ratio excludes coke added to the furnace to establish the bed prior to the introduction of metal and is smaller than that generally employed in conventional cold blast cupolas. In general, for a given amount of excess air, the rate of melting decreases with increasing coke to metal ratio. Control of the melting rate may also be effected by varying the rate of supply of fuel to the burner or burners.
Preferably, a plurality of spaced-apart burners is employed so as to impart essentially uniform cross-sectional heating to the charge.
We have found that the burners may simply each extend into a passage through the wall of the furnace without creating an unacceptable rate of erosion of the furnace lining or an unstable flame. If desired, however, the or each burner may fire into a separate combustion chamber outside the furnace which communicates with the shaft of the furnace. The use of such an external combustion chamber although helping to reduce the rate of furnace lining erosion can entail some loss of temperature in the hot gas mixture and is generally therefore not preferred.
According to a preferred feature of the invention, the hot gas mixture has a temperature and oxygen content sufficient for the molten metal to be superheated before it encounters the said coke bed at the bottom region of the furnace. Such superheating limits the amount of additional superheating that needs to be provided by the hot coke bed, and hence limits the amount of heat that needs to be generated in the coke bed. This tn turn reduces the rate at which oxygen or oxygen-enriched air needs to be injected into the bed which tends to reduce the temperature which is created at the interface between the bed and the furnace wall, thereby reducing the rate of erosion of the lining on the wall.
A secondary flame or flames are typically created by the dilution air (or other oxygen-containing gas) within the shaft of the furnace above the charge. We have found that the presence of such secondary flames in the region of the shaft immediately above the charge reduces the amount of carbon monoxide in the gaseous mixture leaving the shaft of the furnace. Typically, when air is used to support combustion of the fuel supplied to the or each burner, the level of carbon monoxide is found to be in the order of 5 to 6% by volume at a sampling point a little below the gas outlet from the furnace. The air that supports the combustion of the fuel is however preferably enriched in oxygen. Preferably, the enrichment increases the oxygen content of the air to a value of up to 26% by volume. Such oxygen-enrichment increases the temperature of the hot combustion gases and facilitates reaction between the dilution air and residual combustibles therein above the level of the charge. Indeed, we have by this means found it possible to eliminate the emission of visible fume from the furnace, and to reduce the aforesaid carbon monoxide concentration to less 1%. We have further found that enriching in oxygen the air employed to support combustion of the fuel stream or streams also facilitates superheating of the molten metal. Care needs to be taken, however, when so employing oxygen-enriched air to avoid creating so high a flame temperature that local erosion of the furnace lining proceeds at such a rate that damage is done to the structure of the furnace or that the lining is eroded at an unacceptable rate.
Enrichment of the combustion air is preferably performed by mixing it with oxygen upstream of the flame zone of the or each burner. Direct inflection of the oxygen into the or each burner flame is however also possible.
The source of some of the dilution air is typically a door in the furnace through which the charge is loaded. Additional air is preferably provided by a fan which has an outlet in communication with the shaft at a level about that of the charge but below that of the door.
Preferably, the shaft of the furnace is pre-heated by operation of said at least one burner prior to charging of the furnace. Typically, the or each burner is operated for up to an hour before charging is commenced. It is also preferred to bring the bed of coke to its desired operating temperature before charging of the furnace is started. Accordingly, the bed is preferably ignited to establish an elevated temperature and then said injection of oxygen commenced prior to the charging of the furnace.
Whereas the combustion of the stream of fuel provides all the necessary need for the melting of the metal and preferably for some superheating of the molten metal, the injection of the oxygen or oxygen-enriched air into the coke bed as aforesaid provides a means for controlling the discharge temperature of the molten metal. The rate at which oxygen needs to be injected is not particularly great. Typically, such rate is from 0.5 to 5%. preferably 1.0 to 2.5%, of the rate at which air is supplied for the purposes of supporting combustion of the fuel. It is however preferred that the oxygen be injected at particularly high velocity, say, at least 100 m/s and preferably at sonic or supersonic velocity depending on the diameter of the furnace. It is also preferred that the oxygen be injected generally horizontally in a plane perpendicular to the longitudinal axis of the shaft of the furnace to ensure that the oxygen can penetrate the central regions of the bed of coke and thereby enable a high temperature to be created in the center of the bed while at the same time minimizing the flow of unreacted oxygen into the charge above the bed. Preferably a plurality of spaced apart lances are used to inject the oxygen into the bed. Each lance preferably has such an internal diameter that enables the preferred velocity to be created. Each lance may terminate at the interface between the coke bed and the wall of the furnace. Alternatively, each lance may communicate with the coke bed via a passage of diameter similar to or the same as the internal diameter of the lance itself. Such an arrangement helps to minimize erosion of the lances in use.
It is not essential that the oxygen be supplied to the coke bed continuously during operation of the furnace to melt metal. Even if continuous operation is not desirable from the metallurgical point of view, however, it is sometimes desirable that oxygen be supplied continuously through each lance so as to prevent blockages occurring. We therefore prefer to vary the rate of oxygen injection from a maximum to a minimum rate. Preferably the oxygen is supplied from a commercially pure source thereof.
Alternatively, the source of oxygen may be oxygen-enriched air. Preferably the proportion of oxygen in the oxygen-enriched air is at least 50% by volume, and most preferably it is at lest 90% by volume.
The metal and coke are preferably charged to the furnace in alternate layers. If desired, additional constituents may be included in the charge, for example a slagging agent such as limestone or other form of calcium carbonate. An alloying substance such as silicon, for example in the form of ferrosilicon may also be included.
A cupola may be built to custom for operation by the method according to the invention. Alternatively, a furnace originally adapted to be operated by another method may be converted to operate the method according to the invention. An air blast cupola may be converted by locating air-fuel burners in the tuyeres themselves and using the air source to supply the burners rather than the tuyeres and, if not already provided, by fitting lances for the injection of oxygen.
BRIEF DESCRIPTION OF THE DRAWINGS
The method according to the invention will now be described by way of example with reference to the accompanying drawings, in which:
FIG. 1 is a schematic side elevation, partly in section, of a cupola; and
FIG. 2 is a schematic plan view of the cupola shown in FIG. 1.
The drawings are not to scale.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings, a cupola 2 has a vertical shaft 4 extending between a floor 10 and an arrester 6. The shaft 4 is defined by a cylindrical wall 12 formed of refractory brick with an inner refractory lining 14 typically of a silica-based refractory. Near the top of the cupola 2 there is an outlet 16 for hot gases. The furnace 2 has a charge door B formed in its wall. Below the level of the charge door 8 a plurality of air inlets q is formed through the wall 12 and each inlet 9 communicates with a fan 11 which in operation draws in air from outside the furnace.
The cupola 2 is provided with three air-oil burners 18 which, in use, fire into the cupola 2 through respective ports 20 in the wall 12. As shown in FIG. 2, the burners 18 are equally spaced about the circumference of the wall 12. In addition, the ports 20 are at the same level as one another, each having an axis extending downwardly from the outer surface to the inner surface of the wall 12 at an angle of about 10° to the horizontal though this angle is not critical. Each burner 18 is provided with an inlet 17 for oxygen-enriched air and an inlet 19 for hydrocarbon fuel.
The wall 12 has formed therethrough three circumferentially disposed apertures 22 at a level beneath the ports 20. Each aperture comprises an outer bore 21 of relatively wide diameter and an inner counterbore 23 of relatively narrow diameter. Each aperture 22 receives the distal end of a lance 24 in the bore 21. Each lance 24 has a relatively narrow passage 25 formed therethrough of the same diameter as the counterbore 23 of its respective aperture 22. Each lance 24 is positioned such that its passage 25 is contiguous to and coaxial with the counterbore 23 of the associated aperture 22. As shown in FIG. 2, the lances 24 are equally spaced around the circumference of the wall 12. The axes of the apertures 22 and the lances 24 are preferably horizontally disposed.
The cupola is provided with a slag hole 26 in the wall 12 of the shaft 4 through which, in operation, slag formed during the metal melting process can be run off. Beneath the slag hole 26 is a tap hole 28 formed through the wall 12 of the shaft 4 of the cupola 2. In operation, the molten metal can from time to time be tapped off through the tap hole 28. Other arrangements for tapping slag and molten metal can alternatively be provided. For example, slag and metal can both be continuously tapped via a conventional front slagging box (not shown).
In order to operate the cupola shown in FIGS. 1 and 2, the lances 24 are connected to a source (not shown) of commercially pure oxygen and the burners 18 are connected to a source (not shown) of oil and a source (not shown) of air. A bed 30 of silica sand is established on the floor 10 of the shaft 4 up to the level of the bottom of the tap hole 28. A bed 32 of coke is then established up to the level of the bottom of the ports 20 by introducing coke into the cupola 2 through the door 8. The bed 32 is then ignited by means of a gas poker (not shown) that can be introduced into the bed through a bottom door (not shown) in the wall 12 of the cupola 2. This door may be left open to enable a flow of air to be induced into the coke bed so as to support combustion. Alternatively, such air flow can be induced through the slag hole 26. The coke is then consolidated using a rabble (not shown) and the bed 32 topped up with fresh coke to the level of the bottom of the ports 20. Next, operation of the burners 18 is started. The burners are capable of being operated with up to 100% excess air, that is to say with air at a rate up to 100% in excess of the stoichiometrtc rate required for complete combustion of the fuel. The walls 12 of the shaft 4 of the cupola 2 are pre-heated by hot combustion products from the burners 18 for a period of 30 minutes. During this period no excess air is supplied to the burners 18. Five minutes before the end of this period, injection of pure oxygen into the coke bed 32 via the lances 24 and the counterbores 23 of the apertures 22 is commenced. (At the same time the air flow to the coke bed is cut off by closing the bottom door or the slag hole 26, as the case may be.) The injection of oxygen into the coke bed 32 accelerates the rate of combustion of coke and causes its temperature to rise rapidly. During the final five minutes of pre-heating the coke bed is made up again to the level of the ports 20. At the end of pre-heating, the cupola 2 is loaded through the door 8 with a charge comprising iron and steel, ferrosilicon, coke and limestone or other slagging agent. This charging is performed such that layers 34 of ferrous metal alternate with coke layers 36. The limestone is included in the layers 34 and the ferrosilicon is included in the layers 36. The top layer of the charge is arranged to be below the level of the air inlet 9.
In operation of the cupola 2 to melt the ferrous metal, the combustion air to the burners 18 is preferably enriched in oxygen. In addition, the burners 18 are operated with up to 100% excess air. The flame from each burner typically extends into the shaft of the furnace. A hot gas mixture including oxygen leaves each flame and ascends the shaft 4, thereby heating the ferrous metal by convection. In addition, the oxygen in the hot gas mixture reacts with coke to generate additional heat. The resulting hot gas mixture emanating from the top of the charge is diluted with air by operation of the fan 11. Typically, secondary flames are thereby created, and these flames help to oxidize combustible gases in the hot gas mixture. The resulting gas, typically containing minimal visible fume, is vented from the cupola 2 through the outlet 16. The molten metal in the lowermost of the layers 34 begins to melt by virtue of being heated by the hot gas mixture leaving the burners. A region of molten metal is thus created at the level of the burners. The limestone reacts with ash in the coke to form a slag. The molten ferrous metal falls under gravity into the coke bed 32 and trickles therethrough. Typically, the molten ferrous metal is in a superheated state as it encounters the bed 32. During its residence in the coke bed 32 the molten ferrous metal is further superheated by radiant heat emanating from the coke which is maintained at a suitably high temperature by the continued injection of oxygen at high velocity into the bed 32. A small amount of the coke is dissolved in the molten ferrous metal, thereby increasing its carbon content and hence improving its metallurgical properties. In addition, the silicon also dissolves in the ferrous metal If desired, the carbon level of the ferrous metal in be further enhanced by direct introduction of graphite into the molten metal through a port (not shown) specially adapted for this purpose. If the temperature of the molten ferrous metal is suffiently high, there will also be reduction of silica at the interface between the coke and molten slag with the result that additional silicon is incorporated into the molten ferrous metal.
The molten metal and the slag may be periodically run off through the respective holes 28 and 26. It can therefore be appreciated that the charge will gradually sink downwards through the shaft 4. In addition, the reaction between the oxygen and the coke in the bed 32 will cause this bed gradually to be eroded. However, the height of the bed is restored each time melting of a layer 34 of ferrous metal has been completed and the resulting molten metal has passed into the coke bed 32 since the next coke layer 36 then merges with the bed 32. In order to enable molten metal to be produced throughout a chosen period of time, fresh charge is periodically loaded into the shaft 4 through the door 8.
It has been typically observed that tap temperatures in the order of 1500° C. have been maintained over a period of time, while being able to operate the cupola 2 with a maximum rate of production of molten ferrous metal some four times in excess of a minimum rate. Moreover, carbon monoxide levels of less than 1% by volume have been detected on the outlet 16, while no Smoke emissions have been observed. Other advantages that have been obtained include a reduced requirement for ferrosilicon and graphite additions.
The method according to the invention is further illustrated by the following examples:
EXAMPLE 1
A cupola was converted to the form shown in FIGS. 1 and 2. The cupola was of a capacity such that it was able to produce 4 tons of ferrous metal per hour. Its shaft 4 had an internal diameter of 27" and an external diameter of 48". The mouth of the tap hole 28 was located 8" above the floor 10 and the slag hole 26 a further 11" thereabove. The vertical distance from the floor 10 to the level of the bottom of each port 20 was approximately 48". Accordingly, the sand bed 30 had a depth of 8" and the coke bed 32 when first made up a depth of about 40". The counterbores 23 of the apertures 22 were formed at a level 15" below the top of the coke bed (when first made up). Each counterbore 23 had a diameter of 7 mm. The lances 24 were each formed of stainless steel and each had an internal bore of 7 mm.
The procedure described above with reference to FIGS. 1 and 2 was used for preparing the cupola 2 for charging. During the pre-heating period light fuel oil was supplied to the burners 18 at a total rate of 36 gallons per hour and air at approximately the stoichiometrtc rate required for complete combustion of the oil. Five minutes before the end of the pre-heating period the injection of oxygen at sonic velocity into the coke bed 32 was initiated but no oxygen was used to enrich the combustion air to the burners. The rate of supplying oxygen to the lances 24 was 1650 cubic feet per hour and the supply pressure was 150 psig. Five minutes after initiation of the oxygen injection, charging of the cupola was commenced. The charge consisted of 305 kg of ferrous metal pieces comprising 30 kg of pig iron, 125 kg of iron scrap, 120 kg of iron returned from the foundry and 30 kg of baled steel scrap; 2.75 kg of silicon added as ferrosilicon containing 70% Sl; 6.0 kg of limestone and 18.0 kg of coke. There were thus 5.9 parts by weight of coke for each 100 parts by weight of ferrous metal (excluding the ferrous metal added in the form of ferrosilicon). This charge was loaded in the form of a lower metal layer including the ferrosilicon and an upper coke layer including limestone.
The cupola was operated for a period of 51/2 hours from the start of charging. From time to time molten ferrous metal was tapped off into a ladle and its temperature and composition measured. Similarly, from time to time fresh charge was introduced into the cupola to replenish the original charge. During operation, the oxygen flow rate to the lances was varied as was the rate of supplying air and oil to the burners. In each case, the flow regime was selected from two alternatives. For the oxygen supply to the lances 24, one alternative was as stated above (1650 cubic feet per hour at 150 psig) and the other alternative was 1100 cubic feet per hour at 100 psig. For the operation of the oil burners 18, one flow regime was 36 gallons per hour of oil and 1750 cubic feet per minute of air and the other alternative was 30 gallons per hour of oil and 1400 cubic feet per minute of air.
After operation for just over one hour, the silicon in the fresh charge was reduced to 1.5 kg. After 4 hrs 6 mins of operation no more charging of the cupola was performed.
The results obtained for some the ladles of ferrous metal taken during a period starting after 52 mins had elapsed from the start of charging and ending after 4 hrs 6 mins are set out in the Table below. The Table also includes the air, oil and oxygen flow rates that were being employed at the time each tapping was made.
TABLE______________________________________ T (°C.) O2 Oil AirTime CE (%) C (%) Si (%) (ladle) (cfh) (gph) (cfm)______________________________________0.52 4.30 NM 2.9 1480 1100 30 14001.02 4.21 3.5 2.9 1460 1100 30 14001.25 3.92 3.28 2.68 1450 1650 30 14001.37 3.81 3.24 2.40 1440 1650 30 14003.30 4.12 3.55 2.45 1450 1110 36 17503.54 4.19 3.60 2.54 1450 1110 36 17504.06 4.18 3.60 2.48 NM 1110 36 1750______________________________________ NM = Not Measured CE = % C + 0.25 × % Si + 0.5 × % P
It was found that high tap out temperatures were obtained throughout the melting period, that less ferrosilicon was required to give a given silicon level in the tapped-out metal, and that high carbon values were obtained with graphite addition only during the first 20 rains of the melting period. Moreover, the graphite injection port was maintained operational throughout the whole melting period without becoming blocked. It was observed that the emissions of fume from the cupola were not visible for most of the day and were considered to be at least as good as those obtained by operation of cupolas heated entirely by burners without any coke being present. Furthermore, the lances 24, which did not have water cooling, were undamaged at the end of the melting period. Some wear to the refractory lining did occur particularly in the vicinity of the counterbore 23 of each aperture 22. The wear was nevertheless tolerable and could easily be repaired before the cupola was used again. It can therefore be seen that to the invention makes it possible to achieve considerable operating advantages over previously practised method.
EXAMPLE 2
The procedure of Example 1 was generally followed but this time the air supplied to the burners was enriched in oxygen.
The charge had the following composition:
______________________________________Pig Iron 35 KgReturns 110 KgCylinder Scrap 130 KgSteel 30 Kg 305 KgCoke 18 KgSi 2.25 Kg as 70% FeSi______________________________________
Oxygen was supplied to the burners during melting at an approximate rate of 400 ft 3 /hr. The rate of injection of oxygen into the coke bed was varied between 1,000 ft 3 /hr and 1200 ft 3 /hr. The aim was to produce molten metal in the ladle having a temperature of at least 1400° C.
The following results were achieved.
______________________________________Metal Composition Oil AirTime gph cfm C % Si % T ° C. Ladle______________________________________8.00 30 1575 3.50 2.40 14408.30 30 1575 3.49 2.47 14309.00 30 1750 3.40 2.41 14109.25 30 1750 3.49 2.31 14309.40 24 70010.00 24 700 3.48 2.35 1410 1st ladle10.05 18 875 1440 2nd ladle10.20 27 157511.05 30 1750 3.41 2.80 146011.15 30 1750 3.43 2.29 142511.40 30 1750 3.50 2.24 142011.45 27 1400 3.38 2.67 141512.05 24 1400 141512.29 27 1050 3.59 2.21______________________________________
In addition, the CO level was measured at 0.3% by volume at 1 m below the outlet 16. No smoke was observed in the gas passing out of the cupola.
The variations in the rate of supply of oil and air to the burners in Examples 1 and 2 enabled large variations to be made in the rate of melting the ferrous metal. For example, the average metal melting rate between 11:05 and 11:45 hrs was 3.66 tons per hour, while between 9:40 and 10:05 hrs it was sufficiently low that there was no need to tap any molten metal from the furnace during this period. The rate of injection of oxygen into the coke bed could be varied to ensure that an adequate tap temperature was obtained.
Although the invention has been described with reference to specific example, it will be appreciated by those skilled in the art that the invention may be embodied in any other form.
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A hot coke bed is established at the bottom of a vertical shaft furnace, e.g. an iron melting cupola. The cupola is then charged with alternate layers of ferrous metal and coke material, respectively. Burners burn hydrocarbon fuel in the presence of a stoichiometric excess of oxygen-enriched air and thus form a hot gas mixture including oxygen. The hot gas mixture passes upwards through the shaft of the cupola thereby providing sufficient heat to melt the ferrous metal. Molten ferrous metal flows downwards under gravity into and through the coke bed and may be removed through a tap hole. At least one jet of oxygen is injected into the hot coke bed so as to maintain it at a temperature sufficient to superheat the molten metal. Preferably a fan is operated to dilute with air the combustion gases above the level of the charge in the shaft and thereby create secondary flames. No air blast is supplied to the cupola. A significant degree of superheating can be achieved while keeping down the proportion of environmentally undesirable components (i.e. particulates and carbon monoxide) in the gas exhausted from the cupola.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority or the benefit under 35 U.S.C. 119 of U.S. provisional application no. 60/911,308 filed Apr. 12, 2007, the contents of which are fully incorporated herein by reference.
CROSS-REFERENCE TO DEPOSITED MATERIALS
[0002] The present application refers to deposited microorganisms. The contents of the deposited microorganisms are fully incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates to wastewater treatment in general and to methods of controlling odors, reducing chemical oxygen demand (COD), and degrading compounds contained in wastewater in particular.
[0005] 2. Description of Related Art
[0006] The main chemical compounds in wastewater are nitrogen, phosphorus, fats, oils and grease.
[0007] Objectionable odors are caused by a variety of substances typically present in wastewater. These include sulfur and several sulfur containing compounds including hydro sulfuric acid, sulfuric acid, mercaptans (R—SH) including especially methyl and dimethyl mercaptans, and dimethyl disulfide (DMDS); numerous organic acids including propionic acid, acetic acid, butyric acid, isovaleric acid; ammonia; urea; and various terpenes including carene, pinene, limonene. These substances most frequently lead to noticeable odors under anaerobic conditions.
[0008] Octel Gamlen has sold a wastewater treatment composition comprising a strain of each of Mucor hiemalis, Trichoderma atroviride, Paecilomyces variottii, and Aspergillus niger.
[0009] U.S. Pat. No. 7,160,458 discloses a method for purifying process water from a kerosene desulfurization plant comprising adding bacterial species.
[0010] It is an object of the invention to provide an improved wastewater treatment composition.
SUMMARY OF THE INVENTION
[0011] The present invention is directed to wastewater treatment compositions comprising a strain of Mucor racemosus, Paecilomyces lilacinus, Aspergillus ustus or Trichoderma inhamatum (anamorph is Hypocrea gelatinosa ).
[0012] In another embodiment, the present invention relates to methods for the treatment of wastewater comprising adding to the wastewater a strain of Mucor racemosus, Paecilomyces lilacinus, Aspergillus ustus or Trichoderma inhamatum (anamorph is Hypocrea gelatinosa ).
[0013] The present invention also relates to a process of degrading compounds contained in a wastewater and biologically pure cultures of one or more microbial strains.
DETAILED DESCRIPTION OF THE INVENTION
Wastewater Treatment Compositions
[0014] The present invention is directed to wastewater treatment compositions comprising a strain of Mucor racemosus, Paecilomyces lilacinus, Aspergillus ustus or Trichoderma inhamatum and to methods for the treatment of wastewater comprising adding to the wastewater a strain of Mucor racemosus, Paecilomyces lilacinus, Aspergillus ustus or Trichoderma inhamatum.
[0015] Strains of Mucor racemosus, Paecilomyces lilacinus, Aspergillus ustus and Trichoderma inhamatum strains were deposited for patent purposes under the terms of the Budapest Treaty at the NRRL USDA-ARS Patent Culture Collection, 1815 N. University Street, Peoria, Ill. 61604. The deposits were made on Mar. 20, 2007 by Novozymes Biologicals Inc. and were accorded deposit numbers:
Mucor recemosus NRRL 50031 Paecilomyces lilacinus NRRL 50032 Aspergillus ustus NRRL 50033 Trichoderma inhamatum NRRL 50034
[0020] In a preferred embodiment, the wastewater composition comprises a strain of Mucor racemosus.
[0021] In another preferred embodiment, the wastewater composition comprises a strain of Paecilomyces lilacinus.
[0022] In another preferred embodiment, the wastewater composition comprises a strain of Aspergillus ustus.
[0023] In another preferred embodiment, the wastewater composition comprises a strain of Trichoderma inhamatum.
[0024] In another preferred embodiment, the wastewater composition comprises a strain of Mucor racemosus and Paecilomyces lilacinus.
[0025] In another preferred embodiment, the wastewater composition comprises a strain of Mucor racemosus and Aspergillus ustus.
[0026] In another preferred embodiment, the wastewater composition comprises a strain of Mucor racemosus and Trichoderma inhamatum.
[0027] In another preferred embodiment, the wastewater composition comprises a strain of Paecilomyces lilacinus and Aspergillus ustus.
[0028] In another preferred embodiment, the wastewater composition comprises a strain of Paecilomyces lilacinus and Trichoderma inhamatum.
[0029] In another preferred embodiment, the wastewater composition comprises a strain of Aspergillus ustus and Trichoderma inhamatum.
[0030] In another preferred embodiment, the wastewater composition comprises a strain of Mucor racemosus, Paecilomyces lilacinus, and Aspergillus ustus.
[0031] In another preferred embodiment, the wastewater composition comprises a strain of Mucor racemosus, Paecilomyces lilacinus, and Trichoderma inhamatum.
[0032] In another preferred embodiment, the wastewater composition comprises a strain of Paecilomyces lilacinus, Aspergillus ustus and Trichoderma inhamatum.
[0033] In another preferred embodiment, the wastewater composition comprises a strain of Mucor racemosus, Paecilomyces lilacinus, Aspergillus ustus and Trichoderma inhamatum.
[0034] The strains may be wild-type or mutant strains.
[0035] In a preferred embodiment, the composition comprises the microorganism at a concentration of 1×10 2 to 1×10 9 colony forming units (CFU)/mL, preferably 1×10 4 to 1×10 9 colony forming units (CFU)/mL. When the composition contains more than one microorganism, each microorganism is present at a concentration of 1×10 4 to 0.5×10 9 colony forming units (CFU)/mL.
[0036] In another preferred embodiment, the composition further comprises nutrients for the microorganism(s). For example, the nutrients may be an inorganic phosphorus compound, particularly a soluble phosphate or an ortho phosphate, preferably, phosphoric acid, mono, di, or tri sodium phosphate, or diammonium phosphate. In addition, the nutrients may be ammonia (NH 3 ) or an ammonium (NH 4 + ) salt, preferably anhydrous ammonia, ammonia-water solutions, ammonium nitrate, or diammonium phosphate. The nutrients may also be trace metals, preferably aluminum, antimony, barium, boron, calcium, cobalt, copper, iron, lead, magnesium, manganese, molybdenum, nickel, strontium, titanium, tin, zinc, and/or zirconium.
[0037] In another preferred embodiment, the composition further comprises a sugar selected from the group consisting of arabinan, arabinose, cellulose, fructose, galactan, galactose, glucan, glucose, mannan, mannose, sucrose, xylan, and xylose, or wood fiber, wood pulp, or other pulping byproducts. Preferably, the composition comprises the sugar at a concentration between 100 and 400 mg/L, when the sugar is a monosaccharide and a concentration between 8,000 and 15,000 mg/L, when the sugar is a polysaccharide.
[0038] The wastewater to be subjected to the process of this invention may contain sufficient nutrients, e.g., nitrogen and phosphorus, for culturing without the need for any additional source of nitrogen or phosphorus being added. However, in the event the wastewater is deficient in these components, nutrients can be added to the wastewater. For example, phosphorous can be supplemented, if necessary, by addition of a phosphorous source such an inorganic phosphorus compound, particularly a soluble phosphate or an orthophosphate, preferably, phosphoric acid, mono, di, or tri sodium phosphate, or diammonium phosphate, to achieve a phosphorus level in the wastewater of about 1 ppm or more per 100 BOD 5 . Similarly, a nitrogen source, such as ammonia (NH 3 ), urea, or an ammonium salt, preferably anhydrous ammonia, ammonia-water solutions, ammonium nitrate, or diammonium phosphate, can be added to achieve an available nitrogen content of at least about 10 ppm or more per 100 BOD 5 .
[0039] In another embodiment, the nutrients comprise trace metals, preferably aluminum, antimony, barium, boron, calcium, cobalt, copper, iron, lead, magnesium, manganese, molybdenum, tin, or zinc.
Methods for Treating Wastewater
[0040] The present invention also relates to methods for treating wastewater with a wastewater treatment composition of the present invention.
[0041] The wastewater treatment process of the present invention may reduce odor, as well as degrade compounds contained in wastewater such as butanoic acid, 2-methylphenol, heptanoic acid, nonanoic acid, 5-bromothiophene-2-carboxamide, isoxazolidine and 2-methyl-1-nitropropane.
[0042] Other odor-causing compounds which may be degraded by a wastewater treatment composition of the present invention are hydrogen sulfide, trimethylamine, methanethiol, butanoic acid, 3-methylbutanoic acid, pentanoic acid, 4-methylphenol, dimethylsulfide, dimethyldisulfide, propanoic acid, acetic acid, 2-methylpropanoic acid, indole, and 3-methyl-1H-indole.
[0043] The wastewater treatment compounds may also reduce chemical oxygen demand (COD) of wastewater.
[0044] The strains used in the present invention can be cultured in wastewater from, e.g., a pulp or paper mill either using a batch process, a semi-continuous process or a continuous process, and such is cultured for a time sufficient to degrade compounds present in the wastewater and remove them or break them down into components capable of being degraded by other organisms normally found in biological wastewater treatment systems.
[0045] The microbial strains of this invention can be employed in ion exchange resin treatment systems, in trickling filter systems, in carbon adsorption systems, in activated sludge treatment systems, in outdoor lagoons or pools, etc.
[0046] Basically, all that is necessary is for the microorganism(s) to be placed in a situation of contact with the wastewater effluent from a pulp or paper mill. In order to degrade the material present in the wastewater, the wastewater is treated with the organism(s) at a temperature between 15° C. and 45° C., preferably between 20° C. and 45° C., more preferably between 18° C. and 37° C., and most preferably between 30° C. and 35° C. Desirably, the pH is maintained in a range of 4 and 10, preferably 4.5 to 8.5. The pH can be controlled by monitoring of system and an addition of appropriate pH adjusting materials to achieve this pH range.
[0047] In general, the treatment is conducted for a sufficient time to achieve the reduction in odor or degradation of compounds desired and, in general, about 24 hours to about 8 weeks or longer, although this will depend upon the temperature of culturing, the liquor concentration and volume to be treated and other factors. In a preferred embodiment, the wastewater is treated with the microorganism(s) for between 2 hours and 14 days, preferably between 2 hours and 5 days.
[0048] The treatment can be conducted under aerobic or anaerobic conditions. When aerobic conditions are used, the treatment is conducted at a dissolved oxygen concentration of between 0.5 and 7.0 milligrams per liter. These conditions can be simply achieved in any manner conventional in the art and appropriate to the treatment system design being employed. For example, air can be bubbled into the system, the system can be agitated, a trickling system can be employed, etc. In an aerobic process, the treatment is done at a REDOX potential between −200 mV and 200 mV, preferably between 0 mV and 200 mV. When anaerobic conditions are used, the treatment is done at a REDOX potential between −550 mV and −200 mV.
[0049] Normally aerobic measures are undertaken to reduce colorants and biochemical oxygen demand (BOD) in wastewater. Aerobic technologies include trickling filter, activated sludge, rotating biological contactors, oxidation ditch, sequencing batch reactor and even controlled wetlands.
[0050] An anaerobic or anaerobic-friendly type of technology can also be used for treating the wastewater. Anaerobic technologies currently available are high-rate systems including continuous-flow stirred tank reactors, contact reactors, upflow sludge blankets, anaerobic filters (upflow and downflow), expanded or fluidized bed and two-stage systems that separate the acid-forming and the methane-forming phases of the anaerobic process.
[0051] Aerobic and anaerobic processes can be combined into a treatment system. Anaerobic treatment may be used for removing organic matter in high concentration streams, and aerobic treatment may be used on lower concentration streams or as a polishing step to further remove residual organic matter and nutrients from wastewater.
[0052] In a preferred embodiment, the wastewater treatment comprises 1-5 cycles, preferably 1 cycle or two cycles, of treatment with the microorganism(s). Preferably, each cycle comprises alternating aerobic and anaerobic treatments. More preferably, the first cycle is conducted under aerobic conditions. In a preferred embodiment, the cycles are conducted in a sequencing batch reactor. In another preferred embodiment, the process further comprises adding an alkali between cycles.
[0053] Preferably, the wastewater is a pulp and paper mill wastewater such as strong or concentrated pulp mill wastewater, weak black liquor, acid stage bleach plant filtrate, or alkaline stage bleach plant filtrate. Other types of wastewaters that might be treated include cleaning and laundry wastewaters, food processing wastewaters, and industrial process waters such as vegetable oil extractions or waste materials having fiber-containing by-products.
[0054] The process also can be used to treat waste from chemical color separation processes commonly used in wastewater treatment, including gravity clarifiers, gas flotation units, or in filtration processes such as membrane processes.
[0055] In another preferred embodiment, the ratio of solids to liquid waste is between 1:50 to 10:1 preferably 1:10 to 5:1.
[0056] In another preferred embodiment, the wastewater passes through wood fibers at anaerobic conditions, particularly in a packed biological reactor or column, an artificial wetland, or an anaerobic sequencing batch reactor (AnSR). Alternatively, the wastewater passes through a mass comprising waste wood fiber from a pulp & paper process, lime, and fly ash. Preferably, the wastewater passes through wood fiber together with cellulosic fiber, plastic, powdered or ceramic media. The rate of the wastewater is preferably 0.05-1 liter wastewater/day per kilogram of wet wood fiber mass.
[0057] In a most preferred embodiment, wood fiber is used as a biological medium at anaerobic conditions, comprising one or more of the following steps of: (a) sequencing batch reactors, (b) a facultative lagoon or a stabilization basin, (c) an activated sludge system, (d) coagulation and flocculation followed by settling, and (e) filtration.
[0058] The wastewater may be treated with the microorganism(s) in the presence of an electron acceptor, particularly chloroethanes, chloroform, chlorolignins, chloromethanes, chlorophenols, humates, lignin, quinines, or sulfonated lignins.
[0059] The microorganisms of the present invention can be employed alone or in combination with conventionally means for treating wastewater, e.g., chemical (e.g., alum, ferric, lime or polyelectrolytes), biological (e.g., white rot fungus), and physical processes (e.g., ultrafiltration, ion exchange and carbon absorption).
[0060] In the above manner, organic compounds which are present in such wastewater streams, can be advantageously treated to provide treated wastewater suitable for discharge after any additional conventional processing such as settling, chlorination, etc. into rivers and streams.
Formulations
[0061] The individual fungal strains or the blends noted above can be provided on the original media material used to culture the strains, or they can be removed from the original growth substrate by various physical mechanisms and reblended on a separate substrate or addition to achieve the desired concentration for a given application. For example, fungal spores or other discreet propagules might be removed by sonication, washing, or substrate breakdown, followed by a concentration strep such as sieving, centrifugation, or other size-exclusion techniques familiar to those skilled in the art. Such separated and/or concentrated, propagules may be either blended and applied directly, or placed on a separate substrate for application. In this way, undesirable physical properties of the original growth substrate, such as lack of solubility, or poor liquid pumping characteristics, can be improved and the product may be more readily, easily, or economically applied. In a preferred embodiment, fungal spores of the Mucor racemosus strain can be removed from the growth media by sonication, concentrated by sieving and centrifugation, then combined with one or more of the other strains, to provide a liquid concentrate suspension that may be automatically delivered by pumping to the desired wastewater reaction area. Various suspension agents and/or surfactants could be added to aid pumping or reduce settling of the concentrated fungal propagule blend.
Cultures
[0062] The present invention also relates to a biologically pure culture of a strain of Mucor racemosus, Paecilomyces lilacinus, Aspergillus ustus or Trichoderma inhamatum.
[0063] The following examples are given as exemplary of the invention but without intending to limit the same. Unless otherwise indicated herein, all parts, percents, ratios and the like are by weight.
EXAMPLES
Example 1
Materials and Methods:
Media and Substrates:
[0064] Pulp and Paper Mill waste streams: The wastewater used in the laboratory studies were obtained from various pulp and paper mills in the U.S. and France. The waste stream material was brought to pH 7.8 by the addition of a nutrient (N&P) amended media based on SSC (see the table below).
[0000]
SAMPLE A
SAMPLE B
packaged in 0.5 kg water-soluble sachet
packaged boxes of bulk powder
2 fungal strains:
3 fungal strains:
Mucor hiemalis
Mucor hiemalis
Trichoderma atroviride
Aspergillus niger
Paecilomyces variottii
Carrier of fungi: maltodextrine
Carrier of fungi: maltodextrine
Additional medium (excipient):
Additional medium (excipient):
lithothamne
wheat bran
Dosage rate: 2 g of A per kg
Dosage rate: 2 g of B per kg
of COD
of COD
Total count: 1 × 10 4 propagules
Total count: 1 × 10 4 propagules
per gram
per gram
[0065] Industrial Waste Stream: The waste stream was used as received in this study except where noted. The waste stream comes from a site that produces architectural and functional coatings and plastics additives (impact modifiers and processing aids) and has regular problems with latex. The pH of the waste stream was found to be 8.9 and it was also found to contain a number of protozoa. The soluble COD was 477±8 mg/L. The waste stream was reported to have an average influent COD of 1400 mg/L with an effluent COD of 400 mg/L. The waste stream as received had a low COD which was not due to COD loss during transportation, but instead was due to the low COD of the waste stream when collected. Microscopic examination of the waste revealed protozoa present in the sample.
[0066] Laundry Waste Stream: The laundry waste stream was used as received and was from a denim fabric factory with 0.2% Aquazyme Ultras 1200 L. The initial pH of this waste stream was 5.6.
[0067] Waste stream preparation: Sterilization of the waste stream where noted was accomplished by filtration. The waste stream was first centrifuged at 12,000× G for 60 minutes. This material was then passed in 100-150 mL aliquots over Whatman 934-AH filters, followed by filtration through Whatman GF/F filters, followed by filtration though a Gelman Sciences 0.45 micro-m Metricel membrane filter. Final sterilization was accomplished by filtering though a pre-sterilized Nalgene filtration unit equipped with a 0.22 micro-m membrane filter.
[0068] Nutrent Additions: The components of the nutrient media are listed in the table below. These were prepared as a ten fold concentrate and added to the waste stream to give the final concentrations listed in the following table.
[0000]
Nutrient Media
Component
(g/L)
K 2 HPO 4
2.0
KH 2 PO 4
3.06
NH 4 Cl
0.8
MgSO 4 •7H 2 O
0.2
CaCl 2 •H 2 O
0.01
ZnSO 4
0.000140
MnSO 4 •H 2 O
0.000084
NaMoO 4 •2H 2 O
0.000024
FeSO 4 •7H 2 O
0.000028
CuSO 4 •5H 2 O
0.000025
CoCl 2 •6H 2 O
0.000024
Adjust pH to 7.5 with KOH
[0069] Culture Conditions: Incubations of the pulp mill waste were carried out in sterile 150 mL serum vials containing 10 mL of filter-sterilized waste. The tops of the vials were covered with “steam paper” to allow for oxygen transfer. Incubations were carried out at 30° C. The reactions with the Laundry waste and the Industrial waste were carried out in 250 mL shake flask with 50 or 100 mL of filter-sterilized waste.
[0070] Inoculum Preparation: For experiments involving the formulated Sample A, Sample B, or NZB—C sample product, to 0.1-1 grams of product was added sterile phosphate buffer to give a final concentration of 0.11 grams product/ml of buffer. This was then agitated on a wrist action shaker for 30 minutes. Except were noted, the products were added to a final concentration of 1 gram/300 mL waste stream.
[0071] Dry product production: The dry products used in this study had the characteristics listed in table below. The sample products were made by first growing the isolated fungus in 110 gram lots on a medium consisting of 50 grams of rice hulls, 50 grams bran and 10 grams starch. To this material was added 100 mL of 50% potato dextrose agar (PDA) for moisture. The material was autoclaved and inoculated with fungal mycelia and spores from pre-grown PDA plates. With the exception of P. chrysosponum, all incubations were initially carried out at 25° C. for 7-10 days in a humidified growth chamber in 190×100 mm glass dishes. P. chrysospoium was initially cultured at 39° C. At the end of the initial incubation, the cultures were removed from the humidified growth chamber and allow to air dry at room temperature for an additional 5-7 days. Final drying was accomplished under reduced pressure in a lyophilizer.
[0072] The raw material was then subjected to hydration and serial dilution to determine the number of propagules/gram using standard laboratory procedures. With the exception of P. chrysosporium, all fungi had yields of 1.0×10 9 to 1.0×10 7 propagules/gram. P. chrysoporium yielded 4.0×10 3 propagules/gram.
[0000]
Concentration (propagules/gram) of
Organisms in NZB-C Dry Formulated sample
SINGLE ORGANISMS
NZB-C
Mucor racemosus
2.0 × 10 5 (range 0.1 to 10 × 10 5 )
Aspergillus ustus
2.9 × 10 5 (range 0.1 to 10 × 10 5 )
Paecilomyces lilacinus
1.3 × 10 5 (range 0.1 to 10 × 10 5 )
Trichoderma inhamatum
3.0 × 10 5 (range 0.1 to 10 × 10 5 )
Total
9.2 × 10 5 (range 0.4 to 40 × 10 5 )
[0073] COD Assay. At the indicated time, soluble COD was determined by Method 5220C (Standard Methods). All material was centrifuged at 13,000× G for 20 minutes to remove particulates. All data represents soluble COD and unless noted the mean of three determinations ± one standard deviation unit.
Results:
[0074] Experiments with Pure Cultures: In order to assess the role of individual fungi, pure and mixed cultures of the fungi were incubated with waste from a pulp and paper mill “strong pond.” The species and concentration of each fungus are listed in the table below. It is important to note that for the fungal consortia, the competitor fungi were added in greater concentrations.
[0000]
ORGANISMS AND THEIR CONCENTRATIONS USED FOR “PURE”
CULTURE STUDIES
Consortia
Consortia
Single Organisms
Propagule/mL
Name
Composition
Propagule/mL
Mucor racemosus
1.8 × 10 4
Sample A
Hypocrea gelatinosa
2.8 × 10 5
Trichoderma
1.4 × 10 5
atroviride
Phenerochaete
1.0 × 10 4
Mucor hiemalis
1.8 × 10 7
chrysosporium
Aspergillus ustus
3.2 × 10 4
Sample B
Paecilomyces lilacinus
1.4 × 10 5
Mucor hiemalis
8.0 × 10 5
Aspergillus sp.
5.4 × 10 7
Paecilomyces
2.7 × 10 4
variottii
Aspergillus niger
3.1 × 10 4
[0075] The degradation of the waste from the primary clarifier from a pulp and paper mill is shown in Table 1. The NZB—C sample demonstrated better removal of COD than the competitor samples.
[0000]
TABLE 1
Laboratory pulp and paper mill wastewater assessment;
9 Days post-treatment
Total COD
% COD Reduction
Treatment
(mg/L)
vs. Control
Control
310
0
Sample A
285
5
Sample B
270
13
NZB-C
225
28
Example 2
[0076] For this experiment, a total of 60 150 ml serum vials were used and were capped with butylated rubber stoppers. Each sample was done in triplicate. Vials were then sterilized by autoclave @ 121° C. for 30 min.
[0077] The wastewater was obtained from France. Due to the large amount of particulate matter suspended in the samples, the middle and outlet wastewaters were filtered. Filtering was accomplished by using successively smaller filter sizes until the final filter size was 0.2 micro-m. A Whatman 934-AH filter (1.5 micro-m) was used first to remove large particulate matter in the samples. Then a Fisherbrand 0.45 micro-m Membrane MCE filter (catalog #09-719-2E) and Fisherbrand 0.2 micro-m Membrane MCE filter (catalog #09-719-2B) was used successively to achieve the desired filtration size.
[0078] After filter-sterilizing the middle and outlet waste, a 10 ml volume of wastewater was added to each of the vials under a laminar flow hood. Each vial was supplemented with 1×SSC to aid in fungal growth.
[0079] A 1×SSC nutrient media was prepared as follows:
[0000]
1xSSC Nutrient Media
Component
g/L
K 2 HPO 4
2.0
KH 2 PO 4
3.06
NH 4 Cl
0.8
MgSO 4 •7H 2 O
0.2
CaCl 2 •H 2 O
0.01
ZnSO 4
0.000140
MnSO 4 •H 2 O
0.000084
NaMoO 4 •2H 2 O
0.000024
FeSO 4 •7H 2 O
0.000028
CuSO 4 •5H 2 O
0.000025
CoCl 2 •6H 2 O
0.000024
Adjust pH to 7.5 with KOH
[0080] 1×SSC was added to each of the serum vials. To prepare the inocula from the two dry products (NZB—C, a consortium of strains of Mucor racemosus, Paecilomyces lilacinus, Aspergillus ustus, and Trichoderma inhamatum deposited with NRRL and accorded deposit nos. NRRL 50031, NRRL 50032, NRRL 50033, and NRRL 50034, respectively, and Bi-Chem1005PP, a bacterial product from Novozymes Biologicals) 2.5 g of the product was added to 25 ml of sterile phosphate buffer in a sterile test tube which was then agitated on a wrist action shaker for 15 min. To prepare the inocula from a single fungal strain culture, a plate of each strain was obtained and the mixture of spores and mycelia were scraped from the surface of the plate with a sterile cotton swab. The swab was then submerged in 99 ml 0.3 mM phosphate buffer with 2 mM MgCl 2 , pH 7.4 and vigorously agitated for 15 min to release the spores/mycelia into the buffer. Due to the absorbent properties of the cotton swabs, some volume of the phosphate buffer was lost. The volume was brought back to 10 ml after completion of the swabbing of the plate. In the case of Mucor, two plates of Mucor grown on PDA were cut into 8 sections and were added to 99 ml of phosphate buffer. After agitation, the inocula (dry blend or scrapped from individual culture) was set to stand for 10 min allowing the particulate matter to settle, then 100 microliters of each suspension was taken and used to inoculate the corresponding serum vials containing the wastewater and 1×SSC. Vials were then incubated at 35° C. for 14 days.
[0000] GC/MS With SPME Analysis of Treated Wastewater from Norampac
[0081] In order to detect specific compounds present in the wastewater, GC/MS (Gas chromatography/Mass spectrometry) analysis of the samples was conducted using SPME (Solid-Phase Microextraction). After COD analysis of each sample, the remainder of the sample (roughly 9 ml) was added to a 20 ml head space vial. A Divinylbenzene/Carboxen/Polydimethylsiloxane (DVB/CAR/PDMS) fiber (grey holder) was selected. The samples were heated to 60° C. for 5 minutes while being agitated at 320 rpm for 5 seconds and off for 30 seconds to aid in volatilization. Samples were then extracted for 30 minutes at 60° C. while being agitated as prescribed before. Samples were desorbed for 1 minute at 250° C. The split ratio was set to 1:2 and the septum purge was set at 2.5 ml/min. The samples were analyzed on a SPB-1 sulfur column because it was believed that sulfurous compounds contributing to the odor would be present in the samples. After desorbtion, the column was held at 40° C. for 3 minutes. Then the temperature was raised to 125° C. at a rate of 4° C./min. This was followed by a more rapid ramp of 25° C./min to 200° C. The mass spectrometer was set to scan from 45-1000 amu after a fresh tune.
[0000] GC/MS With SPME Analysis of Treated Wastewater from Norampac Trial 2
[0082] After it was confirmed that compounds can be detected using GC/MS with SPME, a second trial was set up in order to show degradative ability of the unknown compounds in the wastewater. It was hypothesized that if NZB—C was capable of degradation then it would show up in the chromatograms generated from untreated vs. treated samples. For example, a peak with a retention time of 16.382 minutes in an untreated sample should theoretically show up at 16.382 minutes in the treated sample. One could analyze the areas of these peaks and draw a conclusion as to the degradative ability of the fungal product. For this particular study, outlet water from Norampac was filtered through a 0.2 micro-m sterile filter, and then added to each respective 20 ml headspace vile. This was done in triplicate. SSC was added to each vial to bring the SSC concentration to 1×. The following recipe was used for this:
[0000]
SSC Trace Minerals Solution for 10xSSC preparation
Component
mg/L
ZnSO 4 •7H 2 O
140.0
MnSO 4 •H 2 O
84.0
NaMoO 4 •2H 2 O
24.0
FeSO 4 •7H 2 O
28.0
CuSO 4 •5H 2 O
25.0
CoCl 2 •6H 2 O
24.0
DI Water
To 1000
mL
[0083] The media components for ten fold concentrate of SSC are shown in the following table. A white precipitate will form and is normal. The 10× medium is shaken then diluted 10 fold before use into distilled water. The final medium may be autoclaved, but filter sterilization is preferred.
[0000]
10X SSC Nutrient Medium
Component
g/L
K 2 HPO 4
20.0
KH 2 PO 4
30.6
NH 4 Cl
8.0
MgSO 4 •7H 2 O
2.0
CaCl 2 •H 2 O
0.1
FeCl 3
0.05
SSC 3 Trace Minerals Solution found in Table 2
10.0
mL
DI Water
To 1000
mL
Adjust pH to 7.0-7.5 with KOH
[0084] To prepare the treated samples, a 10% solution of NZB—C was prepared using 2.5 g of NZB—C dry product added to 25 ml of sterile phosphate buffer housed in a 50 ml test tube. The tube was the agitated for 15 minutes. Once agitation was complete and the bran was allowed to settle to the bottom, 100 microliters were taken from the liquid layer above the bran. This was used to inoculate each of the respective treated vials. Vials were then capped and incubated at 30° C. for 14 days and then read using the GC/MS protocol prescribed in the previous section entitled, “GC/MS with SPME Analysis of Treated Wastewater from Norampac.”
[0000] GC/MS With SPME Analysis of Treated Wastewater from Norampac Trial 2
[0085] After confirming that certain compounds could be detected using GC/MS headspace analysis with SPME, a comparison of the degradation of the compounds by simple peak comparison between treated and untreated samples was made. Three peaks were isolated for this comparison study. The identity of these peaks was provided by the internal compound library of the Shimadzu GC/MS system used (GCMS-QC2010S). The results are provided in Table 2. It is evident that NZB—C is able to degrade these detected compounds.
[0000]
TABLE 2
Assessment of NZB-C Activity against Waste Compounds in
Pulp and Paper Mill Middle and Outlet Wastewater using
GC/MS with SPME.
Amount
Amount
% NZB-C
Remaining -
Remaining -
Degradation
Control (Peak
NZB-C
Improvement
area units)
(Peak area units)
vs. Control
Compound in Middle
Waste Water
5-bromo-thiophene-2-
3,058
1,721
43.7
carboxamide
Isoxazolidine
9,945
8,860
10.9
Dodecamethyl-
13,064
11,987
8.2
cyclohexasiloxane
Compound in Outlet
Waste Water
5-bromo-thiophene-2-
6,800
1,822
73.2
carboxamide
Isoxazolidine
10,779
7,177
33.4
2-methyl-1-
4,507
1,228
72.7
nitropropane
[0086] The results show that NZB—C degrades 5-bromothiophene-2-carboxamide, isoxazolidine and 2-methyl-1-nitropropane.
Example 3
[0087] A field assessment of the ability of the NZB—C fungal consortium to reduce odor-causing and certain recalcitrant waste compounds in a Pulp and Paper mill lagoon treatment facility in Bonduelle, France was undertaken. NZB—C material, prepared as described above, was added at a rate of 1.5 g NZB—C per 1.0 Kg of total COD present into a treatment lagoon with a flow rate of 7,500 m 3 /day. A similar but separate lagoon on location was not treated with NZB—C and served as a control. Samples were taken at the lagoon outlet at the initiation of the experiment (Day 0) and at Day 23. These were assessed using the GC/MS with SPME analytical method described in Example 1. The results are provided in Table 3, and indicate that considerable and significant reduction in certain odor-associated compounds occurred in this time period.
[0000]
TABLE 3
Field Assessment of NZB-C Activity against Odor-Associated
Compounds in Pulp and Paper Mill Outlet Wastewater using
GC/MS with SPME.
Amount
Amount
% NZB-C
Odor Associated
Degraded -
Degraded -
Degradation
Compounds
Control (Peak
NZB-C (Peak
Improvement
(Outlet water)
area units)
area units)
vs. Control
Butanoic Acid
837,019
894,748
6.90
2-Methylphenol
192,031
401,809
109.24
Heptanoic Acid
6,275,573
8,593,919
36.94
Nonanoic Acid
708,757
1,410,612
99.03
|
The present invention relates to wastewater treatment in general and to methods of controlling odors and degrading compounds contained in wastewater in particular.
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BACKGROUND
[0001] The present invention relates to a centrifugal high-speed compressor, which drives lubrication free, comprising an internal drive mechanism of a compressor with an impeller on an impeller shaft and with an input shaft, which is driven by a motor or other means of power.
[0002] It is well known that a centrifugal compressor is able to compress air to a certain pressure ratio. It is also known that a centrifugal compressor is the most efficient air pump known. The most important part in the centrifugal compressor is the pump wheel or impeller. To work efficiently, however it needs very high rotational speed.
[0003] Therefore, a step-up ratio of minimum 6:1 from an input shaft to the impeller is generally. The internal drive mechanism of such a step-up gear typically consists of planetary gears or planetary gear drives. Because gears need lubrication, an oil supply is needed for the step-up transmission. To separate the compressed media from the oil a high-speed seal is needed between the media and the gear.
[0004] One way to avoid the oil system is to use a transmission that does not need lubrication. One such example is disclosed in U.S. Pat. No. 6,763,812 B2. However, this design limits the maximum ratio to below 4:1, which is not enough for smaller, efficient high-speed impellers.
[0005] The belt drive known from U.S. Pat. No. 6,763,812 B2 has only one cog belt and two sprockets. To cope with the high torque from the input shaft the belt has to be very wide to withstand the high tension in the belt cord. One of the issues in a single belt high-speed belt drive is to evacuate air trapped between the belt and the high-speed sprocket. The wider the belt for increased strength the more difficult is the evacuation of air. If the belt is made narrower and the air can escape to the sides, the belt will not withstand the tension.
SUMMARY OF THE INVENTION
[0006] The intension of the invention is to provide a compact compressor or supercharger with an internal drive mechanism, which, as compared to prior internal drive mechanisms, operates with greater efficiency, higher speed, and low noise compared to the compressing noise of the media. In addition, the invented drive needs no lubrication and has a concentric input- and impeller shaft for compactness.
[0007] A more specific object is to provide the drive with synchronous belts and pre-greased bearings. This makes the supercharger easy to install and maintenance free.
[0008] Another object is to provide an internal drive mechanism that incorporates stabilizing design features that reduce stress and tension to the belts.
[0009] The invention incorporates two sets of sprockets mounted on parallel shafts. Each shaft has a large and a small sprocket. The input shaft is connected to the first of the larger sprockets.
[0010] On that sprocket, an endless synchronous belt, preferable with carbon core for reduced elongation, lower weight and higher strength, transfers the torque to the first of the smaller sprockets being positioned on an idler shaft together with the second of the two larger sprockets in a rotatable combined locked manner. The other endless synchronous belt then transfers the torque from the second large sprocket on the idler shaft to the other small sprocket sitting on the impeller shaft concentric with the input shaft.
[0011] The ratio of this internal drive is the ratio of the two drives being multiplied. If as an example, the ratio each of the two drives is 3:1 the final ratio will be 9:1. Since the ratio 3:1 in each step is less than the ratio in U.S. Pat. No. 6,763,812B the belt on the small sprockets engage more teeth, due to the smaller diameter difference of the two sprockets, which reduces the stress in the belt because more teeth are sharing the load.
[0012] Due to the torque conversion of the first stage gear, a belt can be used in the second stage, which is approximately one third the width of the first stage belt width. A second stage belt with one third of the width of the first stage belt will allow the air caught between the belt and the sprocket to escape easily and the belt will only require the same tension as the wider input belt, because the torque is dramatically reduced.
[0013] Normally one of the sprockets in a pair has guiding plates on the sides, to keep the belt in place on the sprockets. When running two pairs of sprockets it is possible to avoid both side plates on the small high-speed sprocket and one of the guide plates on the larger high-speed sprocket. This because the two larger sprockets can be chamfered on the side pointing towards the opposite belt. This design secures the best possible way for the air to escape.
[0014] To further help the air escape during engagement between sprocket and belt a special design at the bottom of the teeth on the high-speed sprockets is used. This could typically be a 1 mm×1 mm axial channel, which is enough for the air that could find itself trapped under the belt, to escape at even very high belt speeds.
[0015] If the high-speed cog-belt has the longitudinal tensioning members made of carbon fibers, the strength is so high compared to conventional belts, that only a thin layer is needed. Since the bending forces on the belts are reduced with a minimized thickness, the heat developed in the belt also is reduced. This improves not only the operational life of the belt but also the efficiency.
[0016] When a normal endless cog belt is used, it is advisable to run idlers on both sides of the belt to prevent vibrations. The very high strength and longitudinal stiffness in the carbon fibers make these costly and complex idlers redundant.
[0017] A further advantage of the design is the possibility to use cheaper high-speed bearings on the output shaft. Since the output shaft is running in bearings situated inside the input shaft, the speed difference between the outer and inner races of the bearings is reduced because of the same rotational direction.
[0018] If the shape of the input shaft, keeping the outer high-speed bearings in place is conical, this will keep dirt away from the bearings due to the centrifugal forces transporting dirt to a larger diameter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] Embodiments of the invention will in the following be described referring to the drawing, where
[0020] FIG. 1 is a full longitudinal view of a first embodiment of a compressor,
[0021] FIG. 2 is a cross-section taken along line II-II in FIG. 1 ,
[0022] FIG. 3 is a cross section of the small high-speed sprocket illustrating the axial air channels,
[0023] FIG. 4 is a full longitudinal view of a second embodiment of a two-stage direct drive centrifugal compressor,
[0024] FIG. 5 is a cross-section taken along line V-V in FIG. 4 .
[0025] FIG. 6 is a third embodiment of a compressor and
[0026] FIG. 7 is a cross-section taken along line VII-VII in FIG. 6 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0027] Referring now to FIGS. 1 and 2 , a first embodiment of a double carbon-belt drive compressor will be described.
[0028] The double carbon-belt drive unit includes a compressor 10 having a compressor housing 11 and impeller 12 , an input drive 20 connected to the double carbon-belt drive 30 .
[0029] The input drive 20 has a pulley, clutch or connective coupling 21 connected to the input shaft 22 . The input sprocket 23 is locked to the input shaft 22 . Bearings 24 and 25 are keeping the input shaft 22 rotatable in place.
[0030] The double carbon-belt drive 30 contains an idler shaft 31 . On the idler shaft 31 is a wide sprocket 32 , which has a smaller diameter and is wider in the axial direction than another sprocket 33 , which are positioned in an internally locked rotatable position. The idler shaft 31 runs in bearings 34 and 35 .
[0031] The second large narrow sprocket 33 drives a narrow small sprocket 36 that may for instance have a small diameter and be more or less comparable in width (in the axial direction) to the sprocket 33 but be narrower in width as compared to wide sprocket 32 as shown. The sprocket 36 is positioned on output shaft 13 running in high-speed bearings 37 , 38 and 39 . High-speed bearing 39 is axially locked to output shaft 13 by screw 44 . High speed bearing 39 is then axially secured by screws 41 .
[0032] Sprockets 33 and 23 have chamfer 45 on the side to guide the belts in axial position.
[0033] Input shaft 22 has a conical shape 46 to reduce dirt and particles reaching the high-speed bearings 37 and 38 .
[0034] A wide tooth belt 42 transfers high torque from input sprocket 23 to wide sprocket 32 .
[0035] A narrow tooth belt 43 transfers lower torque in the high-speed drive from sprocket 33 to sprocket 36 .
[0036] FIG. 3 shows how air channels 14 are machined into the high-speed sprocket 36 . When air is trapped between sprocket and belt in a normal high-speed application, the belt is lifted by the air cushion and will not have the ideal contact path to the sprocket. The channels 14 at the bottom of the grooves between the teeth help the trapped air to escape to the sides. If the sprocket with the highest speed has air channels and no flanges, the belt speed can be very high.
[0037] A second embodiment shown on FIG. 4 and FIG. 5 will now be described.
[0038] If very high boost and flow is needed this embodiment is able to provide very high efficiency in an extremely lightweight and quiet solution that runs oil free. Production cost compared to other type of high-pressure compressors is very low.
[0039] In this embodiment, the unit has a second compressor 50 .
[0040] The impeller shaft 13 is in this embodiment extended through the housing 39 and carries a second impeller 52 that runs in compressor housing 51 .
[0041] The process media from compressor 10 is routed to the inlet of compressor 50 for further serial compression. Since the final pressure ratio is the pressure ratios from compressor 10 and compressor 50 multiplied, a total pressure ratio above 10:1 is possible.
[0042] An advantage of this design, since the two impellers compress the same amount of media, is that the axial shaft forces almost outbalance each other.
[0043] Power is supplied to the compressor via belt 61 . Belt 61 drives the input sprocket 60 . Input sprocket 60 then again drives the sprocket 32 on idler shaft 31 through belt 42 . Sprocket 32 is connected to the narrow larger diameter sprocket 33 that again via belt 43 drives a smaller diameter narrow sprocket 46 . Sprocket 46 is fitted to impeller shaft 13 .
[0044] Impeller shaft 13 runs in high-speed bearings 37 and 38 . Bearings 37 and 38 are mounted inside the input sprocket 60 . Impeller shaft 13 and input sprocket 60 rotate in the same direction. Therefore, the demand to the high-speed bearings 37 and 38 can be reduced and cheaper bearings of standard quality can be used.
[0045] Input sprocket 60 runs in bearings 24 and 25 , and has a groove 47 towards the small high-speed sprocket 36 where the air can escape.
[0046] To avoid axial belt guidance on the small high-speed sprocket 36 , the input sprocket 60 has a chamfer 45 and the larger sprocket 33 has on the opposite side a flange 49 .
[0047] FIGS. 6 and 7 show a third embodiment and will now be described.
[0048] If very high durability is needed the load on the high-speed bearings has to be reduced. One way of doing this is by fitting a second idler shaft in an opposite position to the other. Then the forces from the belt pull on the output sprocket can be almost eliminated.
[0049] Further, the load on the inner input-shaft bearing can be almost removed. Then a less space demanding bearing can be used.
[0050] This embodiment is able to provide very high durability in a lightweight and quiet solution that runs oil free. Production cost compared to other type of high-pressure compressors is very low.
[0051] The double carbon-belt drive unit 30 includes a compressor 10 having a compressor housing 11 and impeller 12 , an input drive 20 connected to the double carbon-belt drive 30 .
[0052] The input drive 20 has a pulley, clutch or connective coupling 21 connected to the input shaft 22 . The input sprocket 23 is locked to the input shaft 22 . Bearings 24 and 25 keep the input shaft 22 rotatable in place.
[0053] The double carbon-belt drive 30 contains two idler shafts 31 A and 31 B. The idler shaft 31 A has an oppositely positioned idler shaft 31 B. Sprockets 32 A and 32 B and the larger sprockets 33 A and 33 B are positioned in an internally locked rotatable position on the respective shafts. The idler shaft 31 A runs in bearings 34 A and 35 A. The opposite positioned idler shaft 31 B runs in bearings 34 B and 35 B. This helps to minimize the radial load on the bearings 38 and 39 .
[0054] The two large narrow sprockets 33 A and 33 B drive the common small sprocket 36 . The sprocket 36 is positioned on output shaft 13 running in high-speed bearings 38 and 39 . High-speed bearing 39 is axially locked to output shaft 13 by screw 44 . Screws 41 then axially secure high speed bearing 39 .
[0055] Sprockets 33 A and 33 B have respective chamfers 45 A and 45 B on the sides to guide the belts 43 A and 43 B in axial position. Therefore, no side guides are needed on sprocket 36 .
[0056] Input shaft 22 has a conical shape 46 to reduce dirt and particles reaching the high-speed bearings 39 and 38 .
[0057] The wide tooth belt 42 transfers the high torque from input sprocket 23 to sprockets 32 A and 32 B.
[0058] The narrow tooth belts 43 A and 43 B transfer the lower torque in the high-speed drive from sprockets 33 A and 33 B to common small sprocket 36 .
|
The invention relates to a centrifugal compressor or supercharger with an internal drive mechanism ( 30 ), which operates with great efficiency, higher speed and low noise. The compressor needs no lubrication and has a concentric input-and impeller shaft ( 13 ) for compactness. The compressor has two sets of belt drives ( 36 ) connected to a large sprocket ( 33 ).
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 60/744,966, filed Apr. 17, 2006, the disclosure of which is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a protective girth-weld cover system and method. More specifically, the present invention relates to a protective girth-weld cover system that provides for the release of air trapped under the girth-weld cover.
BACKGROUND
[0003] In the oil and gas industry, transmission pipelines are laid to transport a variety of liquids and gases. These pipelines are formed of many miles of steel piping that can vary from 8 to 80 inches in diameter. Depending on the location and environmental conditions, the pipe may be installed above ground or buried. The exterior of the pipe can be in contact with highly corrosive environments, such as seawater, soil, rock, air, or other gases, liquids or solids.
[0004] To protect the pipes from stresses due to exposure from often extreme environmental conditions, the pipe exteriors are generally coated with a protective coating in the factory, not the site where the pipes are to be installed. Conventional protective coatings are described in J. A. Kehr, “Fusion-Bonded Epoxy (FBE): A Foundation for Pipeline Corrosion Protection”, NACE Press (Houston, Tex.), 2003 (see e.g., Chapter 4 and pages 234-246). For example, a three layer protective coating, that includes a fusion bonded epoxy, an adhesive, and a polyolefin topcoat, is typically applied to pipe in the factory.
[0005] However, the pipe ends are not coated, with about 6 inches (axial length) of uncoated pipe at each end, where pipe segments are welded together. The resulting welds are referred to as “girth-welds” or “field joints” and are not coated with a protective coating before the installation is complete.
[0006] As such, girth-welds can be susceptible to corrosion and other environmental effects. Several methods to protect the girth-weld are known. The most frequently used and accepted method is utilizing a protective cover, such as a heat shrink sleeve, to cover the girth-weld. However, conventionally installed heat shrink sleeves tend to provide diminished protection prior to the end of the expected service lifetime as the sleeves are susceptible to moving away from the weld, thereby leaving the joint unprotected. Moreover, most conventional installation processes leave heat shrink sleeves with bubbles and wrinkles, thus entrapping air underneath the protective cover. In addition, the use of a torch to shrink the protective sleeve is highly skill dependent, meaning that a completely and uniformly shrunk protective cover is not ensured under all circumstances.
[0007] Other approaches (and their problems) are described in J. A. Kehr, “Fusion-Bonded Epoxy (FBE): A Foundation for Pipeline Corrosion Protection”, NACE Press (Houston, Tex.), 2003 (see e.g., Chapter 7).
SUMMARY
[0008] In one aspect, the present invention provides a heat recoverable polymer material comprising a plurality of holes extending therethrough. The heat recoverable polymer material can be part of a pipe system that includes first and second pipes having first and second ends welded together forming a girth-weld, where the heat recoverable polymer material comprising a plurality of holes extending therethrough is disposed to cover the girth-weld. The heat recoverable polymer material can be formed as a cover or sheet having a surface having an adhesive coated thereon.
[0009] In another aspect, a method of forming a protected girth-weld, comprises disposing a heat recoverable polymer material comprising a plurality of holes extending therethrough covering the girth-weld, and shrinking the heat recoverable polymer material over the girth-weld. The recoverable polymer material can include a surface having an adhesive coated thereon disposed on the girth-weld, where a portion of the adhesive flows through the holes during the shrinking step. The method can also include providing first and second pipes having first and second ends, welding the first and second pipe ends together to form the girth-weld, cleaning the girth-weld, coating the girth-weld with a corrosion coating, and curing the corrosion coating prior to the disposing step.
[0010] The above summary of the present invention is not intended to describe each illustrated embodiment or every implementation of the present invention. The figures and the detailed description that follows more particularly exemplify these embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIGS. 1A-1C are schematic views of a girth-weld and of a heat recoverable protective coating having a plurality of holes according to an aspect of the present invention.
[0012] FIG. 2 shows a cross-section view of a pipe having a heat recoverable protective coating having a plurality of holes according to an aspect of the present invention.
[0013] These figures are not drawn to scale and are intended only for illustrative purposes. While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION
[0014] Aspects of the present invention relate to a protective cover for girth-welds having an air release mechanism. In an exemplary embodiment, a heat recoverable polymer material (such as a heat shrink sleeve or sheet) having a plurality or matrix of holes is provided to be placed over a girth-weld that can facilitate air release during the shrinking process. The porous structures (e.g., holes extending through the inner and outer surfaces of the heat recoverable polymer sheet) will automatically direct air out of the sleeve as the heat shrink sleeve is activated (e.g., by shrinking). This process can prevent entrapped air from remaining trapped underneath the protective cover. In a preferred aspect, as the sheet or sleeve is shrunk, an adhesive material (e.g., a hot melt adhesive or a mastic) can flow through the porous structures after all the air is removed from the system. With the adhesive material now filling the plurality of holes, a protective layer is reestablished, thus preventing penetration of external elements (e.g., water). The adhesive flow can also act as an indicator of correct installation. For example, the adhesive can be a color different from that of the sheet or sleeve. An indicator can thus be a contrasting color visible on a top surface of the sheet or sleeve (e.g., a pattern of different color dots would appear) when the installation is complete. Additionally, the porosity and contrasting protective media can reduce the cathodic shielding normally seen in a typical heat shrink sleeve, whereby the adhesive could be modified to be more conductive.
[0015] A first aspect of the present invention is shown in FIGS. 1A-1C , a pipeline 100 having a girth-weld 104 with a heat recoverable polymer material 120 , such as a heat shrink protective cover, sheet, or sleeve. In this exemplary embodiment, girth-weld 104 joins pipe ends 101 and 102 and can be protected by exemplary heat recoverable polymer sheet 120 . The heat recoverable polymer sheet 120 preferably surrounds the entire girth-weld.
[0016] Pipe ends 101 , 102 can be formed from a standard pipe material, such as steel. Pipe ends 101 , 102 also include an outer coating 106 that can comprise a conventional protective coating, such as a polyolefin-based coating. In an exemplary embodiment, protective coating 106 comprises a three-layer coating having an epoxy, an adhesive and a polyolefin top coat that are melt-fused together on the pipe ends 101 , 102 . As would be understood by one of ordinary skill in the art given the present description, other formulations of protective coatings, such as two-layer coatings, and those described in J. A. Kehr, “Fusion-Bonded Epoxy (FBE): A Foundation for Pipeline Corrosion Protection”, NACE Press (Houston, Tex.), 2003 (see e.g., Chapter 4 and pages 234-246) (incorporated by reference herein), can also be utilized as the protective coat 106 .
[0017] As is also shown in FIG. 1A , in an exemplary embodiment, portions of the pipe coating 106 , e.g., about 2 to 10 inches in length from the pipe ends, can be removed, stripped, or sanded off to help promote better welding in the field.
[0018] As shown in FIG. 1B , the girth-weld 104 can be coated with a corrosion (prevention) coating 108 after the welding operation. An exemplary corrosion coating 108 comprises an epoxy or urethane material. For example, the corrosion coating 108 can be a 2-part liquid system or a fusion bonded epoxy powder (e.g., prepared from a commercially available powdered SCOTCHCAST Resin 226N, available from 3M Company, St. Paul, Minn.).
[0019] As shown in FIG. 1C , the heat recoverable polymer material 120 includes a plurality of holes 124 extending through the material. The holes can be formed in a random manner or may be provided in an ordered pattern or matrix. For example, holes 124 can be from about 0.1 mm to about 10 mm in diameter, preferably from about 0.1 mm to about 1 mm in diameter. The density of holes 124 formed in heat recoverable polymer material 120 can cover from about 0.01% to about 25% of the total surface area of the heat recoverable polymer material 120 , preferably from about 0.1% to about 2% of the total surface area of the heat recoverable polymer material 120 . The holes 124 can be formed in heat recoverable polymer material 120 through a standard technique, such as mechanical process (e.g., drilling, puncturing, etc.), focused radiation (e.g., laser, or other), or thermal process. The size and density of holes 124 can be varied to provide for optimal air release without adversely affecting the structural integrity or performance of the heat recoverable polymer material 120 .
[0020] The heat recoverable polymer material 120 can comprise a pre-expanded EPDM rubber or cross-linked polyethylene materials. Other example materials that can be used to form heat recoverable polymer material 120 includes those described in U.S. Pat. No. 6,015,600, and commercially available materials such as are available from Raychem (e.g., model WPCT M05106).
[0021] Further, an inner surface of the heat recoverable polymer material 120 can optionally be coated with an adhesive layer or coating 122 to help further bond the heat recoverable polymer material 120 to the pipe ends 101 , 102 . For example, the adhesive layer 122 can comprise a mastic or hot melt material. In one exemplary embodiment, the adhesive or coating 122 can have a color different from the color of the heat recoverable polymer sheet 120 . Alternatively, adhesion of the heat recoverable polymer material 120 to the girth-weld region can be accomplished using corrosion coating 108 .
[0022] In operation, a girth-weld is formed in the field by joining pipe ends 101 and 102 . After welding, optionally, the girth-weld area can be further cleaned. Additionally, a field-applied corrosion coating 108 can be applied to the girth-weld. This optional coating 108 can be a liquid epoxy, such as Scotchcast 323 available from 3M Company, St. Paul, Minn.
[0023] After the optional corrosion coating 108 is applied and/or at least partially cured, heat recoverable polymer sheet 120 having a plurality of holes 124 is disposed (e.g., wrapped) over the girth-weld 104 . As mentioned above, in an exemplary embodiment, an inner surface of the heat recoverable polymer sheet 120 is coated with an adhesive layer 122 .
[0024] To conform the heat recoverable polymer material 120 to the surface of the girth-weld region, heat is applied (e.g., via a hot air gun or torch) to material 120 . In one exemplary embodiment, the protective sleeve is wrapped around the pipe (to cover the girth-weld), then sealed longitudinally (e.g., by heating the overlap region). The sleeve can then be shrunk by applying heat. A technician, for example, can start at the center of the sleeve (with the weld seam being directly underneath the sleeve) and can seal the sleeve around the pipe by heating radially, working outward (longitudinally) from the middle, while alternating in each direction, to completely shrink the sleeve.
[0025] As the heat recoverable polymer material 120 is shrunk, air trapped underneath can be released through holes or pores 124 formed in sheet 120 . As shown in FIG. 2 , air trapped, for example between corrosion coating 108 and adhesive 122 can be forced out through hole 124 as the sheet 120 is shrunk via suitable heating. After the trapped air has escaped, a portion of adhesive 122 can then flow through hole 124 .
[0026] This exemplary embodiment can reduce or eliminate undesirable bubbles and wrinkles that often form under protective covers, helping to ensure more optimal conformity to the weld. Further, the above method and system can reduce the likelihood of incomplete installation, as the bubbles formed during shrinking can be visually monitored in a straightforward manner. Moreover, different colors for the adhesive and heat recoverable polymer material 120 can be selected to provide greater visual contrast as bubbles form in the plurality of holes to indicate the completion of the process.
[0027] In another embodiment, the adhesive 122 can be modified to have some conductive properties, for example, by chemically modifying the adhesive with polar groups (e.g. maleated polyolefin) or by adding conductive nanoparticles to the adhesive. As the adhesive 122 is designed to penetrating the sleeve 120 through holes 124 , this arrangement can provide for the current to flow to ground and reduce the shielding effect of the bulk sleeve.
[0028] While the present invention has been described with a reference to exemplary preferred embodiments, the invention may be embodied in other specific forms without departing from the scope of the invention. Accordingly, it should be understood that the embodiments described and illustrated herein are only exemplary and should not be considered as limiting the scope of the present invention. Other variations and modifications may be made in accordance with the scope of the present invention.
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A pipe system comprises first and second pipes having first and second ends welded together forming a girth-weld and a heat recoverable polymer material comprising a plurality of holes extending therethrough covering the girth-weld. The heat recoverable polymer material can include a surface having an adhesive coated thereon disposed on the girth-weld. Air trapped underneath the recoverable polymer material can be released through the plurality of holes during shrinking of the heat recoverable polymer material. Also, a portion of the adhesive can flow through the holes during a shrinking of the heat recoverable polymer material.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. Ser. No. 10/371,894, filed Feb. 21, 2003, now U.S. Pat. No. 6,689,490 B2 which was a continuation of U.S. Ser. No. 09/269,490, filed Jun. 8, 1999, now U.S. Pat. No. 6,663,981 B1, which was a National Stage Application under 37 CFR 371 of PCT/DE98/01984, filed Jul. 15, 1998, which claimed priority from German 197 32 872.5, filed Jul. 30, 1997.
BACKGROUND OF THE INVENTION
The present invention is directed to a marker for use in a magnetic anti-theft security system. The marker is of a type composed of an oblong alarm strip composed of an amorphous ferromagnetic alloy, and at least one activation strip composed of a semi-hard magnetic alloy.
Magnetic anti-theft security systems and markers for security systems of the above type are well known and are described in detail in, for example, EP 0 121 649 B1 and WO 90/03652. First, there are magneto-elastic systems wherein the activation strip serves for activation of the alarm strip by magnetizing it; second, there are harmonic systems wherein the activation strip, after being magnetized, serves for the deactivation of the alarm strip.
The alloys with semi-hard magnetic properties that are employed for the pre-magnetization strip include Co—Fe—V alloys, which are known as VICALLOY, Co—Fe—Ni alloys, which are known as VACOZET, as well as Fe—Co—Cr alloys. These known semi-hard magnetic alloys contain high cobalt parts, some at least 45 weight %, and are correspondingly expensive.
In addition, while in their magnetically finally annealed condition, these alloys are brittle, so that they do not exhibit adequate ductility in order to adequately meet the demands given markers or display elements for anti-theft security systems. One important demand, namely, is that these activation strips should be insensitive to bending or deformation.
In the meantime, a switch has been made to introduce the markers of the anti-theft security systems directly into the product to be secured (source tagging). Such source tagging imposes the additional demand that the semi-hard magnetic alloys should be able to be magnetized from a greater distance or with smaller fields. To satisfy this additional demand, it has been shown that the coercive force H must be limited to values of, at most, 24 A/cm.
On the other hand, however, an adequate opposing field stability is also required, which determines the lower limit value of the coercive force. Only coercive forces of at least 10 A/cm are thereby suited.
Further, the remanence should be optimally slight under bending or tensile strength. A change of less than 20% is prescribed as a guideline.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a marker of the above-described type for a magnetic anti-theft system, having an activation strip which satisfies the above demands for source tagging.
This object is inventively achieved in a marker having an activation strip composed of a semi-hard magnetic alloy comprising 8 to 25 weight % nickel, 1.0 to 4.5 weight % aluminum, 0.5 to 3 weight % titanium and the balance iron.
In a preferred embodiment of the invention, the content of aluminum is between 1.2 and 2.8 weight %. Optimum results are achieved with a content of aluminum between 1.5 and 2.8 weight %.
For best results, the content in weight % of nickel, aluminum and titanium should satisfy the following formula:
35≦Ni(1,75Al+Ti)≦110, preferably 40≦Ni(1,75Al+Ti)≦90.
The alloy can further contain 0 to 5 weight % cobalt and/or 0 to 3 weight % molybdenum or chromium and/or at least one of the elements Zr, Hf, V, Nb, Ta, W, Mn, Si in individual parts of less than 0.5 weight % of the alloy and in an overall part of less than 1 weight % of the alloy and/or at least one of the elements C, N, S, P, B, H, O in individual parts of less than 0.2 weight % of the alloy and in an overall part of less than 1 weight % of the alloy.
The alloy is characterized by a coercive strength H c of 10 to 24 A/cm and a remanence B r of at least 1.3 T (13,000 Gauss).
The inventive alloys are highly ductile and can be excellently cold-worked before the annealing, so that cross-sectional reductions of more than 90% are also possible. An activation strip having a thickness of less than 0.05 mm can be manufactured from such alloys, particularly by cold rolling. In addition, the inventive alloys are characterized by excellent magnetic properties and resistance to corrosion.
A preferred alloy is a semi-hard magnetic iron alloy according to the present invention that contains 13.0 to 17.0 weight % nickel, 1.8 to 2.8 weight % aluminum as well as 0.5 to 1.5 weight % titanium. By reducing the aluminum content, the magnetostriction can, in particular, be especially favorably set.
Typically, the activation strips are manufactured by melting the alloy under a vacuum and then casting to form an ingot. Subsequently, the ingot is hot-rolled into a tape or ribbon at temperatures above 800° C., then intermediately annealed at a temperature above 800° C. and then rapidly cooled. A cold working, expediently cold rolling to provide a cross-sectional reduction of approximately 90% is followed by an intermediate annealing at approximately 700° C. A cold working, expediently cold rolling to provide a cross-sectional reduction of at least 60% and preferably 75% or more subsequently occurs. As a last step, the cold-rolled tape or ribbon is annealed at temperatures from approximately 400° C. to 600° C. The activation strips are then cut to length.
Other advantages and features of the invention will be readily apparent from the following description, the claims and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the demagnetization behavior of the inventive Fe—Ni—Al—Ti alloys after an alternating field magnetization at 4 A/cm, dependent on the coercive force H c ;
FIG. 2 illustrates the demagnetization behavior of the inventive Fe—Ni—Al—Ti alloys after an alternating field magnetization at 20 A/cm, dependent on the coercive force H c ;
FIG. 3 illustrates the change of the remanence B r under tensile stress of two embodiments of the inventive alloy, compared to a prior art alloy; and
FIG. 4 illustrates the relative change of the magnetic flux, in percent, at various coercive field strengths after mechanical deformation for an embodiment of an inventive alloy compared to a prior art alloy.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following demands derive for the suitability of an alloy for an activation strip in an anti-theft security system, particularly for a system employing source tagging:
The change of the remanence under bending or tensile stress should be optimally slight. A change of 20% is prescribed as a guideline. As can be seen from FIG. 3, values ≦10% are achieved with the alloys of the present invention.
It can be seen from FIG. 4 that, in addition to being determined by the alloy, the coercive field strength and the bending radius also determine the change of the flux. Given corresponding coercive field strengths, the alloys according to the present invention achieve values <5% given bending radii ≧12 mm or, respectively, values <10% given bending radii ≧4 mm and thicknesses of approximately 50 μm.
The relationship of the saturation at a given, slight magnetizing field strength of, for example, 40 A/cm to the saturation B f given a magnetic field in the kOe range should be nearly 1, which can be seen from FIG. 3 .
The opposing field stability should be of such a nature that the remanence B s still retains at least 80% of its original value after an opposing field magnetization of a few A/cm.
Finally, the remanence should retain only 20% of the original value after a demagnetization cycle with a predetermined magnetic field.
In detail, this means that a magnetization of the activation strip, i.e., an activation/deactivation of the marker or display element, can also occur on site. However, only very small fields are generally available there. The saturation that is achieved should differ only slightly from the value given high magnetizing fields in order to guarantee identical behavior of the marker or display elements.
The display elements or markers must be of such a nature that their remanence B r changes only slightly in the proximity of the coils in the detection locks as a consequence of a field that is elevated thereat and is potentially oriented in the opposite direction. As can be seen from FIG. 1, the inventive alloys exhibit an opposing field stability as demanded.
Finally, the markers or display elements must be capable of being demagnetized with relatively small fields, i.e., deactivated given magneto-elastic markers or, respectively, activated given harmonic display elements or markers. FIG. 2 illustrates these relationships given the inventive alloys.
Simultaneously, meeting these last three demands yields extremely great limitations for the accessible ranges of the coercive forces H c , since the three demands are contradictory.
The alloys of the present invention are typically manufactured by casting a melt of the alloy constituents in a crucible or furnace under a vacuum or a protective gas atmosphere. The temperatures thereby lie at approximately 1600° C.
The casting typically utilizes a round ingot mold. The cast ingots of the present alloys are then typically processed by hot working, intermediate annealing, cold working and a further intermediate annealing. The intermediate annealing is performed for the purpose of homogenization, grain sophistication, shaping or the creation of desirable mechanical properties, particularly a high ductility.
An excellent structure is achieved, for example, by the following process:
Thermal treatment at, preferably, temperatures above 800° C., rapid cooling and annealing. Preferred annealing temperatures lie at 400° C. through 600° C., and the annealing times typically lie advantageously between one minute through 24 hours. A cold working corresponding to a cross-sectional reduction of at least 60% before the annealing is, in particular, possible with the inventive alloys.
The coercive force and the rectangularity of the magnetic B—H loop are enhanced by the step of annealing, and this is implemented for the demands made of the activation strips.
The manufacturing method for especially good activation strips comprises the following steps:
1) Casting at 1600° C.
2) Hot rolling of the ingot at a temperature above 800° C.
3) Multi-hour intermediate annealing at about 800° C. with quenching in water.
4) Cold rolling corresponding to a cross-sectional reduction of approximately 90%.
5) Intermediate annealing at approximately 700° C.
6) Cold working corresponding to a cross-sectional reduction of approximately 90%.
7) Multi-hour intermediate annealing at approximately 700° C.
8) Cold working to produce a cross-sectional rejection of approximately 70%.
9) Multi-hour annealing at approximately 480° C.
10) Cutting and trimming the activation strips.
Activation strips that exhibited an excellent coercive force H c and a very good remanence B r were manufactured with this method. The magnetization properties and the opposing field stability were excellent.
The manufacture of several embodiments of Fe—Ni—Al—Ti activation strips in accordance with the invention is described in detail on the basis of the following examples:
EXAMPLE 1
An alloy with 18.0 weight % nickel, 3.8 weight % aluminum, 1.0 weight % titanium and the balance iron was melted under a vacuum. The resulting ingot was hot-rolled at approximately 1000° C., intermediately annealed for one hour at 1100° C. and rapidly cooled in water. After a subsequent cold-rolling with a cross-sectional reduction of 80%, the resulting ribbon was again intermediately annealed for one hour at 1100° C. and rapidly cooled in water. After a further cold working with a cross-sectional reduction of 50%, the ribbon was intermediately annealed for four hours at 650° C. To provide a cross-sectional reduction of 90%, the ribbon was subsequently cold-rolled and annealed at 520° C. for three hours and then cooled in air. A coercive force H c equal to 23 A/cm as well as a remanence B r equal to 1.48 T were measured.
EXAMPLE 2
An alloy with 15.0 weight % nickel, 3.0 weight % aluminum, 1.2 weight % titanium and balance iron was processed as in Example 1 but with the last intermediate annealing at 700° C., the last cold working provided a cross-sectional reduction of 70% as well as a final annealing was at 500° C. A coercive force H c equal to 21 A/cm and a remanence B r equal to 1.45 T were measured.
EXAMPLE 3
An alloy with 15.0 weight % nickel, 3.0 weight % aluminum, 1.2 weight % titanium and balance iron was manufactured as in Example 2. Deviating therefrom, the last intermediate annealing occurred at 650° C., the last cold working to provide a cross-sectional reduction of 85% and the annealing treatment was at 480° C. A coercive force H c equal to 20 A/cm and a remanence B r equal to 1.53 T were measured.
EXAMPLE 4
An alloy with 15.0 weight % nickel, 3.0 weight % aluminum, 1.2 weight % titanium, 2.0 weight % molybdenum and balance iron was manufactured as in Example 2. After an annealing treatment at 480° C., a coercive force H c equal to 20 A/cm and a remanence B r equal to 1.56T were measured.
EXAMPLE 5
An alloy with 15.0 weight % nickel, 3.0 weight % aluminum, 0.8 weight % titanium and balance iron was melted under a vacuum. The resulting ingot was hot-rolled at approximately 1000° C., intermediately annealed at 900° C. for one hour and rapidly cooled in water. After a following cold-rolling with a cross-sectional reduction of 90%, the resulting ribbon was intermediately annealed for four hours at 650° C. To produce a cross-sectional reduction of 95%, the tape was subsequently cold-rolled and annealed for three hours at 460° C. and then air-cooled. A coercive force H c equal to 14 A/cm and a remanence B r equal to 1.46T were measured.
EXAMPLE 6
An alloy with 15.0 weight % nickel, 2.5 weight % aluminum, 1.2 weight % titanium and balance iron was manufactured as in Example 5, but with a cross-sectional reduction of 83% and an annealing treatment at 420° C. A coercive force H c equal to 17 A/cm and a remanence B r equal to 1.44T were measured.
EXAMPLE 7
An alloy with 20.0 weight % nickel, 1.0 weight % aluminum, 1.2 weight % titanium and the balance iron was melted under a vacuum. The resulting ingot was hot-rolled at approximately 1000° C., intermediately annealed for one hour at 1100° C. and rapidly cooled in water. After a subsequent cold-rolling with a cross-sectional reduction of 80%, the resulting ribbon was again intermediately annealed for one hour at 1100° C. and rapidly cooled in water. After a further cold working with a cross-sectional reduction of 50%, the ribbon was intermediately annealed for four hours at 650° C. To provide a cross-sectional reduction of 75%, the ribbon was subsequently cold-rolled and annealed at 450° C. for three hours and cooled in air. A coercive force H c equal to 13.4 A/cm as well as a remanence B r equal to 1.35 T were measured.
EXAMPLE 8
An alloy with 15.0 weight % nickel, 1.3 weight % aluminum, 0.6 weight % titanium and the balance iron was melted under a vacuum. The resulting ingot was hot-rolled at approximately 1000° C., intermediately annealed for one hour at 1100° C. and rapidly cooled in water. After a subsequent cold-rolling with a cross-sectional reduction of 80%, the resulting ribbon was again intermediately annealed for one hour at 1100° C. and rapidly cooled in water. After a further cold working with a cross-sectional reduction of 50%, the ribbon was intermediately annealed for four hours at 660° C. To provide a cross-sectional reduction of 85%, the ribbon was subsequently cold-rolled and annealed at 550° C. for three hours and cooled in air. A coercive force H c equal to 17.3 A/cm as well as a remanence B r equal to 1.31T were measured.
A satisfactory magnetization behavior and a usable opposing field stability are derived in all exemplary embodiments.
Although various minor modifications may be suggested by those versed in the art, it should be understood that we wish to embody within the scope of the patent granted hereon all such modifications as reasonably and properly come within the scope of our contribution to the art.
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A semi-hard magnetic alloy for activation strips in magnetic anti-theft security systems is disclosed that contains 8 to 25 weight % Ni, 1.0 to 4.5 weight % Al, 0.5 to 3 weight % Ti and the balance iron.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of irradiating a running steel or other strip with energy beams. Energy-beam irradiation is performed by utilizing a plurality of individually located and oriented energy-beam irradiating devices and can be performed along the width of the strip even when an edge deviation or so-called "strip wind" occurs on the strip.
In accordance with the present invention, the strips used include not only metal strips such as cold-rolled steel sheet and aluminum sheet, but also various non-metal strips which are capable of running continuously along a production line.
The applied energy beam may include any irradiation beam emitted from plural energy sources using any of a variety of beam-like irradiations, such as electron beams, laser beams, plasma beams, or the like.
2. Description of the Related Art
Treatments for improving physical, chemical and surface characteristics of various strips or sheets are widely performed in various fields. For example, metallurgical, thermal and chemical treatments and the like are performed by irradiating strips or sheets with one or more of various energy beams.
In order to carry out these irradiations industrially, methods are available such as irradiating a running strip with a flat beam or a plurality of beams so as to cover the overall width of the strip, or the use of scanning beams arranged along the width of the strip.
The latter method is often used when the beam-generating device is expensive, when irradiation is performed with a view to improving the beam-focusing rate, or when the surface of the strip is intended to be irradiated with a plurality of different linear beams in order to finely divide the magnetic domain of a silicon steel sheet, for example, as disclosed in Japanese Patent Publication No. 2-40724, Japanese Patent Laid-Open No. 1-281708, or the like.
When energy-beam irradiation treatment of such a scanning type is applied to a wide strip running at a predetermined speed, such as a cold-rolling steel sheet, a plurality of individual energy-beam irradiating devices may be used according to the width of the strip.
Known energy-beam irradiation will now be described by way of an example using an electron-beam device as an energy-beam irradiating device.
FIGS. 1 and 2 of the drawings indicate a conventional method of uniformly scanning electron beams along the width of a strip by utilizing a plurality of electron-beam irradiating devices.
Although five electron-beam irradiating devices are shown as placed along the width of the strip in this example, two or more irradiating devices, or some other number, may be used.
FIGS. 1 and 2 indicate respectively electron-beam irradiating devices 1-5, an electron-beam controller 6 and a strip driving controller 7.
The strip irradiating beams are applied from the devices 1-5 in accordance with the width (W) obtained by taking the amount of linear deviation or strip winding into account, in addition to the width of the strip. According to a signal from the electron-beam controller 6, electron beams can be scanned along the width of the strip. The effective electron-beam irradiating device is selected with respect to the width W as follows (FIG. 1).
where W≦W 1 : Device 3 only
where W 1 ≦W≦W 2 : Devices 2-4
where W 2 ≦W≦W 3 : Devices 1-5
where W 1 shows the scannable width when only the electron-beam irradiating device 3 is desired to be used; W 2 indicates the scannable width when the electron-beam irradiating devices 2-4 are desired to be used; and W 3 represents the scannable width when all of the electron-beam irradiating devices 1-5 are desired to be used.
The irradiation con, and signal from controller 6 is controlled by the strip driving controller 7, taking the strip running speed into consideration. Further, the electron-beam irradiating regions are determined in real time, and the respective electron-beam scannings by the electron-beam irradiating devices 1-5 are constantly parallel to each other at a fixed pitch.
In the above conventional operation, since the actual amount of lateral deviation or winding of the strip is not taken into account, irradiation is performed within the regions of the scannable maximum values W 1 -W 3 of the selected electron-beam irradiating device.
These conventional methods of scanning electron beams by utilizing a plurality of electron-beam irradiating devices encounter important problems.
When a band-like strip is run continuously, it has been found that some amount of out-of-plane deformation of the sheet referred to as strip winding is caused by the conveying system, and cannot be avoided.
When the strip is run at a relatively low speed, the edge of the strip is clamped by a guide roller or the like, thereby inhibiting such strip winding. On the other hand, however, when the strip is run at a relatively high speed, considerable forces act upon the sheet, thus causing distortion or deformation. In such a case, the edge of the sheet simply cannot be clamped in place as a practical matter.
Instead, a so-called steering device has been tried to put a strip in the center of the line without touching the edge. However, even a high-cost and high-performance steering device cannot totally avoid sheet winding due to limited response and other causes. Further, when the strip itself possesses camber, the occurrence of strip winding is effectively unavoidable while continuously running.
In particular, when the electron-beam irradiating devices are longitudinally positioned in the machine direction to form steps, non-irradiated beam portions or overlapping-irradiated beam portions are produced in the vicinities of the borders between the neighboring irradiated regions on the strip, thus causing serious strip quality problems.
An electron-beam irradiating device requires very substantial peripheral space because of a vacuum system associated with it. Also, economical high-speed treatment of strip requires high energy density, and accordingly, the width scanned by one electron gun must be rather narrow.
Thus, electron-beam irradiating devices of the type described are normally longitudinally displaced along the machine direction to form steps in the high-speed treatment lines normally used.
As shown in FIG. 3, the electron-beam irradiating devices 1-5 are displaced to form steps along the strip running direction so that each irradiating device is displaced by the distance K. In this condition, when a strip wind shifts toward the "+" direction (toward the right in the drawing) such as to provide an amount of strip wind G within a distance M obtained by running the strip from the strip wind start point to the end point, non-scanned-omitted portions V 1 -V 4 are unavoidably produced due to the distance K, the displacement of the two neighboring irradiating devices.
In the stepped electron-beam irradiating devices of FIG. 3, when a strip wind shifts toward the "-" direction (toward the left in the drawing), the strip is scanned with overlapping.
A further problem occurs in irradiating edge regions. An electron-beam irradiating device is selected with the maximum width of a steel strip in mind, and irradiating as nearly as possible within the scannable maximum width. Hence, as shown in FIG. 2, the portions of the apparatus, for example, the strip support roll or the wall within the vacuum chamber, is repeatedly or continuously irradiated, seriously deteriorating these components and causing major problems of equipment maintenance.
In order to overcome the above problems, a beam-shielding cover is suggested, for example, in Japanese Patent Laid-Open No. 58-181820 However, such a shielding cover is not complete and the usage of high-energy beams requires a cooling unit, disadvantageously enlarging the device even more.
Further, when the amount of strip wind is unexpectedly increased, and consequently, the edge regions of the strip fall outside the scannable width of the pre-positioned electron-beam irradiating devices. The non-irradiated portions are produced at the edge of the strip, thus further causing serious problems in terms of the quality of the strip. The electron-beam devices cannot be modified easily.
Though irradiation has been described by using electron beams as energy beams, the application of laser beams or plasma beams also creates similar problems.
OBJECTS OF THE INVENTION
Accordingly, it is an object of this invention to overcome the difficulties just described. Another object of the present invention is to provide a method of irradiating strip with energy beams, even when strip winds are present, and to cause the regions scanned by respective energy-beam irradiating devices and the energy-beam irradiating devices to be quickly modified in accordance with the actual amount of strip wind, thereby effectively preventing the disadvantageous production of unwanted beam non-irradiated portions and overlapping-irradiated portions, and also preventing damaging beam irradiation on any area other than the strip, thus achieving stably uniform irradiation all along the desired portions of the width of the strip.
SUMMARY OF THE INVENTION
In order to achieve the above objects, according to one embodiment of the present invention, a continuously-running strip is irradiated with energy beams achieved by scanning and tracking along the width of the continuously-running strip by utilizing a plurality of energy-beam irradiating devices installed along the width of the strip. This can remarkably be achieved by sensing in advance the allocation of scanning regions along the width of the strip to the respective energy-beam irradiating devices and quickly adjusting the regions in response to a strip wind. This can conveniently be achieved by strategic and advantageous location of a strip-edge detecting device placed closer to the upstream line than the energy-beam irradiating devices, in accordance with the detected amount of the strip wind, thereby constantly and in advance scanning the predetermined regions on the strip by the allocated energy-beam irradiating devices.
According to another embodiment of the present invention, a continuously-running strip is irradiated with energy beams by scanning along the width of the strip on the continuously-running strip by utilizing a plurality of additional neighboring energy-beam irradiating devices installed along the width of the strip. This may be achieved by sensing or determining in advance the allocation of scanning regions along the width of the strip to the respective energy-beam irradiating devices; shifting from the respective energy-beam irradiating devices for scanning the predetermined regions to the neighboring devices adjacent to a strip wind when the amount of strip wind detected by the strip-edge detecting device exceeds the scannable regions by the energy-beam irradiating devices; and scanning the regions by the shifted energy-beam irradiating devices.
According to still an other embodiment of the present invention, a plurality of energy-beam irradiating devices may be installed to form steps arranged to cross the strip obliquely longitudinally.
In accordance with the present invention, the strip-edge detecting device, which may be referred to as an edge sensor, is placed upstream of the energy-beam irradiating devices, thereby detecting deviations of the aforementioned edge regions in real time. Also, the allocated regions scanned by the main energy-beam irradiating devices are changed by angular beam adjustment in response to the sensing of the edge sensor, thus enabling energy-beam scanning in accordance with the amount of the strip wind. As a result, non-irradiated portions or overlapping-irradiated portions on the strip are effectively eliminated, significantly improving the quality of the product and its yield.
Further, in regard to the irradiation of the edge regions, the strip, except for a small amount of non-irradiated regions at the strip edges, can be scanned, thus effectively preventing leakage of irradiating beams on any area other than the strip and remarkably reducing the manpower required to maintain equipment such as a vacuum chamber, a strip support roll, or the like.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows typical electron-beam scanning according to a conventional method by utilizing a plurality of electron-beam irradiating devices;
FIG. 2 shows the irradiation of edge regions with electron beams in scanning electron beams according to the conventional method by utilizing a plurality of electron-beam irradiating devices;
FIG. 3 shows the non-irradiated portions of a strip with scanning electron beam according to the conventional method by utilizing a plurality of electron-beam irradiating devices;
FIG. 4 shows one embodiment of electron-beam scanning according to this invention, utilizing a plurality of electron-beam irradiating devices;
FIGS. 5(a), 5(b) and 5(c) show modifications of scanning regions of electron beams according to that embodiment; and
FIGS. 6(a) and 6(b) show the shifting of electron-beam irradiating devices according to still another embodiment of the present invention, with certain portions shown in dash lines.
It will be appreciated that the following description is intended to be directed toward specific forms of the invention selected for illustration in the drawings, and is not intended to define or to limit the scope of the invention, which is defined in the appended claims.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
One embodiment of the present invention will now be described with reference to a typical example using an electron beam as the energy beam and a steel sheet as the strip.
FIG. 4 of the drawings shows irradiation of electron beams. It is understood that strips are welded and continuously treated as a continuous strip or sheet. Five electron-beam irradiating devices 1, 2, 3, 4 and 5 are provided in FIG. 4, though any other numbers may be used.
Since the skeleton construction of FIG. 4 is somewhat similar to that of FIG. 1, some components corresponding to FIG. 4 have been given the same reference numerals as in FIG. 1. FIG. 4 also indicates a strip-edge detecting device 8', further to be described in detail, a detecting controller 9 also to be explained in detail, and a process computer 10, the details and arrangement of which are important features. Said devices are conventional ones.
Sensed or measured data of the width W of a strip S is first transmitted to a strip driving controller 7 from the process computer 10 using electronic devices such as modem. Then, a device for irradiating with electron beams is selected in a known manner, and according to the signal from an electron beam controller 6, electron beams are scanned along selected portions of the running strip width. The strip driving controller 7 and the electron beam controller 6 are conventional devices.
The selected electron-beam irradiating devices selected from devices 1-5, as shown, are selected with respect to W as follows.
where W≦W 1 : Device 3 only is energized.
where W 1 ≦W≦W 2 : Devices 2-4 are energized.
where W 2 ≦W≦W 3 : Devices 1-5 are energized.
As will be apparent, W 1 shows the scannable width that is applicable when only the electron-beam irradiating device 3 is to be used; W 2 indicates the scannable width when the electron-beam irradiating devices 2-4 are to be used; and W 3 represents the scannable width when the electron-beam irradiating devices 1-5 are to be used.
The strip-edge detecting devices 8' (FIG. 4) are connected and arranged for detecting the position of the strip edge in real time. It is arranged at or upstream of the electron-beam irradiating device 5, preferably as closely as possible to the device 5 (preferably, within about 10 m). A detecting signal 32 from the edge detecting device 8' is electronically connected in a manner known per se and thereby tracked by the strip driving controller 7. When the thus-detected amount of a strip wind arrives directly under the respective electron-beam irradiating devices 1-5, the scanning regions of the devices 1-5 are immediately shifted by the electron-beam controller 6 in accordance with the detected amount of the strip wind.
As an example, where the amount of strip wind is expressed as ΔW, as in FIGS. 5(a), 5(b) and 5(c), the scanning distance from the start point to the end point of the respective electron-beam irradiating devices are shifted by ΔW along the width of the strip when the detected amount of the strip wind passes by.
This phenomenon is shown in greater detail in FIGS. 5(a), (b) and (c). The correlation of the amount of the strip wind ΔW and the right and left edge positions X 1 and X 2 is as follows.
ΔW=(X.sub.1-X.sub.2)/2 (1)
When five electron-beam irradiating devices 1-5 are utilized as in FIGS. 4, 5(a), 5(b) and 5(c), the width of the strips is also divided into five parts, B 1 -B 5 representing the regions scanned by the respective electron-beam irradiating devices. The allocations of these regions to the respective electron-beam irradiating devices may be determined in advance.
Thus, as illustrated in FIG. 5(a), when there is no strip wind, the respective electron-beam irradiating devices 1, 2, 3, 4 and 5 scan directly over the corresponding regions B 1 , B 2 , B 3 , B 4 and B 5 , respectively.
As shown in FIG. 5 (b), however, when a strip wind occurs on the running strip, in a direction displacing the strips by the distance ΔW toward the "+" direction (toward the right in FIG. 5(b)), the start point and the end point of scanning are modified so that the scanning regions of the respective electron-beam irradiating devices are shifted by a distance of ΔW toward the "+" direction in accordance with the instantaneous amount of the strip wind. As a result, the regions B 1 -B 5 on the strip are still constantly scanned by the same electron-beam irradiating devices as had already been determined in advance.
Likewise, as shown in FIG. 5(c), when the strip S is displaced by a distance ΔW toward the "-" direction (toward the left in FIG. 5(c)), the scanning regions of the respective electron-beam irradiating devices 1-5 are modified by the distance ΔW toward the "-" direction, and the regions B 1 -B 5 are also scanned by the same electron beam irradiating devices as were determined in advance.
The modification of the scanning regions of the electron beams is accomplished not only to the two irradiating devices 8",8" for irradiating the edges of the strip but to all the individual electron-beam irradiating devices 1-5, thus preventing the beams from overlapping into neighboring regions scanned by the electron beams, and avoiding any failure to irradiate other regions.
Hence, even though the electron-beam irradiating devices may be longitudinally arranged in the form of steps in accordance with another embodiment of the present invention), quick and highly accurate beam scanning can be realized without causing non-irradiated portions and without producing overlapping-irradiated portions.
In regard to the strip edges, with or without the strip wind, electron-beam irradiation can be directed to the appointed regions of the strip edges, thereby avoiding beam-irradiation of any area other than the intended area of the strip. Also, the designated regions are readily oriented to be within the limit of the edges, thereby remarkably reducing any non-irradiated portions at the edge of the strip.
In accordance with a further embodiment of the present invention, means are provided for directing irradiation even when the amount of the strip wind exceeds the scannable region of the electron-beam irradiating devices. There is particularly shogun in FIGS. 6(a) and 6(b) of the drawings.
FIG. 6(a) shows irradiation when the amount of a wind falls within the scannable region of the electron-beam irradiating devices. En this case, as described, the respective electron-beam irradiating devices are directed to scan the predetermined corresponding strip regions allocated to the devices.
FIG. 6(a) indicates the actual electron-beam scanning region A and the electron-beam scannable region C.
However, a considerable or unexpected amount of strip wind sometimes occurs for some reason, and accordingly, the amount of the strip wind sometimes exceeds the scannable region of the electron-beam irradiating device.
The respective electron-beam irradiating devices for scanning predetermined regions are each shifted to the neighboring device adjacent to the scan wind, and consequently, these regions are still scanned by the shifted electron-beam irradiating device.
More specifically, as shown in FIG. 6 (b), when a considerable strip wind occurs toward the "+" direction, and the electron-beam irradiating device 1 cannot cover the predetermined region of the strip S, the irradiation of the electron-beam irradiating device 1 is turned off, and the region B 1 which has theretofore been scanned by the electron-beam irradiating device 1 before the major wind occurred is instantly scanned by the neighboring electron-beam irradiating device 2. Likewise, the regions B 2 , B 3 , . . . which had been scanned by the electron-beam irradiating devices 2, 3, . . . are now immediately scanned by their neighboring electron-beam devices 3 (shown in dash lines in FIG. 6(b) and even by further neighboring electron-beam devices, not shown.
After return to normal from the unexpectedly large strip wind, when the edge portion of strip S is returned to fall within the scannable region of the electron-beam irradiating device 1 again, the reverse operation is performed, thereby returning to normal irradiation with continuing strip wind control as heretofore described.
Accordingly, in FIGS. 6(a) and 6(b), it is necessary to set the total scannable width of the overall electron-beam irradiating devices to cover an enlarged area obtained by adding the possible maximum amount of a strip wind to the maximum width of the strip to be irradiated.
In FIGS. 6(a) and 6(b), the modifications of the electron-beam scanning regions are also made to all individual electron-beam irradiating devices, and thus, even when the electron-beam irradiating devices are longitudinally positioned or displaced to form steps, extremely fast and accurate beam scanning can be realized without permitting or causing any non-irradiated portions or producing overlapping-irradiated portions.
Although the foregoing examples have been discussed from the viewpoint of the irradiation of a steel sheet with electron beams, other kinds of strips may be irradiated with electron beams. Further, when strips including steel sheet are irradiated with laser beams or plasma beams, irradiation may readily be carried out in a manner similar to the embodiments disclosed, thus reliably obtaining the same advantages.
As will be clearly understood from the foregoing description, the present invention offers many advantages.
A strip-edge detecting device according to this invention is placed upstream of the energy-beam irradiating devices, thereby detecting the exact edge positions of the strip in real time, thus enabling energy-beam scanning in accordance with the amount of the existing wind on the strip. As a result, even though the energy-beam irradiating devices may be arranged in the form of steps, appropriate beam scanning can be realized without non-irradiated portions or overlapping-irradiated portions on the strip, thus improving the quality of the product and the yield.
In regard to the irradiation of the edge regions, the strip, except for a controllably small margin of non-irradiated regions at the strip edges, can be accurately scanned, thus preventing irradiation of beams on any area other than the desired areas of the strip and remarkably reducing the load to maintain equipment such as vacuum equipment, strip support rolls, or the like. Also, since beam-irradiation out to the edge portions, the outer limit, is possible, the amount of edge-trimming (if any) is significantly reduced, thus improving strip yield.
Although this invention has been disclosed with reference to particular forms selected for illustration, it will be appreciated that many other modifications may be made without departing from the basic idea of this invention, including the use of different kinds of strips or sheets, different kinds of radiations, and the use of certain features independently of the use of other features, all without departing from the basic idea and scope of this invention, as defined in the appended claims.
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A method of irradiating a continuously-running strip with energy beams. Scanning the width of continuously-running strip positions energy-beam irradiating devices along the width of the strip. Allocation of scanning regions along the width of the strip corresponding to respective energy-beam irradiating devices is determined. When an edge deviation or strip wind is detected by a strip-edge detector upstream of the energy-beam irradiating devices, the strip regions to be scanned are adjusted. If the amount of strip wind exceeds the limits of the scannable energy-beam irradiating devices, neighboring irradiating devices are re-oriented, all in response to upstream strip wind detection.
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This invention relates to a biological method for controlling field infestations of corn rootworm. More particularly this invention is directed to the use of viable populations of parasporal-inclusion-forming bacteria of the species Bacillus laterosporus to reduce crop damage caused by corn rootworm.
BACKGROUND AND SUMMARY OF THE INVENTION
Corn rootworms are the most serious pests of corn in the major corn growing regions of North America. Root feeding of the larvae has a pronounced effect on corn growth and corn yields. Corn rootworm infestations have been shown to decrease yields of corn by 13 to 16 bushels per acre. The present day toll paid by U.S. farmers in treatment costs and crop losses is estimated to be in the range of $1 billion per year.
Since crop rotation is the only practical, non-chemical control for corn rootworms [e.g., Western Corn Rootworm, Diabrotica virgifera virgifera (LeConte), and Northern Corn Rootworm, D. barberi (Smith and Lawrence)], there has been heavy reliance placed on the use of chemical insecticides. However the present day control of corn rootworms with soil insecticides has been complicated by additional technological problems. Not only has low levels of resistance developed to some of the newer insecticides, but accelerated microbial degradation has been noted where the soil microorganisms have developed a capacity to use the soil insecticide. Such has resulted in degradative rates of carbofuran and other soil pesticides as much as 10-fold higher in problem soils than in non-problem soils. These adverse factors, together with legal restrictions on use of insecticides because of potential user toxicity and environmental contamination, resulted between 1950 and 1983, in the withdrawal of recommendations for use of the following soil insecticides for corn rootworm control: benzene hexachloride, aldrin, dieldrin, heptachlor, chlordane, parathion, diazinon, disulfoton, fensulfothion, isofenphos, carbaryl, metalkamate, landrin, and carbofuran. Only a few new insecticides have been introduced during the 1980's as replacements. Thus the prognosis for long-term continuation of successful soil insecticide control of rootworms does not look promising.
There are a number of parasporal-body-forming Bacilli that produce toxins for insect larvae. A number of soil bacteria effective in the control of insects of several orders have been commercially available since the 1960's. Examples are Bacillus popilliae for the control of Japanese beetle (Scarabaridae), several serotypes of Bacillus thuringiensis for the control of Lepidoptera pests of food and fiber crops and B. thuringiensis subsp. israelensis effective on Diptera, i.e., mosquitoes and black flies. A more recent isolate, B. thuringiensis subsp. tenebrionis, seems to be toxic to certain Coleoptera, that is, the Colorado potato beetle. In all cases, perhaps with the exception of B. popilliae, the bacteria produce a proteinaceous parasporal inclusion during sporulation. Generally, it is this inclusion which contains the lethal agent; that is, it is composed of protoxin molecules which are cleaved in the larval gut to toxins. In a few cases, the bacterial spore may also participate in the killing, and in the case of B. popilliae (and a few less prevalent related organisms), it is probably the multiplication of the bacterium in the larval haemolymph that results in the death of the host.
There has been no isolation/description of soil bacteria that are effective on the coleopteran species, Diabrotica (corn rootworm).
In view of the above-mentioned technological limitations on chemical control of corn rootworm, including Pest resistance, non-biodegradability, and animal toxicity, a biological control agent for corn rootworm would be a most desirable alternative. Accordingly, this invention is directed to the use of parasporal-inclusion-forming Bacillus laterosporus, which when present in the soil of growing corn crops are effective for controlling corn rootworm infestations. Compositions comprising (1) viable parasporal-inclusion-producing bacteria of the species Bacillus laterosporus in the form of vegetative cells or spores, and (2) an agriculturally acceptable carrier therefor can be applied to the soil in conjunction with (either before, with or after) planting of a corn crop.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graphical illustration of the protection afforded growing corn from Diabrotica virgifera virgifera (Western Corn Rootworm) by Bacillus laterosporus P5 (ATCC 53694).
FIG. 2 is a graphical illustration similar to that in FIG. 1 except showing protection by treatment with B. laterosporus P5 spores and inclusions.
DETAILED DESCRIPTION OF THE INVENTION
Soil samples were screened for bacteria capable of controlling corn rootworms. Soil samples were obtained from cornfields which had not been treated with insecticides in recent years. They were taken from fields infected with corn rootworm and from fields apparently free of corn rootworm infestation. Portions of soil (100 mg) were suspended in buffer, heated and plated on enriched media. The plates were incubated for sufficient time to permit cells to sporulate and these were then screened in the phase microscope for unusual morphology and particularly the presence of parasporal inclusions. The screening procedure turned up several unique isolates, all with similar morphology but present only in soil samples from non-infested portions of one field located at the Throckmorton Purdue Agricultural Center in Randolph Township, Tippecanoe County, Ind. One particular isolate, designated as Bacillus laterosporus P5, was found in a low frequency in eight of nine samples from non-infested soil but was absent in all nine samples of soil from areas known to be infected with corn rootworms. This correlation prompted initial tests of the toxicity of the B. laterosporus P5 species (cells or spores thereof) on various Lepidoptera as well as on corn rootworm. No toxicity was observed on the larvae of three test Lepidoptera (Manduca sexta, Trichoplusia ni, Heliothis virescens) but experiments with the Western Corn Rootworm looked promising.
The Bacillus isolate, designated Bacillus laterosporus, P5 was deposited on Nov. 23, 1987, at the American Type Culture Collection and was assigned ATCC Designation "53694". Other isolates of Bacillus laterosporus having either free or attached parasporal inclusions have been found in soil samples free of corn rootworm.
Both vegetative cells and spore suspensions were tested on corn seedlings in flats supplemented with larvae of Western Corn Rootworm. The mean height of the plants was then measured for at least 35 days. Those plants growing in flats infested with corn rootworm grew slowly for about 14 days and then stopped while plants exposed to both rootworm and either cells or spores of one of the B. laterosporus isolates continued growing at the control rate for 18-20 days before tapering off. Other studies confirming the efficacy of parasporal-inclusion-forming Bacillus laterosporus species for control of corn rootworm have been conducted and are described below.
The plant protection properties of the P5 strain of Bacillus laterosporus were evaluated in a greenhouse study using Ohio 43 inbred corn planted in 15 cm diameter plastic pots. Individual kernels were planted approximately 2.5 cm deep in Promix, a commercial planting medium, that had been water saturated prior to being placed in the pots. There were two groups of treatments, and initially 13-14 pots were planted for each treatment. The first group was designed to evaluate the effects of actively growing B. laterosporus cells and the second group to evaluate B. laterosporus spores. Cells were applied with NYSM growth medium while spores were applied with water. There were three treatments in each group. In the first group, the treatments were: 1) and 2), 15 ml of sterile medium per pot and 3) 15 ml of NYSM media containing approximately 3.0×10 8 cells/ml. In the second group, treatments were: 4) 15 ml H 2 O containing approximately 6.0×10 8 spores/ml, and 5) and 6), 15 ml sterile H 2 O. Treatments were to the surface and applied above the kernel at planting time. Eight days after Planting, germination was evident. The number of Pots with germinated corn was reduced to 10 per treatment, and treatments were repeated. The following day, each plant in treatments 2, 3, 4 and 5 was infested with Western Corn Rootworm, Diabrotica virgifera virgifera (LeConte), eggs by placing 0.5 by 2.0 cm filter paper strips bearing the eggs 2.5 cm deep at the base of each plant. Treatments 1 and 6 were not infested. To estimate hatch time and rate, 20 eggs were kept on moist filter paper in a petri dish. (Beginning five days after infestation, 85% of these hatched over a three day period.) Extended plant height was the criterion used to evaluate treatment effect. Heights 48 days after planting were determined for each treatment and treatment means were compared using the general linear model (GLM) procedure on the Statistical Analysis System (SAS).
In the spore group, results indicate that plant protection occurred in response to treatment of the planting medium with B. laterosporus. Infested plants treated with spores were numerically taller than those without spores (74.4 vs. 63.3 cm) but the difference was not statistically significant at the 95% confidence level. Uninfested plants (98.6 cm) were significantly taller than either of the infested treatments.
In the cell group, however, no protection was evident because plants treated with the B. laterosporus cells were the shortest among the three treatments. Uninfested plants were significantly (probability<0.05) taller than infested plants treated with cells (100.6 vs. 80.4 cm) but not significantly taller than infested plants treated with cell free medium (92.9 cm). There was no significant difference in mean height between the infested groups.
FIELD APPLICATION
Large scale preparation of vegetative cells or spores of B. laterosporus can be accomplished in any of a variety of art-recognized complex media containing Yeast extract and peptones. Two liter flasks containing up to 500 ml of media can be inoculated and incubated in a rotary shaker at 30°-37° C. for 12-14 hours to provide the inoculum. Fermentor flasks containing the same medium can then be used for the growth of 10-80 l. Growth times will vary depending upon the nutrient medium, temperature, aeration and growth stage desired. Under typical cell growth conditions vegetative cells can be harvested after 8-10 hours; spores (plus inclusions) are harvested after 24-36 hours. Harvesting may be done in a Sharples continuous flow centrifuge. The resulting cell paste can then be suspended to any desired final concentration (determine the cell numbers with a Petroff-Hauser counter) in either a nutrient-containing medium, distilled water or a buffer of choice. The spores will keep well, but vegetative cells should be prepared immediately before field application.
Field application of B. laterosporus in accordance with this invention can thus be accomplished as a cell or spore suspension in an agriculturally acceptable liquid carrier or as a granular formulation in which viable cells or spores are sprayed or otherwise coated onto a granular substrate. The substrate can be formed, for example, from an inert clay or other agriculturally acceptable mineral or organic material. Granular materials typically range in size from 20 to 80 mesh, sized for easy handling, for example, in equipment designed for application of granular fertilizers. The granular substrate is sprayed with a solution of viable cells and/or spores, optionally containing cell nutrients and coating-excipients, and then dried. Alternatively, the Bacillus species (cells or spores) can be applied, for example, with a nutrient supplement or binder as a seed treatment so that a viable rootworm-confronting population of the microorganism is initiated in the soil environment of the planted seed.
Currently, granular formulations of commercially available rootworm insecticides are applied in an 18 cm band or in furrow at planting time. This method has also been tested on other biological insecticides such as Beauveria bassiana. Granular formulations of B. laterosporus spores can be applied in a similar manner at planting time in equipment already present on corn planters. Spores could also be suspended in water and applied as a spray at planting time. Again, the required equipment is currently used by farmers in other applications. Results from small plot field studies can be evaluated to determine optimal rates and methods of applications. Since planting densities are preset, initial application rates in terms of active ingredient per acre can be determined by extrapolation of the greenhouse treatment levels.
FIELD TESTS WITH B. LATEROSPORUS VARIANT P5 VERSUS WESTERN CORN ROOTWORM (DIABROTICA VERGIFERA VERGIFERA)
In this test, 12 plots were laid out on part of a 1/3 acre field. Each plot contained 4 rows 463 cm long and 84 cm apart and were spaced 168 cm from neighboring plots. All plots were seeded with OHIO 43 corn on May 26. Diabrotica eggs taken from 2-4° C. storage in soil were spread on filter paper strips (20 eggs/strip) on May 22 and incubated at room temperature with high humidity in the dark for hatching (60-80%) some 14 days later at which time most corn shoots were showing. Controls consisted of one plot with corn only, two with corn and rootworms and one corn rootworm treated with Cyanamid's Counter® brand insecticide (15 gm/row). Other plots were treated (30-40 minutes) Prior to the addition of the about-to-hatch egg papers with both sporulated and vegetative cultures of the test strain and with control cultures of B. laterosporus not containing inclusions (NRS-590 in Table I). Concentration of cells or spores varied from 2×10 7 to 1×10 11 per meter of row. Cells or spores grown up in 15 liter batches of NYSM broth, harvested by a "Pellicon" apparatus (Millipore), pelleted by centrifugation and resuspended in water (spores) or NYSM (cells) to 150 mls. The test suspensions at the calculated concentrations were suspended to 1 liter (water for spores and NYSM media for vegetative cells) and sprayed down the rows using a Green-Cross "Superspray" hand pump bottle. A one liter water spray followed to "wash in" the culture. Egg Papers were placed 1-2 cm from the developing roots. Corn growth (plant height) was measured each week for 12 weeks and on October 20 the cobs were weighed for yield.
TABLE I__________________________________________________________________________MEAN Plant Height (and Std. Error) in Cm(Cultures added with rootworms to soil)Doses given per row (463 cm)20 rootworms/plant4 row/plot, n = 36-40__________________________________________________________________________PLOT #9 1 2 3 4 5 6 CONTROLDay (No Rootwormof COUNTER Added A7 (10.sup.10) P5 veg Only (10.sup.10) P5 NRS - 590GrowthCONTROL Rootworms) Veg. (10.sup.10) Control Spores (10.sup.10)__________________________________________________________________________16 59.9 78 71.6 82.3 77.1 53.9 40.6(3.1) (4) (55) (5.2) (4.2) (3.4) (3.4)22 154.6 169 131.7 152.7 143 117.7 95.9(5.1) (7) (8.3) (8.1) (5.2) (5.8) (5.1) 281 309 252 273 234 182.5 178.5(17) (14) (15) (16) (13) (14) (9)36 508.7 533 443 467 414 335 318(24) (20) (21) (23.6) (19.7) (22) (16.2)43 756.6 749 638 701 618 479 515(17) (14) (18) (20.1) (20) (36) (17.2)50 900 902 781 875 827 716 715(30) (23) (24) (28.6) (23) (31) (19.3)57 1032 992 916 1038 983 856 850(19) (36) (29) (29.4) (23) (33) (29)64 1159 1074 1088 1183 1160 958 1042(25) (49) (32) (39) (25) (49) (21.5)72 1401 1287 1384 1460 1427 1225 1313(40) (52) (34) (27) (23) (44) (26.1)78 1508 1467 1512 1561 1560 1390 1490(37) (36) (29) (23) (17) (42) (20.9)85 1554 1495 1569 1573 1603 1535 1620(17) (32) (22) (35) (12) (31.1) (15)CORN 151 136 140 155 94 127 144YIELD__________________________________________________________________________ PLOT # 7 8 10 11 12 Day P5 Spores Rootworm Of + Inc Only (10.sup.8) P5 (10.sup.10) P5 (10.sup.10) A7 Growth (5 × 10.sup.10) Control Spores 2b Spores__________________________________________________________________________ 16 64 55.7 48.3 73.9 52.5 (3.8) (2.4) (5.3) (6.3) (5.5) 22 130 125.3 115.7 143.9 110 (6.3) (4.1) (8.7) (11.2) (7.8) 249 243 213 287.6 205 (11.7) (8.5) (18) (19.5) (12.1) 36 446 457 360 438 326 (16.8) (11.7) (37) (31.4) (19.6) 43 647 675 646 655 421.4 (17.4) (23) (20) (34) (33) 50 838 816 807 818 577 (18) (24) (25) (41) (28) 57 969 951 960 959 671 (21) (15) (26) (39) (29.3) 64 1137 1075 1114 1076 781 (29) (16.8) (30.5) (53) (27) 72 1419 1308 1369 1296 954 (29.5) (24.9) (36.3) (39) (36) 78 1549 1479 1484 1406 1125 (21) (19.3) (29) (33) (44) 85 1587 1524 1487` 1462 1326 (19) (13) (53) (29) (37) CORN 146 133 132 140 114 YEILD__________________________________________________________________________
Raw data for 11 weeks of this 12 plot test are reported in Table I. The best control growth performance was shown by both the corn without added rootworms and the "Counter" treated plots; the latter out-performing the former in later growth and corn yield. A group of plots (Plots 2, 4, 8 and 12) unprotected by Counter or by the test culture or treated with a culture of B. laterosporus not containing inclusions (NRS-590) were suppressed in growth an average of 14% over the 12 weeks and were 20-22% behind Counter control from day 22 to day 42. Corn yields of these unprotected, rootworm treated plants were suppressed by 20%. Addition of resting spores+inclusions of the P5 culture at a dose 2×10 7 /meter showed no improvement, at 10 10 only slight protection and at 10 11 possibly moderate protection. The vegetative culture of P5, however, added at 10 10 /per row (2×10 9 /m) showed full protection of growth and a 29% improvement of corn yield over the unprotected controls (FIG. 1 and Table II). Lower doses of vegetative cells were not tested.
Because of a suspected endogenous infestation of Diabrotica virgifera in the test field, a second series of tests was set up later in the summer when such eggs were presumably hatched out. In this study because of the apparent early failure of P5 spores and inclusions to show Protection, it was decided to pretreat the soil with test cultures. These were sprayed down the rows as in the previous study on Jul. 9.
TABLE II______________________________________MEAN CORN YIELDGrams/Plant______________________________________Control Plot (Plot #1) 136Counter ® Plot (Plot #9) 1512 Rootworm Only Plots (Plots #4 and 8) 1134 Unprotected Plots (Plots 2, 4, 1208 and 12)P5 Vegetative Cell Plot (Plot #3) 155______________________________________
On Jul. 16, the rows were seeded and on Jul. 21 a moist paper strip with 20-30 eggs was added. The positive control here was not treated with insecticide and given no worms. Plant height was measured as before but the study was terminated at 60 days.
The data for these eight plots is reported in Table III. The week's pretreatment apparently made the P5 spores as effective as the vegetative cells.
A graph of controls without rootworms (C) and with rootworms (W) are compared to the rootworm plus P5 spore-treated plot (W+P5) in FIG. 2. Together these field tests suggest that vegetative cells are the active form rendering protection of corn plants to Diabrotica virgifera damage. Given time to germinate, the spores also become effective.
Separate laboratory tests indicated no immediate toxicity when larvae (1st, 2nd and 3rd instar) were exposed to spores plus inclusions or purified inclusions of P5. Late additions of culture to infested corn were not protective. The apparent protective effect of P5 in growth studies suggests the culture, in vegetative form, either invades the very young larvae for immediate or later damage or that it blocks the receipt or response of the rootworm to the corn root signal that directs it to the roots.
TABLE III__________________________________________________________________________Mean Plant Height (and Std. Error) in CmCultures added 7 days before Planting(July 9, 1987)n = 26-28doses in #/row (1080 cm)20 rootworms/plant Plot 20 Plot 14 Plot 15 Plot 17 Plot 19 Mut. P5 21Day of Corn Plot 13 Rootworms P5 Spores P5 Spores Plot 18 Rootworms InclusionsGrowth (Since Control Only + Inc. Plot 16 + Inc. P5 Cells Only + Some Sp.Planting) Corn Only Control 10.sup.10 A7 Spores 10.sup.9 10.sup.10 Control 10.sup.10__________________________________________________________________________15 222 (8.5) 181 (8.7) 217 (6.1) 184 (10) 189 (8.4) 203 (9.6) 164 (8.9) 178 (9.9)23 465 (16) 399 (13) 447 (13) 408 (14) 380 (26) 417 (16) 332 (19) 345 (24)29 660 (20) 578 (17) 634 (17) 575 (17) 502 (42) 556 (29) 466 (27) 521 (23)36 959 (22) 861 (21) 952 (21) 879 (20) 853 (29) 854 (32) 756 (33) 755 (34)43 1134 (21) 1041 (28) 1127 (21) 1096 (41) 1023 (31) 1035 (31) 884 (52) 899 (37)63 1682 (20) 1611 (26) 1635 (24) 1589 (26) 1573 (30) 1616 (34) 1442 (48) 1415 (60)__________________________________________________________________________
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Corn rootworm infestations can be controlled by inoculating the soil with parasporal-inclusion forming species of Bacillus laterosporus to produce viable populations of that bacteria effective to reduce crop damage. Viable populations of B. laterosporus can be initiated by application to the soil, of effective amounts of vegetative cells or spores of the organism either in liquid suspensions, or as coatings on seeds or granular substrates.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of radio or microwave frequency antennas; more specifically, the present invention relates to compact ceramic-embedded antennas suitable for use with apparatus using radio or microwave communication.
2. Description of Problem Sought to be Solved
Many portable devices in use today rely on radio communications to receive and transmit information. Examples of such devices include pagers, cellular telephones, automobile phones, wireless telephones, GPS (Global Positioning Satellite) receivers, portable terminals, personal computers, walkie talkies, baby monitors, and the like. This list is by no means exhaustive and the use of radio and microwave communications for portable devices can only be expected to grow. For example, it is proposed to develop a network of satellites that will make possible the linking of personal computers with the Internet from any place on earth.
Devices that use radio or microwave communications require antenna systems in order to couple their circuitry to the free space around them in order to receive and transmit information. In the past, wire or linear conductor antennas have been employed in such systems. Wire antennas may be coiled into helixes or spirals to reduce the overall length while maintaining a larger effective length. Such antennas frequently are in the form of dipole antennas in which the antenna forms one-half of the dipole and a circuit element, the casing or other metallic structure of the radio apparatus forms the other half of the dipole.
Wire or linear conductor antennas, however, are relatively large, bulky, and fragile. A need exists for antennas that are small, strong, and inexpensive, especially for use with the portable radio communication devices mentioned above.
Helical conductor antennas have been developed that are formed from laminated ferrite ceramic sheets bearing conductive segments on each sheet. The spiral conductive segments are electrically connected through the ferrite ceramic sheets in order to form the spiral conductive element, which is embedded or "potted" in the laminated ferrite ceramic sheets and is a quarter wavelength in effective length. See U.S. Pat. No. 5,541,610 to Imanishi, et al. for an "antenna for a radio communication apparatus." The antenna is miniaturized not only because it is helical but also because it is embedded in a ceramic material having a higher electrical permittivity (.di-elect cons.) and/or magnetic permeability (μ) than that of free space (.di-elect cons. 0 ,μ 0 ). It will be recalled that ##EQU1## wherein λ=wavelength, c=speed of light in free space (vacuum), ν=frequency, .di-elect cons. r =.sup..di-elect cons. /.di-elect cons. 0 =relative electrical permittivity or dielectric constant and μ r =.sup.μ /μ 0 =relative magnetic permeability of the medium of propagation. For a given frequency, an increase in the dielectric constant .di-elect cons. r and/or the relative magnetic permeability μ r decreases the wavelength of electromagnetic radiation in the medium of propagation. The necessary length of the antenna in such a ceramic material is thus reduced.
Previous ceramic embedded antennas have employed the control of magnetic permeability by using ferrite ceramics. The effective length of the spiral conductive elements of these antennas was adjusted by changing the physical size of the spiral conductive element.
A need exists for an improved helical antenna which has low total volume, small dimensions, high mechanical strength, and can be manufactured by inexpensive and high volume manufacturing process. Such an antenna should be readily manufactured to be compatible with radio or microwave frequencies currently in use and likely to be used in the future, without necessarily changing the physical size of the antenna.
A need also exists for devices using radio or microwave communications, especially portable devices, that have improved antennas with the characteristics set forth above.
SUMMARY OF THE INVENTION
An improved antenna according to the invention meets these needs by providing a helical conducting element embedded in a block of non-ferrite ceramic. The dielectric constant of such a ceramic is readily controlled.
A helical antenna according to the invention may be comprised of a helical conducting element having two ends and embedded in a block principally composed of non-ferrite ceramic. At least one end of the conducting element reaches a surface of the block. The dielectric constant of the ceramic block may be selected to match the antenna to the operating frequency and may have a preselected value in the range of from about five to about forty, with a range of about five to about ten being preferred. The dielectric constant of the ceramic is varied by the choice and composition of the ceramic.
A helical antenna according to the invention may be formed of conducting segments printed or screened in predetermined positions and orientations onto ceramic sheets laminated into a stack. The conducting segments, which may be shaped like arcs or segments of an annulus, are electrically and sequentially connected to form a conductive element in the shape of a helix.
The antenna according to the invention is suitable for use at frequencies in the range of about 0.5 GHz to about 10.0 GHz, with the range of about 0.8 GHz to about 3 GHz currently being preferred.
Methods of constructing ceramic inductors may be used to construct antennae according to the invention. A currently preferred and novel method of making helical antennas includes the steps of:
a. preparing a ceramic green tape;
b. punching guideholes at predetermined locations in the ceramic green tape;
c. punching via-holes at predetermined locations in the ceramic green tape;
d. filling the via-holes with a conductive paste containing tungsten, gold, molybdenum, copper or other conductive metal;
e. printing conductive paste at predetermined locations and orientations on the ceramic green tape to form conductive segments;
f. laminating and compressing multiple ceramic green tapes in a predetermined order while using the guideholes to complete and check the alignment of the tapes;
g. cutting the laminated ceramic green tapes into stacks, each stack comprised of ceramic green sheets bearing conductive segments sequentially and conductively joined to form a helical conductive element; and
h. firing the stacks in a controlled atmosphere to sinter the ceramic sheets, the conductive paste, and the conductive segments.
The method may include the further step of plating the antenna's exterior electrical connection with gold, nickel, tungsten, and/or other metals.
According to another aspect of the invention, a radio or microwave apparatus comprises a housing containing radio or microwave circuitry and an antenna as described above. The antenna may be mounted outside the housing of the radio or microwave apparatus, preferably with a protective dielectric housing covering it. This will be necessary if the housing of the radio or microwave apparatus is metallicized or is made of metal. Alternatively, an antenna as described above may be mounted inside the radio or microwave apparatus if the housing is not made of metal or metallicized. The antenna may then be mounted on a circuit board within the housing of the radio or microwave apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a perspective view of an antenna according to one embodiment of the invention, with a cutaway showing the conductor segments;
FIG. 2 shows a side view of the antenna of FIG. 1;
FIG. 3 shows a top view of the antenna of FIG. 1;
FIG. 4 shows a bottom view of the antenna of FIG. 1;
FIG. 5 shows a sectional view of the antenna of FIG. 1;
FIG. 6 shows a top view of a radio apparatus (a portable terminal) according to another embodiment of the invention, with the antenna of FIG. 1 externally mounted thereon;
FIG. 7 shows a sectional view of the portable terminal of FIG. 6; and
FIG. 8 shows a sectional view of an alternative embodiment of a radio apparatus according to the invention in which the antenna of FIG. 1 is mounted internally.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A preferred embodiment of a helical antenna 10 according to the invention is shown in FIG. 1. A conducting element 20, in the form of a helix, is embedded in a ceramic block formed by a laminated stack of sheets 40, 41, and 42. The top sheet is indicated by reference numeral 42, the middle sheets by reference numeral 41, and the bottom sheet by reference numeral 40.
In one preferred embodiment, the sheets are principally (greater than 85% by weight) comprised of alumina (Al 2 O 3 ). The alumina sheets contain one or more minor ingredients or additives selected to determine the dielectric constant of these sheets and alter the effective length of the antenna 10 for emitting or receiving radio or microwave frequency radiation. Alumina will henceforth refer to a ceramic that is principally made of Al 2 O 3 , with additives to alter the dielectric constant if required, unless the context indicates otherwise.
Other non-ferrite ceramics may be employed instead of alumina, such as chromium oxide (Cr 2 O 3 ), titanium oxide (TiO 2 ), beryllium oxide (BeO), forsterite (Mg 2 SiO 4 ), mullite, barium titanate (BaTiO 3 ), aluminum nitride (AlN), and others that will be known to those of skill in the art. The choice of non-ferrite ceramic will depend in part on the desired dielectric constant. Such non-ferrite ceramics may have additives included to adjust their dielectric constant to a desired value. The preferred embodiment described in reference to the drawings uses alumina but it should be understood that other non-ferrite ceramics may be employed in an antenna according to this invention.
Each of the alumina sheets 40 and 41, but not the top-most sheet 42, bears a thin metallic or conductive arc-shaped conductive segment 30 thereon. As is best shown in FIG. 5, the conductive segments 30 are individually curved so that a smoothly curving helical conductive element 20 will be formed (albeit stepped due to the laminar construction). The conductive element 20 will have the appearance of an annulus when viewed (such as by x-ray imaging) from one end (see FIG. 5). Each conductive segment 30 is preferably made of tungsten or molybdenum when the non-ferrite ceramic of the sheets is alumina.
The conducting segments 30 are sequentially and conductively linked to each other by conductive or metallic material filling the via-holes 50 in the alumina sheets 41, and to the bottom of the antenna 10 by conductive material in the via-hole 50 in the alumina sheet 40. The conductive material in the via-holes 50 preferably is tungsten or molybdenum when the non-ferrite ceramic of the sheets is alumina.
The via-holes 50, filled with the conductive material that connect the conductive segments 30, are best seen in FIG. 2, which is a view of the side of the antenna shown in FIG. 1. The laminated structure of the antenna 10 is disclosed in FIG. 2 as a stack of alumina sheets 40 and 41, each sheet bearing a conductive segment 30 printed thereon, and the top-most alumina sheet 42, which does not bear a conductive segment 30.
FIG. 3 is a top view of the antenna 10. The alumina sheet 42 lacks a via-hole 50 filled with conductive material.
FIG. 4 is a bottom view of the antenna 10. The bottom of the alumina sheet 40 is shown together with a via-hole 50 that is filled with conductive material and a printed conducting ring or areola 60 that electrically communicates with the conductive material in the via-hole 50. (The conducting ring 60 may be printed over the conductive material in the via-hole 50 and may be made of gold plated over tungsten).
The purpose of the conducting ring or areola 60 on the bottom of the antenna 10 is to provide an electrical connection with radio or microwave circuitry in order to receive and/or transmit radio or microwave frequency electromagnetic energy.
In general, the effective length of the helical antenna according to the invention will be a fraction of a wavelength of the radio or microwave frequency radiation that will be transmitted or received by the antenna. Typically, the antenna should have an effective length of approximately one-fourth of a wavelength. For a given overall size of the antenna 10 (and the conducting element 20) the non-ferrite ceramic may be selected so that dielectric constant of the ceramic at the desired operating frequency may be higher or lower (without appreciably changing the relative magnetic permeability), in order to reduce or increase the size of the wavelength of the electromagnetic radiation that will be received or emitted by the antenna at the maximum gain, so that the effective length of the antenna is appropriate for the desired operating frequency.
Additives such as CaO, MgO, and SiO 2 may therefore be included in the ceramic of the sheets 40, 41, and 42 in order to adjust the dielectric constant to a pre-selected value. By such means the dielectric constant of the alumina may be tailored to any value in the range of about eight to about eleven. The preferred range for alumina is from about nine to about ten.
Other non-ferrite ceramics may be chosen in place of alumina if lower or higher dielectic constants are needed. An advantage of non-ferrite ceramics is that by the use of such ceramics a dielectric constant in the range of about 5 to about 40 can be achieved, whereas the available range of dielectric constants for ferrite ceramics is more limited. A preferred range for the dielectric constant of the non-ferrite ceramic used in this invention is from about 5 to about 10.
Other non-ferrite ceramics may be employed that have dielectric constants outside the range obtainable using alumina. Alumina glass ceramics that include silica could be employed if a lower dielectric constant (such as 5) is needed. Titanium oxide (TiO 2 ) could be used if a higher dielectric constant, such as 40, is necessary. Additives may be included in such ceramics in order to adjust the dielectric constant to the desired value, as discussed above in connection with alumina.
By appropriate selection of the thickness and number of the sheets 40, 41, and 42, the diameter of the helix formed by the conductive element 20, and the dielectric constant of the sheets, the effective length of the conductive element 20 of the helical antenna 10 can be varied so that the radio or microwave frequency at which the antenna has the most gain (resonant frequency) can be varied from about 0.5 GHz to about 10.0 GHz, although the range that is currently preferred is about 0.8 to about 3.0 GHz. The dielectric constant of the non-ferrite ceramic sheets can be varied while maintaining the other dimensions of the antenna 10 constant, thus permitting the production of antennae of a uniform size but different resonant frequencies.
An example of an antenna 10, with dimensions and compositions, is described with reference to FIGS. 1-5. The antenna 10 has fifteen sheets 40, 41, and 42 made of 90% black alumina, which has the composition stated in the following table:
______________________________________COMPONENT PERCENT BY WEIGHT______________________________________Al.sub.2 O.sub.3 90%SiO.sub.2 + MgO + CaO 10%______________________________________
Each alumina sheet is 0.152 mm (0.006 inches) thick.
The conducting segments 30 printed on fourteen of the alumina sheets (sheets 40 and 41) are made of tungsten with a minimum thickness of 10 microns. The conductive segments 30 are arc-shaped segments 30 with a width radially (i.e., along a radius of the helix) of 0.635 mm (0.025 inches). Each conductive segment 30 subtends an angle of 51.4° in relation to the central axis of the two-turn helix described by the conductive element 20, the angle being measured between the axes of the via-holes in the underlying alumina sheet and the overlying alumina sheet that are in contact with the conductive segment 30.
The via-holes 50 are 0.254 mm (0.01 inches) wide or in diameter and the axis of each via-hole 50 is located 1.346 mm (0.053 inches) from the central axis of the helix described by the conductive element 20. The conductive material filling the via-holes 50 is tungsten.
The areola 60 printed on the alumina sheets 40 is 1.27 mm (0.050 inches) in diameter and is gold over tungsten with a minimum thickness of 1.524 microns (60 micro inches).
The overall dimensions of this example of the antenna 10 are height: 2.29 mm (0.090 inches), width: 4.85 mm (0.191 inches), and length: 4.85 mm (0.191 inches).
The dielectric constant of the alumina sheets of this example of the antenna 10 is 9.6 (as measured at 1 MHz). The preferred or resonant frequency at which the antenna will operate is 2.45 GHz.
It will be understood by those skilled in the art that the conductive segments 30 can have other shapes than the shapes depicted in FIGS. 1 and 5. For example, the conductive segments could be more angular, such as a series of right angle elbows. The helix described by the conductive element 20 need not be a perfect helix in which each portion is at the same radius from the longitudinal axis of the helix. It will also be understood that the antenna 10 need not be rectangular. For example, it could be shaped as a cylinder.
An antenna according to the invention may be made by any process suitable for making chip or ceramic inductors, and such methods will be known to those skilled in the art. An example of such a method is shown in U.S. Pat. No. 3,812,442 to Muckelroy for a "ceramic inductor," the disclosure of which with respect to methods of making ceramic inductors is incorporated explicitly by reference.
A preferred and novel method of making helical antennas according to the invention is described below.
First, non-ferrite ceramic green tapes are prepared. The non-ferrite ceramic of the green tapes could be alumina having a composition as described above, with a binding agent that will be eliminated during the later firing step. The ceramic green tapes may be formed with a backing that will be removed before the lamination step.
Second, one or more guideholes are punched at preselected positions in the tapes.
Third, the via-holes 50 are punched at preselected positions in the tapes. The second and third steps may be reversed in sequence or performed simultaneously.
Fourth, the via-holes 50 are filled with metal or conductive paste for later conductive interconnection between the sheets or layers of the assembled antenna. The metal paste may be made of a combination of glass, a metal powder appropriate for the chosen ceramic (such as tungsten or molybdenum for alumina), and a carrier.
Fifth, metal or conductive paste is screened or printed at preselected positions and orientations on the tapes to form one or more conductive segments 30. The metal paste may be made of a combination of glass, a metal powder appropriate for the chosen ceramic (such as tungsten or molybdenum for alumina), and a carrier. The metal paste for the conductive segments 30 is printed over the metal paste in the via-holes 50. Each tape may contain at least as many conductive segments as the number of antennae to be made.
Sixth, the tapes formed according to the above steps are laminated and compressed one on top of each other in a predetermined order so that the conductive segments, joined by the metal paste in the via-holes 50, together form conductive elements in the form of helixes. The guideholes, with the aid of a pin or pins, are used in this step to align the laminated tapes.
Seventh, the laminated tapes are cut into stacks of ceramic green sheets, each stack containing a conductive element, and the stacks are trimmed into pre-firing form.
Eighth, the stacks are fired in a controlled atmosphere such as nitrogen (N 2 ) and hydrogen (H 2 ). The purpose of the controlled atmosphere is to prevent oxidation of the metallic components, such as the metal paste of the conductive segments and the metal paste filling the via-holes. The ceramic green sheets and the metal paste of the conductive segments and the metal paste filling the via-holes will be sintered during this step.
Ninth, and optionally, the bottom of each fired stack is plated with a metal, such as gold over tungsten, over and/or around a via-hole containing sintered metal paste and connecting to the outside of the stack, in order to form a conducting areola for electrical connection with the conductive element inside each stack.
Antennas (or inductors) could be made with any non-ferrite ceramics of the kinds described above, including alumina, using the method described above.
The antenna according to the invention can be used as part of an apparatus that uses communication by radio or microwave frequency electromagnetic radiation. FIGS. 6 through 8 depict an embodiment of a mobile or portable terminal using an antenna according to the invention.
The portable terminal shown in FIGS. 6 through 8 is a portable computer terminal 80 having a housing 81 which may be made of a thermoplastic. This terminal is used, for example, to record purchases or to arrange transactions such as renting cars. It has a keyboard or touch pad 82, a display screen 84, and a signature screen 86 which records handwritten signatures. An example of such a portable computer terminal is shown in U.S. Pat. No. 5,334,821 to Campo, et al. for a "portable point of sale terminal," the disclosure of which is explicitly incorporated by reference.
In FIG. 6 an antenna 10 according to the invention is shown mounted within a protective weatherproof cover 90 on the exterior of the housing 81 of the portable terminal 80. The cover 90 is made of a dielectric such as a thermoplastic and protects the antenna 10 from exterior hazards.
FIG. 7 shows a cross section of this embodiment of the portable terminal 80. A metallic compartment 100 mounted on circuit board 110 within the housing 81 contains the radio circuitry. The battery compartment 88 contains batteries (not shown) for the power supply of terminal 80. The circuit board 120 mounts other components of the portable terminal 80, such as a microprocessor and memory components (not shown).
The antenna 10 must be mounted on the exterior of the housing 81 of the portable terminal 80 when the interior of the housing 81 metallicized or the housing 81 is itself made of metal. In this case, the metal housing 81 or the metallic layer on the housing 81 can serve as the other half of a dipole antenna, the antenna 10 forming the first half.
Alternatively, if the housing is made of a dielectric such as a thermoplastic, the antenna 10 may be mounted inside the housing 81 of the portable terminal 82. In the alternative cross section shown in FIG. 8 the antenna 10 is mounted on a circuit board 130 which is in turn mounted normal to the circuit board 110. In this case, the metallic container 100 for the radio circuitry can serve as the other half of the dipole antenna or some other suitably large conductive component within the portable terminal could serve that purpose. See U.S. Pat. No. 5,541,610 to Imanishi, et al. for an "antenna for a radio communication apparatus," the disclosure of which is explicitly incorporated by reference.
It will be understood to those skilled in the art that many other apparatus using radio or microwave frequency communication could be employed with an antenna according to the invention, such as pagers, mobile telephones, portable computers and the like.
Various alterations, modifications, and improvements of the invention will readily occur to those skilled in the art in view of the particular embodiments described above. Such alternations, modifications, and improvements are intended to be part of this disclosure and are intended to be within the spirit and scope of this invention. Accordingly, the foregoing descriptions are by way of example, and are not intended to be limiting. The invention is limited only as defined in the following claims and the equivalents thereof.
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A small and durable antenna for use with radio and microwave communications is formed as a helical conductor contained in a multilayered non-ferrite ceramic chip. The dielectric constant of the ceramic is selected to match the antenna to its operating frequency, which may be in the range of 0.5 to 10.0 Gigahertz. A process for making such antennas is also disclosed. The antenna may be used in portable terminals and other devices requiring small, durable and inexpensive antennae.
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CROSS REFERENCE
[0001] The present application is a continuation of and claims priority under 35 U.S.C. §120 of U.S. patent application Ser. No. 14/028,564, filed on Sep. 17, 2013, which is incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the field of social networking using a computer on a communication network, and more particularly to improving the quality, relevance and form of the content delivered along with its impact on delivery bandwidth.
BACKGROUND
[0003] A social networking service is an online service, platform, or site that focuses on facilitating the building of social networks or social relations among people who, for example, share interests, activities, backgrounds, or real-life connections. A social network service consists of a representation of each user, i.e., a profile, the user's social links, and a variety of additional services. Most social network services are web-based and provide means for users to interact over the Internet, such as e-mail and instant messaging. Social networking sites allow users to share ideas, activities, events, and interests within their individual networks.
[0004] Social media depends mainly on user driven content, which is a defining characteristic of the Social Web. As a result, large amounts of data flow through these social network channels daily. However, relevant content received by a user may be buried in low-quality information. For example, users may receive a large amount of content that the user is not interested in receiving. As such, users may quickly find themselves inundated with irrelevant voluminous content that they cannot control. This is especially problematic for users of mobile networks who are trying to limit the cost of their data usage via their smart phones.
SUMMARY
[0005] A method for improving the presentation of social media data from multiple social network feeds is provided. The method may include aggregating social media content received from the multiple social network feeds. The method may also include generating filtered data by eliminating repetitive data from among the received aggregated social media content. The method may further include analyzing the filtered data for determining at least one data category and presenting a digest of social media content based on the determined at least one data category.
[0006] A computer system for improving the presentation of social media data from multiple social network feeds is provided. The computer system may include aggregating social media content received from the multiple social network feeds. The computer system may also include generating filtered data by eliminating repetitive data from among the received aggregated social media content. The computer system may further include analyzing the filtered data for determining at least one data category and presenting a digest of social media content based on the determined at least one data category.
[0007] A computer program product for improving the presentation of social media data from multiple social network feeds is provided. The computer program product may include aggregating social media content received from the multiple social network feeds. The computer program product may also include generating filtered data by eliminating repetitive data from among the received aggregated social media content. The computer program product may further include analyzing the filtered data for determining at least one data category and presenting a digest of social media content based on the determined at least one data category.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0008] These and other objects, features and advantages of the present invention will become apparent from the following detailed description of illustrative embodiments thereof, which is to be read in connection with the accompanying drawings. The various features of the drawings are not to scale as the illustrations are for clarity in facilitating one skilled in the art in understanding the invention in conjunction with the detailed description. In the drawings:
[0009] FIG. 1 illustrates a networked computer environment according to one embodiment;
[0010] FIG. 2 illustrates a networked computer environment with an exemplary program to improve the information content delivered to a user and improve the impact on delivery bandwidth of such content;
[0011] FIG. 3 is an operational flowchart illustrating the steps carried out by a program to improve the information content delivered to a user and improve the impact on delivery bandwidth of such content; and
[0012] FIG. 4 is a block diagram of internal and external components of computers and servers depicted in FIG. 1 .
DETAILED DESCRIPTION
[0013] Detailed embodiments of the claimed structures and methods are disclosed herein; however, it can be understood that the disclosed embodiments are merely illustrative of the claimed structures and methods that may be embodied in various forms. This invention may, however, be embodied in many different forms and should not be construed as limited to the exemplary embodiments set forth herein. Rather, these exemplary embodiments are provided so that this disclosure will be thorough and complete and will fully convey the scope of this invention to those skilled in the art. In the description, details of well-known features and techniques may be omitted to avoid unnecessarily obscuring the presented embodiments.
[0014] Embodiments of the present invention relate generally to the field of social networking using a computer on a communication network, and more particularly to improving the content delivered to a user along with its impact on delivery bandwidth. The following described exemplary embodiments provide a system, method and program product for improving the quality, relevance and form of the content delivered to a user along with its impact on delivery bandwidth.
[0015] As previously described, social media mainly depends on user driven content and as such, large amounts of data flow through these social network channels daily. However, since the content is becoming more poorly structured, relevant content may be buried in low-quality information and users may quickly find themselves inundated with irrelevant voluminous content that they cannot control. This may be especially problematic for users of mobile networks who are trying to limit the cost of their data usage via their smart phones.
[0016] Currently, there are a number of technical approaches to address these problems. Some solutions focus on the extraction, aggregation, cleaning and visualization for data coming from multiple data sources such as databases or feeds from social networks. For example, data quality problems are currently being addressed by data cleaning. Some techniques may be used that allow users to improve the quality of data and handle cases where data is misrepresented (e.g., spelling mistakes), redundant or has different presentations. Other current techniques being explored involve the usage of semantic web techniques for the analysis of social network and the extraction of knowledge from existing data with a focus on topics such as trust and reputation.
[0017] However, with respect to these current technical approaches, the user has no control over the data representation delivered to the user. Additionally, the variability in the user's data usage constraints is not taken into consideration. Furthermore, topics' identification and content filtering are not dynamically based on the user's current timeline and location.
[0018] According to at least one embodiment of the present invention, data is gathered from different social networks and processed in a way that reduces clutter and improves the content quality while controlling and reducing data usage over mobile networks.
[0019] As will be appreciated by one skilled in the art, aspects of the present invention may be embodied as a system, method or computer program product. Accordingly, aspects of the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, aspects of the present invention may take the form of a computer program product embodied in one or more computer readable medium(s) having computer readable program code embodied thereon.
[0020] Any combination of one or more computer readable medium(s) may be utilized. The computer readable medium may be a computer readable signal medium or a computer readable storage medium. A computer readable storage medium may be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing. More specific examples (a non-exhaustive list) of the computer readable storage medium would include the following: an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing. In the context of this document, a computer readable storage medium may be any tangible medium that can contain, or store a program for use by or in connection with an instruction execution system, apparatus, or device.
[0021] A computer readable signal medium may include a propagated data signal with computer readable program code embodied therein, for example, in baseband or as part of a carrier wave. Such a propagated signal may take any of a variety of forms, including, but not limited to, electro-magnetic, optical, or any suitable combination thereof. A computer readable signal medium may be any computer readable medium that is not a computer readable storage medium and that can communicate, propagate, or transport a program for use by or in connection with an instruction execution system, apparatus, or device.
[0022] Program code embodied on a computer readable medium may be transmitted using any appropriate medium, including but not limited to wireless, wireline, optical fiber cable, RF, etc., or any suitable combination of the foregoing.
[0023] Computer program code for carrying out operations for aspects of the present invention may be written in any combination of one or more programming languages, including an object oriented programming language such as Java® (Java and all Java-based trademarks and logos are trademarks or registered trademarks of Oracle and/or its affiliates), Smalltalk, C++ or the like and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The program code may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).
[0024] Aspects of the present invention are described below with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems) and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
[0025] These computer program instructions may also be stored in a computer readable medium that can direct a computer, other programmable data processing apparatus, or other devices to function in a particular manner, such that the instructions stored in the computer readable medium produce an article of manufacture including instructions which implement the function/act specified in the flowchart and/or block diagram block or blocks.
[0026] The computer program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other devices to cause a series of operational steps to be performed on the computer, other programmable apparatus or other devices to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide processes for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
[0027] The flowchart and block diagrams in the figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods and computer program products according to various embodiments of the present disclosure. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that, in some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts, or combinations of special purpose hardware and computer instructions.
[0028] The following described exemplary embodiments provide a system, method and program product for improving the quality, relevance and form of the content delivered to the user along with its impact on delivery bandwidth.
[0029] According to at least one embodiment of the present invention, a repository of user profiles and preferences may be utilized. The repository may contain all of the user's social media accounts that the user wishes to keep track of, the user's list of interests in a prioritized manner and the user's preferences regarding the delivery method of this content (i.e., size limitation or preferable formats). Additionally, at least one embodiment of the present invention may provide another stage of filtering which may be performed at “runtime” and based on the current snapshot of the timeline on different social networks, the filtered content is categorized and presented to the user so the user may choose the desired topics, the user wishes to consult.
[0030] Embodiments of the present invention may include the following main components: A preference repository database, an entities repository database, a proxy and a digest. The preference repository database may comprise of the user preferences related to quality and presentation of content to be delivered. The entities repository database may store entities' name (i.e., a person, a place, a thing, or an event) aggregated with all its possible representations, synonyms, and known names all linked to a single entity ID (i.e., user-identifier).
[0031] The proxy may intercept the content to be transferred to the user from different social network providers, process it and transmit an adapted content to the end user smart phone or computer based on the user preferences. The content may be presented to the user in the form of a digest respecting the user preferences and categorized by topic.
[0032] Embodiments of the present invention may allow the user to control the filter the user wishes to apply on the content received, in order to reduce data usage rather than imposing a specific constrain over size or type of media (as in the current methods being utilized). Additionally, embodiments of the present invention may be implement in a two-stage filtering mechanism that accounts for general preferences guidelines relating to media type and size as set in the preference repository and specific topics or events available at the time the service is requested.
[0033] Referring to FIG. 1 , an exemplary networked computer environment 100 in accordance with one embodiment is depicted. The networked computer environment 100 may include a computer 102 with a processor 104 and a data storage device 106 that is enabled to run a software program 108 . The networked computer environment 100 may also include a social network 112 , a server 114 and a communication network 110 . The networked computer environment 100 may include a plurality of computers 102 and servers 114 , only one of which is shown. The communication network may include various types of communication networks, such as a wide area network (WAN), local area network (LAN), a telecommunication network, a wireless network, a public switched network and/or a satellite network. It should be appreciated that FIG. 1 provides only an illustration of one implementation and does not imply any limitations with regard to the environments in which different embodiments may be implemented. Many modifications to the depicted environments may be made based on design and implementation requirements.
[0034] The client computer 102 may communicate with social network 112 running on server computer 114 via the communications network 110 . The communications network 110 may include connections, such as wire, wireless communication links, or fiber optic cables. As will be discussed with reference to FIG. 4 , server computer 114 may include internal components 800 a and external components 900 a , respectively, and client computer 102 may include internal components 800 b and external components 900 b , respectively. Client computer 102 may be, for example, a mobile device, a telephone, a personal digital assistant, a netbook, a laptop computer, a tablet computer, a desktop computer, or any type of computing devices capable of accessing a social network.
[0035] As previously described, the client computer 102 may access social network 112 , running on server computer 114 via the communications network 110 . For example, a user using an application program 108 (e.g., Firefox®) (Firefox and all Firefox-based trademarks and logos are trademarks or registered trademarks of Mozzilla and/or its affiliates) running on a client computer 102 may connect via a communication network 110 to one of their social network accounts 112 which may be running on server computer 114 .
[0036] Referring now to FIG. 2 , a networked computer environment with an exemplary proxy 210 and a preference program 212 to improve the information content delivered to a user and improve the impact on delivery bandwidth of such content in accordance with one embodiment is depicted. Preference program 212 may be implemented as running on a server 202 , computer 102 B, or an end user mobile device 206 B. However, for example purposes only, preference program 212 is depicted as running on server 202 . Client computer 102 A and end user mobile device 206 A may communicate via a communication network 110 with a social network 112 which may be running on a server computer 114 . Proactively improving the information content delivered to a user on a computer 102 B or an end user mobile device 206 B and improving the impact on delivery bandwidth of such content in accordance with at least one embodiment may be implemented as preference program 212 and proxy 210 running on server 202 interacting with social network 112 running on server 114 . Proxy 210 running on server 202 may also interact with an entities repository database 208 and a preferences repository database 204 .
[0037] Preference program 212 may be a computer program that improves the information content delivered to a user on an end user mobile device 206 B or computer 102 B and improves the impact on delivery bandwidth of such content from a social network 112 , such as, Twitter® (Twitter and all Twitter-based trademarks and logos are trademarks or registered trademarks of Twitter and/or its affiliates) or Facebook® (Facebook and all Facebook-based trademarks and logos are trademarks or registered trademarks of Facebook and/or its affiliates). Proxy 210 may receive user requests from a computer 102 A, collect data from different social media services' providers on a social network 112 and preference program 212 may perform a series of steps (which will be explained in detail below with respect to FIG. 3 ) on the received feeds before sending the content to the users on their end user mobile device 206 B or their computer 102 B.
[0038] Preferences repository database 204 may store the user profiles for subscribers of the proxy 210 service and hold their social media subscriptions (e.g. face book, Twitter, etc.) along with their preferences. The preferences repository database 204 may provide filter configuration which may be topic filtering based on the context or situation when presented in a digest. Interest preferences may be entered as tags and stored as entity IDs (i.e., user-identifiers) into the preferences repository database's 204 underlying storage. Additionally, delivery preferences may be stored. Delivery preferences may be preferences that relate to the delivery format, such as maximum bandwidth consumption allowed, preferable data format (i.e., text, images, and videos). Furthermore, the entities repository database 208 may store entities' name (i.e., a person, a place, a thing, or an event) aggregated with all its possible representations, synonyms, and known names all linked to a single entity ID (i.e., user identifier).
[0039] According to at least one embodiment, users may login to the preference repository database 204 ( FIG. 2 ) to establish and maintain a user profile (i.e., a set of user-defined preferences associated with the social media data). Once the user profiles are set, the preferences may be pushed to the proxy 210 ( FIG. 2 ) for future content filtering. When the user needs to access the service, a service request may be made to the proxy 210 ( FIG. 2 ). Then the proxy 210 ( FIG. 2 ) may connect to the service providers for the social networks 112 ( FIG. 1 ) the user subscribed to 112 ( FIG. 1 ) and the raw content may be provided to the proxy 210 ( FIG. 2 ) from the different social network providers 112 ( FIG. 1 ) associated with the user. Then the proxy 210 ( FIG. 2 ) may process the content merged from all sources and filters it based on the user preferences and may be presented as a digest categorized by topic on the end user's mobile device 206 B ( FIG. 2 ) or computer 102 B ( FIG. 2 ).
[0040] Referring now to FIG. 3 , an operational flowchart illustrating the steps carried out by a preference program 212 ( FIG. 2 ) to improve the information content delivered to a user and improve the impact on delivery bandwidth of such content is depicted. As previously stated the method may be implemented by utilizing a preference repository 204 ( FIG. 2 ), an entities repository database 208 ( FIG. 2 ), a proxy 210 ( FIG. 2 ) and a digest. The preference repository 204 ( FIG. 2 ) may comprise of the user-defined preferences related to quality and presentation of content to be delivered. The proxy 210 ( FIG. 2 ) may intercept the content to be transferred to the user from different social network providers, process it and transmit an adapted content to the end user smart phone 206 B ( FIG. 2 ) or computer 102 B ( FIG. 2 ) based on the user preferences. The content may be presented to the user in the form of a digest respecting the user preferences and categorized by topic.
[0041] At 302 , the content is aggregated, (i.e., the feeds are merged). For example, different feeds coming in from different social networks 112 ( FIG. 1 ) are merged into one timeline and the social network credentials are kept as part of the user profile in the preferences repository database 204 ( FIG. 2 ).
[0042] Then at 304 , the content is filtered (i.e., cleanup data) and the entries may be analyzed to eliminate (i.e., merge or delete) repetitive data. One implementation may be to detect and remove exact matches (i.e., data that is pointing to the same link and has the same file signature). Another implementation may be to detect similar feeds and aggregate them in a single entry utilizing a meta database (i.e., entities repository database 208 ( FIG. 2 )) that contains all spelling variations and known names of entities, where all different single entity mentions are replaced by a unique ID (i.e., user-identifier). Then, based on this ID, redundant feeds and feeds under the same event may be identified. The identified same event ID may be attached to the feed as metadata. Another implementation may be that feeds repeated from different sources within a network or from different feed sources are augmented such that the feed contents itself is kept intact while information regarding the source, such as IDs, geotags and timestamps may be attached as metadata.
[0043] Next, at 306 , the content is analyzed (i.e., the data is categorized). For example, categorization may be deduced by analyzing patterns within the feeds into two main types (i.e., data categories). One type may be permanent categories (such as sports, culture, etc.) which may be identified by relevant category keywords or user-identifiers (i.e., IDS), timestamps and geo-tags. The permanent categories may be categories that the user wishes to receive information about on a permanent basis. The permanent categories may remain as a user-defined preference until the user changes the permanent categories. Another type may be temporary categories that represent an event, such as a live sporting event, identified by meta data information (i.e., same user-identifiers (i.e., IDS), timestamps and geo-tags within narrow intervals). With respect to the temporary category, there may be a link between two entities that is valid only for a certain amount of time. For example, there may be a link between two teams involved in a sporting game. Once the game (i.e., the live sporting event) has finished, the link may no longer be valid.
[0044] Additionally, in case of tight data constraints, using data roaming or a slow connection, one implementation of the present embodiment may allow the user to request (in the user's preferences) to receive a single instance from temporary categories (i.e., the most frequent one within the category). An example of this may be a live picture of a goalie scoring a goal at a soccer game. According to one implementation of the present embodiment, if the user has tight data limits, then the user may request to receive a single instance of an event. With respect to the soccer example, the user may wish to receive one picture depicting the goalie scoring a goal at the live soccer game. As such, geo-tags (i.e., geographical location tag), IDS (i.e., user-identifiers) of the name of the picture and timestamps (i.e., time the picture was taken) may be taken into account. Regarding the soccer example, geo-tags of the location of the stadium, IDs describing a similar name of the picture (e.g. team name) and timestamps showing approximately the same time the picture was taken may be taken into consideration in determining multiple instances of the same event (i.e., involving the same context). Therefore, the user may receive one picture of a particular time during the soccer game as opposed to receiving multiple instances of the same picture. Furthermore, the number of feeds coming under a certain category may be analyzed to aid in trend detection. For example, if a large number of feeds are being associated with a certain category, such as cooking, then this may aid in determining if a trend is occurring with respect to that particular category.
[0045] At 308 , the digest is presented based on the data size, data type and data categories (i.e., applying data presentation preferences) to the user via the end user's mobile device 206 B ( FIG. 2 ) or computer 102 B. According to one implementation of the present embodiment, data size preferences are stored in a preferences repository 204 ( FIG. 2 ). This may act as a first stage of filtering performed on the content based on the user preferences. Data size preferences may define how the data will be presented to the user depending on their bandwidth or connection speed. One implementation may be to display a text representation rather than images (e.g. image alternate tag or image name) when the user's data plan has tight data constrains, using data roaming or has a slow connection. Another implementation may be for data size preferences to be enabled contextually according to a profile (i.e., when a user is roaming) or based on a time schedule. Additionally, data size preferences and data type preferences may be used collaboratively to remove uninteresting feeds from the timeline.
[0046] According to another embodiment of the present invention, a digest of filtered content may be created and presented to the user grouped by categories or events as identified by the previously described component. Then, based on the above, a second stage of filtering may be applied based on the user to select the categories that are most relevant to the user.
[0047] FIG. 4 is a block diagram of internal and external components of computers depicted in FIG. 1 in accordance with an illustrative embodiment of the present invention. It should be appreciated that FIG. 4 provides only an illustration of one implementation and does not imply any limitations with regard to the environments in which different embodiments may be implemented. Many modifications to the depicted environments may be made based on design and implementation requirements.
[0048] Data processing system 800 , 900 is representative of any electronic device capable of executing machine-readable program instructions. Data processing system 800 , 900 may be representative of a smart phone, a computer system, PDA, or other electronic devices. Examples of computing systems, environments, and/or configurations that may represented by data processing system 800 , 900 include, but are not limited to, personal computer systems, server computer systems, thin clients, thick clients, hand-held or laptop devices, multiprocessor systems, microprocessor-based systems, network PCs, minicomputer systems, and distributed cloud computing environments that include any of the above systems or devices.
[0049] User client computer 102 ( FIG. 1 ), and network server 114 ( FIG. 1 ) include respective sets of internal components 800 a, b and external components 900 a, b illustrated in FIG. 4 . Each of the sets of internal components 800 a, b includes one or more processors 820 , one or more computer-readable RAMs 822 and one or more computer-readable ROMs 824 on one or more buses 826 , and one or more operating systems 828 and one or more computer-readable tangible storage devices 830 . The one or more operating systems 828 and software program 108 ( FIG. 1 ) in client computer 102 are stored on one or more of the respective computer-readable tangible storage devices 830 for execution by one or more of the respective processors 820 via one or more of the respective RAMs 822 (which typically include cache memory). In the embodiment illustrated in FIG. 4 , each of the computer-readable tangible storage devices 830 is a magnetic disk storage device of an internal hard drive. Alternatively, each of the computer-readable tangible storage devices 830 is a semiconductor storage device such as ROM 824 , EPROM, flash memory or any other computer-readable tangible storage device that can store a computer program and digital information.
[0050] Each set of internal components 800 a, b , also includes a R/W drive or interface 832 to read from and write to one or more portable computer-readable tangible storage devices 936 such as a CD-ROM, DVD, memory stick, magnetic tape, magnetic disk, optical disk or semiconductor storage device. A software program 108 , such as the proxy 210 , can be stored on one or more of the respective portable computer-readable tangible storage devices 936 , read via the respective R/W drive or interface 832 and loaded into the respective hard drive 830 .
[0051] Each set of internal components 800 a, b also includes network adapters or interfaces 836 such as a TCP/IP adapter cards, wireless wi-fi interface cards, or 3G or 4G wireless interface cards or other wired or wireless communication links. The program 108 in client computer 102 and proxy 210 in network server 202 can be downloaded to client computer 102 from an external computer via a network (for example, the Internet, a local area network or other, wide area network) and respective network adapters or interfaces 836 . From the network adapters or interfaces 836 , the program 108 in client computer 102 and the proxy 210 in network server computer 114 are loaded into the respective hard drive 830 . The network may comprise copper wires, optical fibers, wireless transmission, routers, firewalls, switches, gateway computers and/or edge servers.
[0052] Each of the sets of external components 900 a, b can include a computer display monitor 920 , a keyboard 930 , and a computer mouse 934 . External components 900 a, b can also include touch screens, virtual keyboards, touch pads, pointing devices, and other human interface devices. Each of the sets of internal components 800 a, b also includes device drivers 840 to interface to computer display monitor 920 , keyboard 930 and computer mouse 934 . The device drivers 840 , R/W drive or interface 832 and network adapter or interface 836 comprise hardware and software (stored in storage device 830 and/or ROM 824 ).
[0053] The descriptions of the various embodiments of the present invention have been presented for purposes of illustration, but are not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope of the described embodiments. The terminology used herein was chosen to best explain the principles of the embodiments, the practical application or technical improvement over technologies found in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein.
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A method for improving the presentation of social media data from multiple social network feeds is provided. The method may include aggregating social media content received from the multiple social network feeds. The method may also include generating filtered data by eliminating repetitive data from among the received aggregated social media content. The method may further include analyzing the filtered data for determining at least one data category and presenting a digest of social media content based on the determined at least one data category.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a washing machine with a balancer, and more particularly to a washing machine, which is equipped with a balancer on a portion of the inner tub of the washing machine having a horizontally disposed drive shaft, thereby reducing its vibration and noise during a spin-drying process.
2. Description of the Prior Art
As shown in FIG. 1, a conventional washing machine includes a cabinet 1 . A door 3 is openably mounted to the front of the cabinet 1 to allow the laundry to be fed and discharged. An outer tub 5 is situated in the cabinet 1 to accommodate water.
An inner tub 7 provided with a plurality of water passage holes 7 a is rotatably positioned in the outer tub 5 . A lifter 9 is mounted on the bottom of the interior of the inner tub 7 to raise the washing water to a predetermined height and, thereafter, allow it to fall down due to gravitational force. A water supply hose 13 passes through the cabinet 1 , and a water supply valve 11 is positioned on the water supply hose 13 , so as to supply water necessary for washing. A detergent container 15 is formed in the upper portion of the cabinet 1 to supply a detergent. A water supply bellows 17 is situated between the detergent container 15 and the outer tub 5 to supply to the outer tub 5 water that has been supplied through the water supply hose 13 and has been mixed with the detergent.
A motor 19 is mounted beneath the outer tub 5 . A belt 21 and a pulley 23 are situated in the vicinity of the motor 19 to rotate the inner tub 7 normally and reversely.
A water drain bellows 25 is situated under the outer tub 5 to drain water that is used in the washing machine. A drain pump 27 is mounted to the end portion of the drain bellows 25 to pump water that is drained through the water drain bellows 25 . A drain hose 29 is connected to the drain pump 27 to drain to the outside water pumped by the drain pump 27 .
A water level sensor 31 is positioned in the cabinet 1 so as to sense a water level by means of water pressure to determine if water is supplied to the outer tub 5 or not. A gasket 35 is interposed between the door 3 and the outer tub 5 to prevent water contained in the outer tub 5 from leaking.
Reference numerals 37 , 39 and 25 a designate a spring for supporting the upper portion of the outer tub 5 , a damper for supporting the lower portion of the outer tub 5 and reducing the vibrations of the outer tub 5 , and a drain valve, respectively.
However, in the conventional drum washing machine, there occurs a shortcoming in which the inner tub 7 is imbalanced due to the maldistribution of the laundry when the inner tub 7 is rotated at a high speed to spin-dry the laundry, thereby generating vibration and noise.
In the meantime, in the conventional vertical washing machine (in which a drive shaft is positioned perpendicular to the ground), there occur shortcomings in which the balancing force of the balancer cannot be adjusted due to its balancer being hermetically sealed, its balancer may be damaged due to its thermal expansion during the heating of washing water and, the manufacture and assembly of its balancer is difficult.
SUMMARY OF THE INVENTION
Accordingly, the present invention has been made keeping in mind the above problems occurring in the prior art, and an object of the present invention is to provide a washing machine with a balancer, which is capable of improving the balancing capacity of its balancer to reduce vibration and noise, of preventing the balancer from being damaged due to thermal expansion to increase the durability of the balancer, and of simplifying the manufacture and assembly of the balancer to reduce the manufacturing cost of the washing machine.
In order to accomplish the above object, the present invention provides a washing machine, comprising an outer tub for accommodating washing water, an inner tub rotatably mounted in the outer tub for washing and spin-drying the laundry, a balancer mounted to the inner tub to be opened at its one side, the balancer accommodating water to balance the inner tub, water supply means for supplying washing water to the balancer, and a cabinet for constituting the boundary of the washing machine and enclosing the components of the washing machine.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a vertical cross section of a conventional washing machine;
FIG. 2 is a vertical cross section of a washing machine in accordance with the preferred embodiment of the present invention;
FIG. 3 is enlarged view of “A” portion of FIG. 2;
FIG. 4 is an enlarged, exploded perspective view showing the principal components of the washing machine;
FIG. 5 is a cross section of a balancer in accordance with the preferred embodiment of the present invention; and
FIG. 6 is a graph in which the displacements of an inner tub are plotted with regard to the rotational speeds of an inner tub.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference now should be made to the drawings, in which the same reference numerals are used throughout the different drawings to designate the same or similar components.
With reference to FIGS. 2 to 6 , there is described a preferred embodiment of the present invention.
FIG. 2 is a vertical cross section of a washing machine in accordance with the preferred embodiment of the present invention. FIG. 3 is enlarged view of “A” portion of FIG. 2 . FIG. 4 is an enlarged, exploded perspective view showing the principal components of the washing machine. FIG. 5 is a cross section of a balancer in accordance with the preferred embodiment of the present invention. FIG. 6 is a graph in which the displacements of an inner tub are plotted with regard to the rotational speeds of an inner tub.
As shown in FIG. 2, the washing machine of the present invention includes a cabinet 1 that constitutes the boundary of the washing machine. A door 3 is openably mounted to the front of the cabinet 1 to allow the laundry to be fed and discharged. An outer tub 5 is situated in the cabinet 1 to accommodate washing water. An inner tub 7 provided with a plurality of water passage holes 7 a is rotatably positioned in the outer tub 5 . A lifter 9 is mounted on the bottom of the interior of the inner tub 7 . A water supply means is mounted to the interior of the cabinet 1 to supply washing water to the washing machine. A motor 19 is attached beneath the outer tub 5 . A belt 21 and a pulley 23 are situated in the vicinity of the motor 19 to rotate the inner tub 7 normally and reversely.
A balancer 100 is mounted to the front end of the inner tub 7 to balance the inner tub 7 during high-speed rotation for a spin-drying process, thereby reducing vibration and noise. The balancer 100 may be attached to the front end of the inner tub 7 in a tight-fitting or welding fashion, or may be integrally formed with the inner tub 7 .
The balancer 100 comprises a cylindrical portion 101 extended horizontally, a bell portion 102 expanded downwardly rearward from the rear end of the cylindrical portion 101 , a skirt portion 103 extended from the rear end of the bell portion 102 to the rear end of the cylindrical portion 101 , and a bent portion 104 extended radially inward from the front end of the skirt portion 103 to be spaced apart from the cylindrical portion 101 and form an opening 105 between the cylindrical portion 101 and itself. Accordingly, a space is formed between the bell portion 102 , the skirt portion 103 and the bent portion 104 to accommodate water, and the cylindrical portion 101 is projected forward past the bent portion 104 .
As a result, as the balancer 100 is rotated, water having being supplied to the space 106 through the opening 105 is moved through the skirt portion 103 and fills the entire space 106 , due to centrifugal force.
A speed sensor 210 is mounted to a portion of the motor 19 to sense that the rotational speed of the inner tub 7 passes through a critical speed (see “C” in FIG. 6) of the inner tub 7 and reaches a speed (see “B” in FIG. 6) at which the centrifugal force exceeds gravitational force. The water supply means is comprised of a water supply source 200 , a water supply hose 230 for supplying water from the water supply source 200 to the space 106 of the balancer 100 through the opening 105 of the balancer 100 , and a water supply valve 220 mounted on the water supply hose 230 for selectively being opened and closed in response to a signal from the speed sensor 210 .
The critical speed denotes a speed in which the amplitude of vibration is infinitely enlarged due to the coincidence of the natural frequency of the inner tub and the rotational speed of a drive shaft during the rotation of the drive shaft along with the inner tub 7 .
Next there is described the operation of the washing machine with a balancer.
When a user starts the washing machine by manipulating a control panel (not shown) after opening the door 7 , feeding the laundry into the inner tub 7 and shutting the door 7 , the water supply valve 220 is turned ON, and water is initially supplied through the water supply hose 230 and sent to the space 106 of the balancer 100 through the opening 105 of the balancer 100 . At this time, water having filled the space of the balancer 100 overflows through the opening 105 of the balancer 100 into the outer tub 5 , and thereafter water having overflowed into the outer tub 5 passes through the water passage holes 7 a and fills the inner tub 7 .
When water fills the outer and inner tubs 5 and 7 to a predetermined height, the water pressure of the interior of the outer tub 5 is transmitted to the water level sensor 31 through the drain bellows 25 and a water level sensor hose 33 . As a result, the water supply valve 220 is turned OFF, thereby stopping a water supply process.
When the water supply is stopped, washing and rinsing processes are performed while the motor 19 is operated and the inner tub 7 is normally and reversely rotated by means of the belt 21 and the pulley 23 .
At this time, the laundry is raised up to a predetermined height by means of the lifter 9 and lowered down from the height by means of gravitational force, so that the laundry is washed through a mechanical operation.
After the washing and rinsing processes are performed, the drain valve 25 a is opened, washing water is drained through the drain bellows 25 , and the washing water having passed through the drain bellows 25 is pumped by the drain pump 27 and drained to the outside through the drain hose 29 .
Meanwhile, after the washing and rinsing processes are performed, the motor 19 is rotated in a predetermined direction to spin-dry the laundry and the inner tub 7 is also rotated in the direction, so that the laundry is spin-dried by means of centrifugal force. Water removed from the laundry is drained to the outside through the water passage holes 7 a of the inner tub 7 , the outer tub 5 , the drain bellows 25 , the drain pump 27 and the drain hose 29 .
When the speed sensor 210 mounted to a portion of the motor 19 senses that the rotational speed of the inner tub 7 passes through the critical speed of the inner tub 7 and reaches a speed at which the centrifugal force exceeds gravitational force, the water supply valve 220 is opened and water is supplied from the water supply source 200 through the water supply hose 230 . Water having been supplied through the water supply hose 230 is supplied to the space 106 through the opening 105 of the balancer 100 .
The water having entered the space 106 balances the inner tub 7 tending to lean while being brought into tight contact with and flowing along the inner surface of the skirt portion 103 of the balancer 100 by means of centrifugal force, thereby reducing vibration and noise.
The balancing capacity of the balancer 100 depends upon the amount of water supplied to the space 106 and the height H of the bent portion 104 .
In the meantime, in the case of utilizing boiled water, the balancer 100 is not damaged due to thermal expansion because the balancer 100 can absorb the effect of the thermal expansion due to the presence of the opening 105 .
Although the speed sensor 210 is described as being mounted to a portion of the motor 19 , the position of the speed sensor 210 is not limited to that position, but the speed sensor 210 may be mounted to a portion of the inner tub 7 to sense the rotational speed of the inner tub 7 .
In addition, although water is described as being supplied through the space 106 of the balancer 100 , the washing water can be supplied in other ways. That is, during washing and rinsing processes water may be supplied through a portion of the outer tub 5 as in a conventional art, while during a spin-drying process water may be supplied to the interior of the balancer 100 .
FIG. 6 is a graph in which the maximum displacements of the inner tub 7 with and without the balancer 100 are plotted with regard to the rotational speeds of the inner tub 7 . In the graph, an “X” axis represents the rotational speeds of the inner tub 7 during a spin-drying process, while a “Y” axis represents the maximum displacements of the inner tub 7 . The speed “B” denotes a speed that the inner tub 7 reaches after passing through the critical speed C and at which centrifugal force exceeds gravitational force.
In the graph, a dotted line represents the displacements of the inner tub 7 without the balancer 100 with regard to the maximum rotational speed of the inner tub 7 without the balancer 100 , while a solid line represents the displacements of the inner tub 7 with the balancer 100 with regard to the maximum rotational speed of the inner tub 7 with the balancer 100 . As apparent from the graph, in a case where the balancer 100 is mounted to the inner tub 7 the displacements of the inner tub 7 can be reduced.
Although the preferred embodiments of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims.
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A washing machine with a balancer is provided which is capable of improving the balancing capacity of the balancer with respect to conventional devices, preventing the balancer from being damaged due to thermal expansion, and simplifying the manufacture and assembly of the balancer. The washing machine includes an outer tab for accommodating washing water. An inner tub is rotatably mounted in the outer tab for washing and spin-drying the laundry. A balancer is mounted to the inner tub to be opened at one side. The balancer accommodates water to balance the inner tub. Water supply means supplies washing water to the balancer. A cabinet encloses the components of the washing machine.
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This is a continuation of application Ser. No. 07/759,261 filed Sep. 13, 1991, now abandoned the Specification which is incorporated by reference herein.
TECHNICAL FIELD
The present invention relates to tunnel-type cryogenic food freezers such as shown and described in U.S. Pat. No. 3,892,104, wherein the product (e.g. food) to be refrigerated and in some cases frozen moves through an elongated tunnel in counterflow relationship to vapors of the cryogen used to effect final freezing of the product.
BACKGROUND OF THE PRIOR ART
One of the more prevalent types of freezers used to provide cryogenic freezing of a product (e.g. foodstuffs) is a continuous, in-line tunnel that utilizes liquid nitrogen as an expendable refrigerant. One such apparatus in commercial use is shown in U.S. Pat. No. 3,813,895 and U.S. Pat. No. 3,892,104, the specifications of both patents being incorporated herein by reference. The apparatus of the prior art can achieve high thermal efficiency because it is designed as a counterflow heat exchanger. The product moves through the tunnel on a continuous belt from an entry end (portal or opening) to a discharge end (portal or opening). Liquid nitrogen is sprayed onto the food product at a location adjacent to the discharge end (opening) of the freezer. The cold nitrogen gas, at -320° F. (-196° C.), evolved in the liquid nitrogen spray zone, moves through multiple zones of gas recirculation as it flows toward the entrance of the freezer. Since the maximum available refrigeration has been utilized at that point, the warmed nitrogen gas can then be vented to the outside atmosphere by an exhaust system placed proximate the entry end of the tunnel.
Liquid nitrogen that is in equilibrium at 35.0 psia (241 kpa) has a latent heat of 80.5 BTU/lb. (187 J/g) when vaporized at atmospheric pressure. When the product enters the freezer at 75° F. (24° C.), the nitrogen gas will leave the freezer entrance at approximately 0° F. (-18° C.) in a freezer such as shown in the aforementioned patents and offered for sale by Air Products and Chemicals, Inc. as a CRYO-QUICK® freezer. At these conditions the freezer is operating at optimum thermal efficiency and the nitrogen gas will have a sensible heat of 79.5 BTU/lb. (185 J/g). Thus, the liquid nitrogen has a total available refrigeration of 160 BTU/lb. (372 J/g). Since the sensible heat of the nitrogen gas is almost one-half of the total available refrigeration, it is necessary to provide correct nitrogen gas flow through the freezer to achieve high thermal efficiency.
The amount of liquid nitrogen injected into the freezer will depend upon the amount of refrigeration required by the product to be frozen (e.g. foodstuff). Further, whenever production is interrupted, the liquid nitrogen flow rate should be reduced substantially to maintain the freezer at its operating temperature. In a typical CRYO-QUICK freezer, having a conveyor belt of 28" (711 mm) width and a length of 66' (20 m), the liquid nitrogen flow rate will vary from 3065 to 358 lb/hr (1390 to 162 kg/hr). In addition, the most efficient operation is obtained when the liquid nitrogen flow is shut off completely during the production interruption. If the production is stopped for a long period of time, then liquid nitrogen is readmitted to the freezer based upon the temperature within the freezer. Thus, the nitrogen gas flow through the freezer must change over a wide range from the maximum flow to zero flow.
If the gas flow control system moves a larger volume of gas than the amount of gaseous nitrogen evolved in the liquid nitrogen spray zone, warm room air will be pulled into the discharge opening of the freezer. The entry of warm room air will be a significant heat input, causing a loss of thermal efficiency. Further, the moisture contained in the room air will result in frost and ice accumulation within the freezer and impair its performance. If the gas flow control system moves a smaller volume than required, cold nitrogen gas will spill out of the discharge opening, causing a significant loss in thermal efficiency. Also, the nitrogen gas spilling into the processing room can cause an oxygen deficient condition that could result in a serious safety hazard.
In early freezers represented by U.S. Pat. No. 3,345,828, to insure that the cold gas would flow countercurrent to the product flow, parallel fans were employed in the tunnel. A thermocouple placed at the collection point of cold gas, where it interfaces with warm gas, was used to detect the level of the hot/cold interface and to change position of a damper (76) to equalize volume of circulation between the parallel flow fans. While this method proved satisfactory for freezers employing parallel flow fans, patentees in U.S. Pat. No. 3,403,527 improved this apparatus by employing additional dampers with the parallel flow fans.
Subsequent to the early parallel flow fan type freezers, it was discovered that a radial flow fan could be used to force the gas in countercurrent flow to the product. U.S. Pat. No. 3,813,895 discloses the type of freezer using all radial fans wherein a curved damper, which is temperature actuated, can be used to control the total flow of gas in the freezer. However, it was found that this apparatus performed satisfactorily on freezers of small dimensions (e.g. tunnel length of 22 ft. or less). The patentees in U.S. Pat. No. 3,892,104 employed a centrifugal fan to move the cold cryogen toward the entry end of the tunnel. Control of the fan and hence control of the movement of gas through the tunnel was effected by sensing the spray header pressure which in turn controlled the speed of the fan.
U.S. Pat. No. 4,528,819 discloses an immersion-type cryogenic freezer suitable for freezing foodstuffs wherein movement of the vaporized cryogen is in concurrent flow with the movement of the product through the freezer. Patentees disclose control of an exhaust fan to control the direction of vaporized nitrogen flow, which in turn prevents air insufflation into the freezer. However, an exhaust fan cannot be used effectively in a tunnel type freezer to move the vaporized cryogen through the freezer. When the freezer is more than 30 ft long, the exhaust fan is unable to move a sufficient volume of vaporized cryogen through the freezer. Although an exhaust fan could be used on smaller freezers, the exhaust fan will also pull room air through the entry end opening of the freezer. When moist room air is mixed with the vaporized cryogen, the moisture will become frost that will clog the exhaust duct. This condition is most severe when the vaporized cryogen is colder than -50° F. and the relative humidity of the room air is greater than 50%.
A conventional CRYO-QUICK freezer with a control system according to that shown in U.S. Pat. No. 4,800,728 employs a constant speed exhaust blower that is selected for a capacity at least one and one-half times the volume of nitrogen gas to assure safe operation. However, when the freezer is operated within a refrigerated room to freeze a cool product, such as a hamburger patty at 32° F. (0° C.), a constant speed exhaust blower is not satisfactory. When processing a cool product, the entrance temperature of the freezer becomes substantially colder, i.e. -50° F. (-46° C.). The excess capacity of the exhaust blower (fan) draws a large volume of room air into the entrance opening of the freezer. As the room air enters the entrance opening, it impinges on the conveyor belt, warming the conveyor belt and increasing the heat loss into the freezer. Further, the warm, moist room air impinging on the cold -50° F. (-46° C.) conveyor belt deposits a layer of frost on the woven wire belt. Over a period of time, the frost layer thickens to restrict the openings in the conveyor belt. When this occurs, the recirculated nitrogen gas cannot pass through and under the conveyor belt. As a result, the bottom surface of the food product will not be adequately frozen.
Another problem with a constant speed exhaust blower is that warm, moist room air is mixed with cold nitrogen in the exhaust duct. When the freezer entrance temperature is -50° F. (-46° C.) or colder, the moisture forms frost that tends to accumulate within the exhaust duct. As the exhaust duct becomes clogged with frost, the flow through the exhaust system is restricted causing a potentially hazardous situation.
When using a constant speed exhaust blower another problem arises in regard to removal of refrigerated air from the processing room. Warm make-up air must enter the processing room to offset this loss, thereby significantly increasing the amount of mechanical refrigeration required to maintain the room at temperature, i.e. +50° F. (10° C.).
When the freezer is cold but not producing frozen food, such as during a lunch break, the LIN flow to the freezer is reduced to about 15% to maintain the freezer at operating temperature. Under those conditions, a constant speed exhaust blower tends to pull additional room air into the discharge opening of the freezer. The warm, moist air entering the discharge opening of the freezer increases the heat losses of the freezer. Further, the moisture forms frost that clogs the freezer, further impeding satisfactory performance.
For those reasons, it is desirable to provide an exhaust system with variable volume that is automatically adjusted to remove only nitrogen gas from the freezer with a minimum of room air.
The known solution to the problem of providing a variable volume exhaust blower employs a pressure transducer to detect the amount of LIN entering the freezer by sensing the pressure in the LIN spray header. In the first version of this system, the pressure transducer provided the speed signal to a DC power supply that varied the speed of a DC motor driving the exhaust blower. In the present system, the pressure transducer provides a speed signal to an AC inverter that varies the speed of an AC motor driving the exhaust blower. Although this system can perform satisfactorily during continuous production, it has several disadvantages. The nitrogen gas is delivered to the entrance of the freezer by a temperature activated gas flow control, e.g. U.S. Pat. No. 4,800,728, that operates independently of the LIN spray header pressure. Thus, during a process upset, the LIN spray pressure may change suddenly without a corresponding change in the gas flow fan speed. Consequently, the exhaust blower may slow down while the gas flow fan is still delivering a large volume of nitrogen gas to the freezer entrance.
Another disadvantage of this system is that it requires a LIN spray header pressure that is high enough to produce the required exhaust blower speed. Since the pressure transducer in the present system has a range of 0 to 10 psi (0 to 69 kPa), the LIN spray header pressure must be 10 psi (69 kPa) to operate the exhaust blower at full speed. In those cases where the LIN spray header pressure is 5 psi (34 kPa) or less, the exhaust blower may not operate at sufficient speed to remove all the nitrogen gas delivered to the freezer entrance.
Another disadvantage of this system is the fact that the mass flow through the LIN spray header is not constant with constant spray header pressure. If the equilibrium condition of the liquid nitrogen, as indicated by the LIN storage tank pressure, changes significantly, the quality of the LIN flowing through the spray nozzles will also change. For that reason, the LIN spray header pressure will be different for the same mass flow of liquid nitrogen. This same condition will occur if one or more of the LIN spray nozzles becomes clogged with debris. When either of these situations occur, the freezer operator must readjust the system to obtain the proper exhaust blower speed.
BRIEF DESCRIPTION OF THE INVENTION
It has been discovered that removal or exhausting of cryogen gas from the continuous cryogenic food freezer can be controlled by placing an exhaust fan or positive fluid mover in the exhaust system of the freezer. The exhaust fan is driven by a variable speed motor connected to a motor controller which in turn is connected to the motor controller which controls the speed of the motor or motors which power the gas flow control fan or fans in the tunnel. Coupling the two motor controllers as taught herein provides for the speed of rotation of the exhaust blower (fan) to be controlled in the same direction (e.g. accelerated or decelerated) and to the same degree as the speed of rotation of the gas flow control fan. Thus the amount is minimized when exhausting vaporized cryogen from the freezer because the exhaust fan is controlled to react immediately to changes in the speed of rotation of the gas flow control fan. Thus, when the volume of vaporizing cryogen (e.g. nitrogen) delivered to the freezer entrance and exhaust duct changes, the exhaust fan speed changes to maintain the correct flow through the exhaust system with a minimum of operator intervention.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic representation of a freezer to which the present invention has been applied.
FIG. 2 is a simplified circuit diagram for the apparatus of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, the numeral 10 depicts a cryogenic freezer or tunnel of the type shown in U.S. Pat. Nos. 3,813,895 or 3,892,104. Freezer or tunnel 10 includes a plurality of recirculating fans powered by a recirculating fan motor, each of which is shown as 12. Each of the recirculating fan and motor assemblies 12 recirculates vaporized cryogen inside the tunnel in accordance with the arrows 14, the recirculation paths being defined by a plurality of baffles 16, 18, 20, 22 and 24 disposed within the freezer in a manner adequately described in the prior art. Liquid cryogen (e.g. liquid nitrogen) is injected into the freezer by means of a spray header 26 and a liquid cryogen 28 (liquid nitrogen) conduit connected thereto. Liquid cryogen conduit 28 is in turn connected to a suitable source of supply such as a liquid cryogen tank (not shown) by means of piping as is known in the art. Disposed inside freezer 10 is a conveyor belt 30 which causes movement of product placed thereon in the direction shown by arrow 32. The liquid nitrogen spray header 26 is disposed near the discharge end 34 of freezer 10. Liquid nitrogen sprayed from the header 26 vaporizes causing a buildup of vaporized cryogen inside the tunnel 10 in the area adjacent to spray header 26. A gas control fan or blower 36 driven by a variable speed motor 38 causes the vaporized cryogen to move through the tunnel in the direction shown by arrow 40. The means of baffling and types of fans suitable for this purpose are also adequately described in the prior art. The freezer or tunnel 10 includes a product entry end 42 adjacent to which is placed an exhaust duct 44. Exhaust duct 44 includes a suitable exhaust fan or blower 45 driven by a variable speed motor 47 and is usually vented outside of the immediate area of the freezer to prevent oxygen depletion in the ambient atmosphere in which the freezer 10 is used.
Disposed adjacent the exit end 34 of the tunnel 10 is a thermocouple 46 which is connected to a temperature controller 48 which in turn is connected to a fan speed controller 50. Fan speed controller 50 is in turn connected to a second fan speed controller 100 which in turn is connected to motor 47 of fan 45.
The Improved Exhaust System for a Cryogenic Freezer is shown in FIG. 2. The gas flow fan controller 50 and its operation are the same as disclosed in the specification of U.S. Pat. No. 4,800,728 which disclosure is incorporated herein by reference. In automatic operation, the speed signal 0-10 mADC comes from a temperature controller with the control thermocouple mounted at the discharge opening of the freezer. The gas flow controller 50, such as "S" type manufactured by T. B. Wood's Sons Company of Chambersburg, Pa., and sold under the trademark E-TRAC, has two terminals labeled FM and CM. These terminals provide a 0 to +10 volt DC signal that is proportional to the output frequency of the controller 50. If this signal is connected to the speed signal terminals 11 and 12 of a second controller 100 similar to controller 50, the second controller will produce the same output speed as the first controller 50 over the entire speed range.
Because the size of a CRYO-QUICK freezer can vary in conveyor belt width from 28 to 50" (711 to 1270 mm) and can vary in length from 31 to 81 ft. (9.45 to 24.7 m), the freezer may have one, two, or four gas flow fans. Further, at least three different size exhaust blowers are used as the freezer size increases. Thus, to achieve the proper exhaust blower speed, it is necessary to modify the system to operate the exhaust blower proportionally slower or faster than the gas flow fan motor. An automatic adjustment potentiometer 104 is inserted across terminals FM and CM of the gas flow controller 56 to act as a voltage divider. As the potentiometer 104 is adjusted from maximum resistance to a lower value, the speed signal delivered to the exhaust blower controller 100 is proportionally reduced, allowing the exhaust blower 45 to operate proportionally slower than the gas flow fan motor.
The operating characteristics of the controllers 50 and 100 disclosed above can be modified by selecting the appropriate program codes that serve as instructions to the central processing unit. To operate the exhaust blower proportionally faster than the gas flow fan motor, program code 1014 sets the exhaust blower AC inverter speed range at 2.5 to 75 Hz, 25% faster than the gas flow AC inverter. However, the exhaust blowers used with the freezer have a maximum speed of 60 Hz when driven by a typical AC induction motor. Thus, it is necessary to limit the maximum speed of the exhaust blower to 60 Hz to prevent overloading the motor. This is accomplished with program code 1208, that limits the maximum speed to 80% of the speed range, i.e. 60 Hz.
The improved exhaust system has provision to operate the exhaust blower 45 controller 100 manually in the event of a malfunction. This is accomplished by a manual speed potentiometer 106 and electrical contacts 108 that are operated by a maintained contact pushbutton, a selector switch or a control relay. The electrical contacts, as shown in FIG. 2, are in the position for manual operation and the exhaust blower speed is varied by turning potentiometer 106.
The electrical contact 110 across terminals FWD and CM is closed to start the motor 47 of exhaust blower 45.
Frequency meters 74 and 112 are added to controllers 50 and 100 to inform the freezer operator of the gas flow fan motor speed and exhaust blower speed during operation. The E-Trac "S" type AC inverter has a potentiometer ADO that can be adjusted to calibrate the frequency meters.
The only purpose for the exhaust blower on a CRYO-QUICK freezer is to remove the nitrogen gas, evolved within the freezer, from the processing room. This is necessary to prevent the accumulation of nitrogen within the processing room that could result in an oxygen deficient atmosphere. However, the nitrogen gas within the freezer must first be delivered to the freezer entrance by the gas flow fan.
The improved exhaust system solves the problem of removing nitrogen with a minimum of room air by responding immediately to changes in the speed of the gas flow fan. Thus, when the volume of nitrogen gas delivered to the freezer entrance changes, the exhaust blower also changes speed to maintain the correct flow through the exhaust system. In actual operation, the operator adjusts the system initially to establish the proper speed proportion between the gas flow fan 36 and the exhaust blower 45. This is done by slowing down the exhaust blower 45 with the automatic adjustment potentiometer 104 until the loading table of the freezer fills with cold nitrogen gas. The operator can readily observe the water vapor cloud formed by cold nitrogen gas as he adjusts the system. When the cloud fills the loading table without spilling over the sides, the exhaust system is properly calibrated to remove all of the nitrogen gas with a minimum of room air.
The improved exhaust system was installed on a CRYO-QUICK freezer model R9-2851-PO and properly adjusted for optimum operation. The following operating data was recorded from this test:
A. Food product 10:1 hamburger patty
B. Production rate 3024 lbs. meat/hour
C. Patty spacing 1/4"-3/8"
D. Retention time 1.79 minutes
E. Entrance controller, actual -54° F. setpoint -100° F.
F. Honeywell LIN controller #55
G. Gas flow controller, actual 0° F. setpoint 0° F.
H. Gas flow fan speed 40 Hz
I. Exhaust fan speed 35 Hz
J. Exhaust AUTO potentiometer #760
K. LIN spray header pressure 5.2 psi
L. Motorized LIN valve position 3:35 pm
M. Discharge gas spill--correct
The exhaust fan operated automatically to remove the nitrogen gas without removing a significant quantity of room air.
When an improved exhaust system according to the invention is installed on a freezer and properly calibrated, the following benefits are realized:
A. Since the conveyor belt is surrounded by cold nitrogen gas, it is not warmed by room air, thus reducing the heat losses into the freezer by as much as 40%.
B. Since room air does not impinge on the conveyor belt, frost accumulation on the conveyor belt is dramatically reduced, thereby allowing optimum gas recirculation through the conveyor belt for uniform, consistent cooling of the top and bottom surfaces of the food product.
C. Because a minimum amount of moist room air enters the exhaust system, the accumulation of frost within the exhaust system is greatly reduced providing more safe operation of the freezer.
D. Since the minimum amount of refrigerated air is removed from the processing room, less mechanical refrigeration is required to maintain the temperature of the processing room, a significant savings of electrical energy.
Under some circumstances when the freezer is not producing frozen food, the LIN flow may be shut off allowing the gas flow fan to operate at minimum speed, 3 Hz. Although the gas flow fan will not deliver an appreciable amount of nitrogen to the freezer entrance, gravity will pull some nitrogen through the freezer because it is inclined for drainage of cleaning water. To compensate for that condition, program code 1309 will establish the minimum speed for the exhaust blower at 16.9 Hz, which is sufficient to remove that nitrogen.
The primary advantage of the improved exhaust system over the existing system is that it is not affected by a process upset to the LIN control system. Wherever the gas flow fan delivers more nitrogen to the freezer entrance, the exhaust blower changes speed immediately to react to the new nitrogen flow condition.
Having thus described our invention what is described to be secured by Letters Patent of the United States is set forth in the appended claims.
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Method and apparatus for controlling removal of gaseous cryogen from a continuous tunnel type freezer wherein the cryogen and product to be frozen travel in counterflow heat exchange relation to minimize ambient atmosphere moving into the tunnel and out of the exhaust system with the exhausted gaseous cryogen.
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BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention relates in general to patterning magnetic media for hard disk drives and, in particular, to an improved system, method and apparatus for hard disk drive patterned magnetic media having a reduced amount of magnetic trench material.
[0003] 2. Description of the Related Art
[0004] Data access and storage systems generally comprise one or more storage devices that store data on magnetic storage media. For example, a magnetic storage device or hard disk drive (HDD) includes one or more disks and a disk controller to manage operations concerning the disks. The hard disks themselves are usually fabricated from an aluminum alloy, glass or a mixture of glass and ceramic, and are covered with a magnetic media coating that contains the bit pattern.
[0005] One common approach to making the bit patterned media (BPM) or discrete track media (DTM) on the disks is to create topographic patterns on the substrate, followed by blanket deposition of the magnetic recording layers. Magnetic material deposited on the tops (or “lands”) of topographic features is used for recording, while material deposited in the etched relief areas (or “trenches”) is not intended to be used for recording.
[0006] However, it has been shown through both modeling and experiments that magnetic material located in the trenches produces significant unwanted magnetic flux, which interferes with the readback signal. The present invention seeks to reduce the amount of magnetic material ending up in the trenches and thereby to reduce readback interference caused by the trench material.
[0007] Referring to FIG. 1 , a schematic sectional side view of a disk 11 having conventional patterned media formed on a substrate 13 is shown. The media includes a soft underlayer 15 , an exchange break layer 17 and non-magnetic pillars 19 or raised track structures having trenches 25 therebetween. A magnetic layer is blanket deposited on the topographically patterned substrate. This deposition forms a magnetic recording layer 21 (i.e., formed as “islands”) on the pillars 19 , and some magnetic material 23 in the trenches 25 between the pillars 19 . The magnetic material 21 deposited on top of the pillars 19 is used for recording, while the trench material 23 generates unwanted magnetic flux that increases the background noise level and interferes with readback operations of the disk drive.
[0008] The amount of magnetic material in the trenches can be reduced by depositing the magnetic material at an angle with respect to normal incidence. However, angled deposition does not completely eliminate the trench material due to the complex, three-dimensional shapes of the pillars (particularly for BPM), and the fact that sputter deposition has only limited directionality. Furthermore, angled deposition can result in significant deposits on the sidewalls of the topography, which also has unintended effects on the magnetic properties of the islands or tracks.
[0009] An alternative solution to this problem is to “poison” the trench material. Poisoning the trench material is attractive from the point of view of totally eliminating the magnetism of the trench material. However, there are some challenges to successfully implementing such an approach for small feature sizes, including the effects of dimensional distortion of feature shapes due to diffusion processes. Thus, an improved solution for reducing the unwanted effects of having magnetic media located in the trenches between the topographic features of disks would be desirable.
SUMMARY OF THE INVENTION
[0010] Embodiments of a system, method and apparatus for reducing the amount of magnetic material located in the trenches between topographic features in bit patterned media are shown. The invention reduces or eliminates the readback interference caused by the trench material. Although the invention described herein may leave a small amount of magnetic material in the trenches, no diffusion is used. Therefore the negative consequences of diffusion are eliminated when scaling down the island size to densities beyond what is currently achieved in conventional perpendicular recording demonstrations.
[0011] In one embodiment, an intermediate and significantly thicker non-magnetic layer is deposited on the topography prior to depositing the functional magnetic layer on the topographic substrate features. Thin seed layers, underlayer structures and/or adhesion layers may be deposited directly beneath the magnetic layer, either above or below the intermediate layer. The non-magnetic layer has the effect of increasing the lateral diameter of the land regions that will ultimately support the functional magnetic layer. This also increases the effective area filling factor of magnetic material that contributes to the readback signal. In addition, the non-magnetic layer reduces the amount of trench deposition that can occur in the subsequent deposition of the magnetic recording layer. By eliminating most of the magnetic trench material, the amount of magnetic flux and readback interference produced by the trench material is reduced to an acceptable level.
[0012] Even if the non-magnetic material is incidentally deposited on the side walls, it will not cause any undesired effects, such as those experienced with magnetic materials. Overall the degree of sidewall overgrowth effects can be mitigated by varying the deposition angle with respect to the surface normal of the substrate.
[0013] The magnetic properties of the recording layers are fairly independent of the non-magnetic interlayer thickness. For example, TaPd alloys or Ta/Pd bilayers may be used for the non-magnetic layer to fulfill this requirement.
[0014] The foregoing and other objects and advantages of the present invention will be apparent to those skilled in the art, in view of the following detailed description of the present invention, taken in conjunction with the appended claims and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] So that the manner in which the features and advantages of the present invention are attained and can be understood in more detail, a more detailed description of the invention may be had by reference to the embodiments that are illustrated in the appended drawings. However, the drawings illustrate only some embodiments of the invention and therefore are not to be considered limiting of its scope as the invention may admit to other equally effective embodiments.
[0016] FIG. 1 is a schematic sectional side view of conventional patterned media for a magnetic media disk;
[0017] FIG. 2 is a schematic sectional side view of one embodiment of a sub-assembly of patterned media for a magnetic media disk before deposition of the magnetic layer, and is constructed in accordance with the invention;
[0018] FIG. 3 is a schematic sectional side view of one embodiment of the patterned media of FIG. 2 after deposition of a magnetic recording layer and is constructed in accordance with the invention;
[0019] FIG. 4 depicts plots of Micro-Kerr remnant reversal curves for different non-magnetic interlayer thicknesses on patterned media constructed in accordance with the invention; and
[0020] FIG. 5 is a schematic diagram of one embodiment of a disk drive constructed in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0021] Referring to FIGS. 2-5 , embodiments of a system, method and apparatus for reducing the amount of magnetic material located in the trenches between topographic features in bit patterned media are shown.
[0022] In one embodiment ( FIG. 2 ), the invention comprises a magnetic media disk 31 for a hard disk drive. The disk may include a substrate 33 , a soft underlayer 35 on the substrate 33 , and an optional exchange break layer 37 on the soft underlayer 35 . Topographic formations or islands 39 extend from the substrate 33 and/or layers formed thereon. An intermediate non-magnetic material 41 is deposited on this structure 39 , followed by the deposition of a magnetic recording layer 43 ( FIG. 3 ). FIG. 2 schematically illustrates the structure after depositing the intermediate layer 41 . FIG. 3 schematically shows the media structure after deposition of the magnetic recording layer 43 . This process and configuration reduces the amount of magnetic material deposited in the trenches 45 .
[0023] The non-magnetic material is deposited under conditions that result in lateral (i.e., left and right in FIGS. 2 and 3 ) as well as vertical growth of the film. Material extends outward laterally from the tops of the islands 39 , which narrows the access aperture for approaching material from any subsequent further deposition of material. These self-shadowing effects prevent a fast coalescence of adjacent islands/pillars and thus prevent any undesired coupling between adjacent islands/pillars. Using an angle of incidence 47 ( FIG. 3 ) other than normal promotes lateral growth of the film and side wall growth, thus increasing the island width and the effective area contributing to the readback signal.
[0024] The magnetic properties of the recording layers are fairly independent of the non-magnetic interlayer thickness. For example, materials such as Ta and Pd may be used to fulfill this requirement as demonstrated in the Micro-Kerr measurements in FIG. 4 . FIG. 4 is a plot of Micro-Kerr remnant reversal curves 51 , 53 , 55 for different non-magnetic interlayers for a Co/Pd multilayer media. In this example the islands are 50 nm in width and formed at a 100 nm pitch. The island switching field is similar in all three cases (i.e., about 11 kOe). However, for an interlayer having a thickness of 28.5 nm, a small shift is observed to lower the reversal fields. The Kerr signal from the trench reversal (at about 2-3 kOe) is reduced with increasing interlayer thickness, which indicates that there is less magnetic trench material for thicker interlayers. Overall, the thickness of the non-magnetic layer should be tuned depending on the lateral periodicity of the pattern and the initial trench width of the pre-patterned substrate. This maximizes the effective area that contributes to the readback signal without causing any inter-island exchange coupling.
[0025] Since access to the trenches is reduced by deposition of the intermediate layer, significantly less magnetic material is deposited in the trenches as also confirmed experimentally by the Kerr measurements in FIG. 4 . The growth of the intermediate layer effectively “pinches off” the access route for deposition of further material in the trenches. Choosing to deposit the magnetic material at an angle other than normal can further reduce deposition of magnetic trench material. Based on experimental results, reducing the amount of trench material by a factor of two or three may be sufficient to achieve adequate readback signal to noise ratio.
[0026] Using magnetic multilayers as magnetic media, one may use different angles for two multilayer materials, which leads to proper multilayer structures on top of the islands. Predominantly, only one material reaches the trenches (i.e., with normal incidence) and the other material reaches the sidewalls (i.e., at an angled incidence). Thus, different material compositions are formed on the sidewalls and trenches which may result in non-magnetic phases in the trenches as well as on the sidewalls.
[0027] In addition, subsequent oxidation processes may play a significant role in such configurations. For example, a Pd/Co multilayer may be used with Pd deposited normal to the substrate surface and Co deposited at an angle. This results in a Pd-rich trench phase (non-magnetic) and a Co-rich side wall phase. However, the Co on the sidewalls does not form a continuous film and thus oxidizes to non-ferromagnetic Co-oxide clusters after the media is exposed to ambient air. In contrast, the multilayer on top of the islands are protected by a final cap layer, such as a Pd cap having a thickness of 2 nm.
[0028] As shown in the drawings, deposition of the intermediate layer causes the lateral dimensions of the lands or islands to grow. Such lateral growth (and additional curvature, which may develop when depositing the interlayer) needs to be taken into account in the magnetic design of the media from a recording system point of view. For example, larger lands or islands increase overall readback flux, which is desirable, but also increases dipole interactions between islands in BPM, which may adversely affect switching field distribution. See, e.g., the publication, Separating Dipolar Broadening from the Intrinsic Switching Field Distribution in Perpendicular Patterned Media , O. Hellwig, et al, Appl. Phys. Lett. 90, 162516 (2007). Such effects may need to be countered by reducing the moment or thickness of the magnetic recording layer. For DTM, increased land width may affect the optimal choice for head element widths and off-track and adjacent track erasure effects.
[0029] In one embodiment, the invention comprises a magnetic media disk including a substrate, a plurality of topographic features formed on the substrate and defining trenches therebetween, a layer of non-magnetic material formed on the topographic features and on the trenches, and a layer of magnetic material formed on the layer of non-magnetic material on at least the topographic features to define a recording layer.
[0030] Referring again to the embodiment of FIGS. 2 and 3 , the layer of non-magnetic material is segmented into portions 41 that are located on the topographic features 39 , and portions 67 that are located in the trenches 45 . In addition, the layer of magnetic material is segmented into magnetic portions 43 on non-magnetic portions 41 , and magnetic portions 65 on non-magnetic portions 67 . Each of the non-magnetic portions 41 has a width 61 that is greater than a width 63 of the topographic features 39 , but narrower than a width 69 of the magnetic portions 43 . However, the widths of non-magnetic portions 67 are greater than the widths of magnetic portions 65 .
[0031] In other embodiments, the topographic features are non-magnetic, and have sidewalls on which some of the non-magnetic material is located. At least portions of the layer of magnetic material also are located on the non-magnetic material formed on the trenches. The substrate has a surface that defines a planar direction, the topographic features extend in a direction that is normal to the planar direction, and the layer of non-magnetic material located on the topographic features extends substantially parallel to the planar direction.
[0032] In still another embodiment, a soft underlayer formed on the substrate, an optional exchange break layer formed on the soft underlayer, and the topographic features extend from the exchange break layer such that the trenches also are located on the exchange break layer. The non-magnetic layer may have a thickness of approximately 15 to 30 nm (e.g., 15 to 20 nm in one embodiment), depending on the pattern periodicity. In addition, the non-magnetic layer may comprise a TaPd alloy or Ta/Pd bilayers. The disk may comprise thin seed layers, underlayer structures and/or adhesion layers deposited directly beneath the magnetic layer, either above or below the intermediate layer.
[0033] As shown and described herein, the topographic features may comprise islands having a spacing therebetween. The non-magnetic material segments located on the islands have a smaller spacing between them than the spacing between the islands. In another embodiment, an aperture is defined between adjacent islands, one trench is defined in each aperture, and the non-magnetic material reduces the size of each aperture.
[0034] Referring now to FIG. 5 , a schematic drawing of one embodiment of an information storage system comprising a magnetic hard disk file or drive 111 for a computer system is shown. Drive 111 has an outer housing or base 113 containing at least one magnetic disk 115 . Disk 115 is rotated by a spindle motor assembly having a central drive hub 117 . An actuator 121 comprises one or more parallel actuator arms 125 in the form of a comb that is pivotally mounted to base 113 about a pivot assembly 123 . A controller 119 is also mounted to base 113 for selectively moving the comb of arms 125 relative to disk 115 .
[0035] In the embodiment shown, each arm 125 has extending from it at least one cantilevered load beam and suspension 127 . A magnetic read/write transducer or head is mounted on a slider 129 and secured to a flexure that is flexibly mounted to each suspension 127 . The read/write heads magnetically read data from and/or magnetically write data to disk 115 . The level of integration called the head gimbal assembly is the head and the slider 129 , which are mounted on suspension 127 . The slider 129 is usually bonded to the end of suspension 127 . The head is typically formed from ceramic or intermetallic materials and is pre-loaded against the surface of disk 115 by suspension 127 .
[0036] Suspensions 127 have a spring-like quality which biases or urges the air bearing surface of the slider 129 against the disk 115 to enable the creation of the air bearing film between the slider 129 and disk surface. A voice coil 133 housed within a voice coil motor magnet assembly 134 is also mounted to arms 125 opposite the head gimbal assemblies. Movement of the actuator 121 (indicated by arrow 135 ) by controller 119 moves the head gimbal assemblies radially across tracks on the disk 115 until the heads settle on their respective target tracks.
[0037] While the invention has been shown or described in only some of its forms, it should be apparent to those skilled in the art that it is not so limited, but is susceptible to various changes without departing from the scope of the invention. For example, the invention also is suitable for magnetic media applications such as magnetic tape.
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A bit patterned magnetic media design for reducing the amount of magnetic material located in the trenches between topographic features is disclosed. An intermediate non-magnetic layer is deposited on the topography prior to depositing the functional magnetic layer on the topographic substrate features. The non-magnetic layer increases the width of the land regions that will ultimately support the functional magnetic layer. The non-magnetic layer also reduces the amount of trench deposition that can occur in the subsequent deposition of the magnetic recording layer. By eliminating most of the magnetic trench material, the amount of magnetic flux and readback interference produced by the trench material is reduced to an acceptable level.
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RELATED APPLICATION
[0001] This application is a continuation-in-part application of U.S. application Ser. No. 09/572,808, filed on May 17, 2000, which was based on, and claimed benefit of, U.S. Provisional Application Ser. No. 60/134,569, filed May 17, 1999.
FIELD OF THE INVENTION
[0002] This invention relates to a pizza food product and a kit for assembling a deep dish pizza. The pizza crust of this invention is especially adapted for use in cartons and/or packages which also contain the other pizza ingredients necessary to assemble a snack or single-service sized, deep dish, ready-to-eat pizza.
BACKGROUND OF THE INVENTION
[0003] Pizzas, while widely available frozen, are generally not as widely available refrigerated. In general, available pizza products, frozen or refrigerated, need to be fully baked before they can be eaten. Once a fully baked pizza crust has been refrigerated or frozen, it tends to “toughen” or become leathery, stale, and/or dry. See, for example, David, English Bread and Yeast Cookery, American Edition, p. 255 (Viking Press, New York 1977). When a crust becomes “leathery” (a term of art), it becomes harder to chew and loses its “chewability.” Furthermore, the distinction between the crisper bottom of the crust and the softer top part of the crust is generally lost when a baked crust is refrigerated.
[0004] Reheating pizza does not generally allow the crust's texture to return to its original state and may, in fact, further “toughen” it to an even more leathery texture. While such leftover pizza may be fully edible from all health and safety considerations, the organoleptic properties are generally diminished. Much of the loss of quality is due to the crust becoming more leathery. Fully baked pizzas or pizzas having a fully baked crust are not often found in grocery refrigerator or freezer cases.
[0005] Refrigerated pizzas with unbaked crust have their own problems. These include, for example, (1) sauce soaking into the crust (moisture migration), (2) sauce and other toppings becoming maldistributed on or knocked off the crust during transport, and (3) flavor, odor and microbiological migration (e.g., from sauce or meat to cheese). Moreover, such products must also be baked by the consumer thereby diminishing the convenience desired by most consumers. Even when baked in the home kitchen with conventional ovens, the overall quality is not as high as desired.
[0006] Feldmeir et al., U.S. Pat. No. 6,048,558, provided a meal kit containing a baked bread or dough product in a sealed pouch which is contained within a compartment contained within a base tray having an anti-fogging agent component. The anti-fogging agent assists in maintaining freshness and retarding staling under refrigerated, non-frozen conditions. Generally the anti-fogging agent is contained within a layer of the base trap or in other container elements so that enters the compartment in a time release manner so that it gradually blooms onto the internal surfaces within the meal kit. The anti-fogging agent is though to prevent the formation of water droplets within the container and thereby allow any trapped moisture to more easily evaporate from the meal kit.
[0007] U.S. Pat. No. 5,747,084 provided a packaged pizza product containing a pre-baked pizza crust and other pizza ingredients (i.e., pizza sauce and one or more pizza toppings). The pizza crusts included in the kit of this patent were generally flat, thin, and circular.
[0008] There remains a need for a pizza crust which can be fully baked, refrigerated, and subsequently eaten cold, warm, or hot (i.e., reheated) without the need for further baking and without becoming leathery and which retains the desired crust properties (especially relating to texture) while, at the same time, providing a relatively rigid, but soft, crust upon which toppings can be placed. Moreover, there still remains the need for a fully baked deep dish pizza crust which can be used in a kit format and which retains its soft texture throughout the expected shelf life of the kit and remains tasty and chewable when eaten hot or cold. There further exists a need for a ready-to-eat deep dish pizza and kit containing a deep dish baked crust which can be refrigerated without the crust becoming leathery, dry, and/or stale; and which remains equally tasty and satisfactorily chewable either hot or cold. There further exists a need for a ready-to-eat deep dish pizza and kit containing a deep dish baked crust which can be refrigerated without the crust becoming leathery, dry, and/or stale; which remains equally tasty and satisfactorily chewable either hot or cold; and which does not require the use of an anti-fogging agent.
[0009] The present invention provides such deep dish, fully baked, ready-to-assemble pizza crusts and kits containing such pizza crusts in combination with other pizza components such as, for example, pizza sauces, cheeses, and/or toppings. Once assembled, the deep dish pizzas of this invention can be eaten as is or after heating.
SUMMARY OF THE INVENTION
[0010] The invention comprises a farinaceous pizza crust which can be fully baked, then refrigerated and later served cold or reheated without becoming leathery, dry, stale and/or tough. Preferably, the pizza crust is configured to have a deep dish shape. After baking, the crust preferably has a water activity in the range of about 0.90 to about 0.95 and retains satisfactory texture and chewability characteristics throughout a refrigerated shelf life that may be, e.g., about 75 days. The pizza crust is preferably adapted for use in a “single-serving” kit which allows easy preparation of a ready-to-eat, deep dish pizza. The kit preferably contains (1) at least one of the pizza crusts, (2) pizza sauce, (3) one or more cheese products, and, if desired, (4) one or more additional components that may include, for example, proteinaceous components such as sausage, pepperoni, ham or anchovies, or vegetable components such as slices of green pepper or olives. The pizza crust products and kits containing the pizza crust products of the present invention do not require the use of an anti-fogging agent to achieve the desired shelf life. The kit may also contain other items, e.g., a soft drink or other beverage and/or candy item. Preferably, the kit is contained in a single serve package having separate pouches and/or compartments for each of the various components to be separately sealed under an inert atmosphere to increase the shelf life of the product or kit. The seals are preferably hermetic, and are capable of withstanding stresses and strains associated with shipping and handling, including pressure variations associated with transport to and through high altitudes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective view of a ready-to-assemble deep dish pizza crust in accordance with an embodiment of the invention.
[0012] FIG. 2 is a perspective view of a pizza kit that includes a plurality of the crusts of FIG. 1 .
[0013] FIG. 3 is a schematic elevation of the pizza kit of FIG. 2 .
[0014] FIG. 4 is a side view of the pizza crust of FIG. 1 .
[0015] FIG. 5 is a side view of a nested stack of the pizza crusts of FIG. 1 .
[0016] FIGS. 6 a - 6 c are schematic plan views of the kit of FIG. 2 .
[0017] FIGS. 7 a and 7 b are schematic plan views of a kit in accordance with another embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0018] The invention is preferably embodied in a fully baked, farinaceous food product that can be refrigerated without development of a leathery texture.
[0019] More particularly, the invention is preferably embodied in a fully baked deep dish pizza crust that has an extended refrigerated shelf life. The preferred pizza crust can be refrigerated without development of a leathery texture, retaining a soft texture for extended periods of time, preferably about 75 days or more. The invention may also be embodied in a kit containing a fully baked deep dish pizza crust and additional components for the assembly of a ready-to-eat pizza that can be eaten cold or heated. The pizza crusts may be nestable, and may be included in a tray-type package with additional pizza components which are storable at refrigerated temperatures and from which one may assemble a ready-to-eat pizza. Neither the pizza crust product nor the packaging materials including in the kit require an anti-fogging agent to achieve the desired characteristics of the refrigerated product. Thus, neither the pizza crust product nor the packaging materials including in the kit contain such an anti-fogging agent.
[0020] A deep dish pizza crust 10 in accordance with a preferred embodiment of the invention is illustrated in FIG. 1 (perspective view) and FIG. 4 (side view). Although the pizza crust 10 is illustrated as being essentially square, other basic shapes (e.g., rectangular, triangular, round, oval, or the like) can be used if desired. It is generally preferred, however, that the basic shape be generally rectangular and, most preferably, generally square. The rectangular/square shapes will generally be more easily packaged in the kits contemplated by this invention. The base 12 is preferably of a smaller dimension than the top or rim 14 so that the sides 16 slope outward from bottom to the top. The slanting sides 16 are of generally uniform thickness, e.g., about ¼ to about ½ in. thick with about ⅜ in. thick being preferred. While the sides may be substantially vertical in other embodiments, in the preferred embodiment the sides 16 are slanted outward. The depth 18 of the “dish” formed in the pizza crust is preferably about ⅝ to about ⅞ in., with about ¾ in. being preferred. Preferably, the bottom or base of the crust 12 in FIG. 1 forms a square of about 3.4 to about 3.6 in. and about ¼ to about ½ in. thick (or about 5 to 9 mm thick) and preferably is about 3½ in. square by about ⅜ in. thick. The top rim 14 is of larger dimension than the base 12 to allow for the slanted sides 16 . Preferably, the top rim 14 will be about 4.2 to about 4.3 in. along each dimension. For a preferred base dimension of about 3½ in. square, the top rim 14 would have a dimension of about 4¼ in. square.
[0021] FIGS. 2 and 3 illustrate a ready-to-assemble pizza kit containing a plurality of fully baked, deep dish pizza crusts 10 in a carton 20 with additional and separate packages of other pizza components. Such other components can include, for example, pizza sauce 22 , shredded or cubed cheese 24 , and/or additional pizza toppings 26 . Such additional pizza toppings can include, for example, additional cheese or a mixture of additional cheeses, pepperoni slices, salami, bacon bits, Canadian bacon, ham dried vegetables (e.g., onions, peppers, olives and the like), sausage, beef, spices, and other pizza ingredients. Examples of pizza sauces include traditional tomato-based sauces, salsa, catsup-based sauce, white sauce, or other spreadable sauce usable to create flavorful pizza-style products. Examples of the cheese products which may be included in the kit comprise natural cheeses such as mozzarella, Parmesan, Romano, Swiss cheddar, Monterey jack, Gruyere, and similar products. If desired, other components can also be included in the kit. Such other components include, for example, a drink 27 , dessert 30 (e.g. candy), an implement or utensils to spread the sauce, salt, pepper, other spices, napkins, and the like. Preferably the pizza ingredients, including the crusts, are packaged in separate containers such as pouches, cups, cans, or jars. In the illustrated embodiment, separate pouches are formed from oxygen-impermeable film. In other embodiments, separate compartments may be formed in the tray and sealed with oxygen-impermeable film. In either case, the components are sealed under an inert atmosphere or under inert gas flushed conditions.
[0022] FIG. 5 illustrates how the slanting side walls 16 allow the pizza crusts to nest together. If desired, parchment or paper liners (not shown) can be used to separate the nested pizza crusts (especially around their rim areas) to allow them to be more easily separated when consumed. If desired, such parchment or paper liners may include pull tabs, strips or other features that the consumer can employ to help separate the nested pizza crusts. Additionally, and if desired, the separating parchment or paper liners may be coated or impregnated lightly with oil (containing various spices if desired) to help retain the desired texture and appearance of the pizza crusts. Generally, it is preferred that pizza kits of the present invention contain 2 to 4 nested pizza crusts. Of course, for kits designed for multi-person use (i.e., family sized units) a higher number of pizza crusts may be included along with proportionally increased amounts of other pizza ingredients. Even in such larger kits, it may still be desirable to package the various components, including the pizza crusts, in smaller single serving sizes so that the consumer may open less than all of the particular component while allowing the remainder to be stored in its original, unopened condition. The interior of the uppermost nested pizza crust (see FIG. 5 ) can be used to store other components in the kit so long as these other components are contained in separate pouches or containers.
[0023] Turning to a more detailed description of the preferred crust, it should first be noted that the percentages used in the present specification to describe the pizza crust dough are generally a baker's percentages, which are weight percentages based on the weight of flour used in a specific recipe (generally per 100 pounds of flour). For example, for 100 pounds of flour in a recipe, 57 percent water and 1.5 percent salt would mean the addition of 57 pounds of water and 1.5 pounds of salt, respectively, to 100 pounds of flour. Of course, such baker's percentages do not normally add up to 100 percent. Conventional percentages can be calculated from bakers percentages by normalizing to 10 percent.
[0024] Baking science involves a complicated process employing time, temperature and relative humidity to produce various food products. The time, temperature and relative humidity parameters are generally different for bread, rolls, pizza crusts, pastry and cereal products, not only with regard to their appearance (crust color, size, etc.), but also with regard to the development, texture, and size. Some of the desirable changes caused by baking are protein denaturing, starch gelatinization, moisture migration and veracity (cell development or grain). Many factors may be involved in preparing a baked product which is appealing in the eyes of the ultimate consumer. A manufacturer must also consider items such as shelf life and how a consumer will actually use a product. Consequently, it is desirable to have some quantitative measure by which one can determine whether a production line product meets specification. One such measure is water activity.
[0025] Water activity is a measure of the percent of water remaining in a baked product after it has been baked. Cracker products typically have a water activity in the range of about 0.35 to 0.50. Common baked goods, for example, bread, dinner rolls and pizza crusts, typically have a water activity in the range of about 0.90 to 0.98. The fully baked pizza crust of this invention preferably has water activities of about 0.90 to about 0.95, with a value of about 0.93 being particularly preferred. Such fully baked pizza crusts have satisfactory refrigeration storage characteristics as well as satisfactory texture and taste when used to prepare a ready-to-eat pizza, whether unheated or heated, and whether eaten cold or warm.
[0026] The water activity of the pizza crust is measured after the crust has come out of the oven and cooled to about 100° F. For deep dish pizza crusts of the present invention, the water activity is generally measured about after the fully baked crust is removed from the baking oven. Moisture content of the deep dish pizza crust may be measured with an a w meter, or by weight difference between the crust after cooling to about 100° F. and after further, more complete drying (i.e., using a desiccator or other suitable and reliable method). Generally, the moisture content of fully baked deep dish pizza crust is about 89 to 99 percent, and preferably in the range of about 91 to about 93 percent.
[0027] Since yeast is included in the formulation of pizza dough, a fermentation or rising step is included in the dough preparation. The fermentation step allows the yeast to produce carbon dioxide gas which stretches and mellows the gluten contained in the flour, and aids in producing good flavor and texture. However, the large commercial baking operations such as will be used to prepare the crusts of the invention, fermenting all the dough to be baked requires large equipment outlays, is time consuming and is therefore costly. It has been found that in practicing the invention, one can produce a flavorful and texturally pleasing pizza crust by fermenting a portion of the dough and adding an aliquot of the fermented dough to bulk unfermented dough. The fermented dough is thoroughly mixed with the unfermented dough, and the resulting mixture is divided, cut to size, shaped, and baked. In the time period from mixing to baking, the dough mixture continues to rise and develop the desired characteristics. It has been found that a dough mixture containing about 2 to about 7 percent fermented dough and about 93 to about 98 percent unfermented dough produces satisfactory results. One preferred embodiment contains about 3 to about 5 percent fermented dough. Other preferred embodiments may contain up to 10% fermented dough.
[0028] The texture of the baked pizza crust of the invention can be additionally changed by laminating the dough somewhat in the manner used to prepare croissants or Danish pastries. A laminate of three to six layers, preferably three to four layers, may be formed by folding the dough back-and-forth across itself (i.e., layering). Lamination is believed to result in a baked product having improved texture and taste when cold or heated. The dough, whether laminated or not, is formed into the desired shape (e.g., see FIG. 1 ).
[0029] A basic recipe (in baker's percentages) for pizza crust prepared according to a preferred embodiment of the invention follows.
Preferred Range Range Most Preferred Ingredient (% flour basis) (% flour basis) (% flour basis) Flour 100 100 100 Sweeteners 5.0-15.0 8.0-12.0 10.0 Butter Chips 7.5-17.5 10.5-14.5 12.5 Salt 1.5-3.5 2.0-3.0 2.5 Dough Relaxer 1.0-2.25 2.0-2.25 2.25 Yeast 0.5-5.0 2.5-3.5 3.0 Shortening 1.0-6.0 2.0-4.0 3.0 Monoglycerides/ 0.4-2.0 0.5-1.5 1.0 Diglycerides Dried Egg White 0-2.0 0.75-1.5 1.0 Sodium Stearoly 0-0.5 0.4-0.5 0.5 Lactylate Calcium Propionate 0-0.5 0.4-0.5 0.45 Alpha Amylase 0.2-0.4 0.3-0.35 0.32 Enzyme Guar Gum 0-0.3 0.15-0.25 0.22 Water 53-63 54-60 60 Spices/Seasonings 0-1.0 0.3-0.4 0.35
[0030] In other embodiments, other ingredients may be substituted for some of those listed above. For example, calcium stearoyl lactylate might be used in place of the sodium stearoyl lactylate, or other mold inhibitors could be used in place of, or combined with, calcium propionate. The flour is preferably hard wheat bread flour made from hard spring or winter wheat. The shortening is preferably a solid, hydrogenated or partially hydrogenated vegetable oil; for example, a hydrogenated or partially hydrogenated cottonseed, corn, soybean, sunflower, canola oil, or mixture thereof, and similar hydrogenated or partially hydrogenated vegetable oils and mixtures. The preferred vegetable oils are corn, canola, sunflower seed, cottonseed and soybean oils, or mixture thereof. The shortening may have a butter flavoring agent added to the shortening by the producer. Alternatively, a butter flavoring agent or other flavoring agent may be added to the recipe in an amount known to those skilled in the art or in accordance with the flavor manufacturer's recommendations. Compressed yeast may be substituted for the dried yeast used in the above basic recipe. If compressed yeast is used, the baker's percentage or weight is approximately tripled to account for the water content of the compressed yeast; likewise, the amount of water added may be reduced to account for the water content of the compressed yeast. Therefore, if compressed yeast is used in the above general recipe in place of dried yeast, the amount of compressed yeast will be in the range of about 1.5 to about 15 percent, preferably about 7.5 to about 10.5 percent.
[0031] The baked pizza crusts can be assembled in any suitable packaging. Such packaging should not, however, contain the anti-fogging agents used in U.S. Pat. No. 6,048,558. Although the pizza crust described herein may be packaged and sold as a stand alone product, it is generally preferred that it be included as part of a ready-to-assemble and eat kit as described above.
[0032] Example of packages of a type that might be adapted for use for the ready-to-eat pizza kit of the invention are shown, e.g., in U.S. Pat. Nos. 5,375,701 and 5,747,084, which are hereby incorporated by reference. As noted above, the food packages of the present invention do not require, and do not contain, the anti-fogging agents used in U.S. Pat. No. 6,048,558. These packages will include a tray portion and a seal portion. The tray portion can be of a relatively rigid or shape retentive material e.g., plastic, and may include walls that define compartments for receipt of food products therein. A main food product or item or entree can be held in a main compartment that can be larger than the other compartments in which other food items are held such as side dishes or snacks, and/or, as in the present invention toppings, to be placed on the deep dish crusts(s) held in the main, larger compartment. Accordingly, one or several of the compartments can contain farinaceous food products, and one or several of the compartments can contain proteinaceous food products. A ready to drink beverage product in a container can also be included in one of the compartments. With the food products in the compartments, the seal portion, film which can be a flexible plastic film material, is attached to the top of the walls, such as on an upper rim area about the compartments, as by an adhesive or the like. This sealing of the package can provide it with a hermetic seal that sufficiently minimizes leakage therethrough to keep the contents fresh for a commercially satisfactory extended shelf life period while refrigerated. In addition, the seal minimizes undesirable transfer of flavor and odor between the products in the different compartments.
[0033] In the illustrated embodiments, the package for the kit takes a different form, comprising an outer paperboard carton 20 having the various different components contained therein in individually sealed pouches. In the preferred embodiments, pouches containing the pizza crusts and a beverage are positioned to be visible through windows in the carton 28 .
[0034] The outer carton 20 is of a generally parallelepiped shape, comprising a rectangular bottom 28 , four generally rectangular upstanding side walls 30 , and a generally rectangular hinged lid 32 . The lid has a depending front flap 34 to cover an opening 36 in the front wall. The lid also preferably has one or more windows 38 therein to permit viewing of the contents of the kit. The lid 32 preferably provided with conventional means for retaining it in closed position, then facilitating opening. Such means may comprise, e.g., securing the front flap to the front wall with adhesive, and providing a flap, tear strip, pull tab or the like on the lid to facilitate opening.
[0035] The contents of the kit preferably are arranged in layers. The embodiment FIGS. 6A-6C has three layers of pizza components on the left side and a beverage 27 such as a 12 oz can of soft drink on the right. The bottom or first layer of pizza components comprises a pouch of shredded cheese 24 , a pouch of pizza sauce 22 , and a confectionary or dessert item 29 such as a candy item or the like, contained in a sealed wrapper. The components in the first layer overlap somewhat, as shown in FIG. 6A .
[0036] The second layer comprises a pouch 26 containing an additional topping, preferably a proteinaceous component, e.g., pepperoni slices.
[0037] The third layer comprises a plurality of pizza crust 10 , sealed in a pouch 40 , supported on a carrier 42 . The carrier has feet 44 at its four corners to mechanically isolate the crusts from the other components, and to laterally stabilize the beverage container. Each of the pouches preferably has a seal that is substantially hermetic. The pouches preferably have easy-open features. In particular, the pouch 40 containing the pizza crusts preferably has a peelable seal 46 at one corner. Each of the seals of the pouches is preferably capable of withstanding the stresses and strains associated with shipping and handling, including atmospheric pressure drops, which may occur due, e.g., to transportation from a packaging facility at an elevation near sea level to or through a rocky-mountain elevation of 5,000 to 10,000 feet.
[0038] The embodiment of FIGS. 7A and 7B is similar to that of FIGS. 6 A-C, except the proteinaceous component is eliminated, to provide a cheese pizza kit.
[0039] In either embodiment, the candy item 29 may comprise, e.g., Reese's Pieces candy, Crispy M&M's candy, Reese's Peanut Butter Cup, or any other suitable candy item.
[0040] For use, the pizza kit package is opened, the crusts removed, and the pizza assembled. The side walls help to retain the toppings on the crust. If desired, the pizza may be heated in a conventional or a microwave oven. A recommended microwave heating time at full oven power falls within the range of about 20 to about 80 seconds, and preferably within about 20 to about 40 seconds in order to preserve the taste, texture, and chewability characteristics of the crust.
[0041] The following examples are intended to illustrate the invention and not to limit or otherwise restrict the invention.
Example 1
[0042] Preparation of Deep Dish Pizza Crust. A pizza dough was made using the following formulation:
Amount Ingredient (% flour basis) Flour 100 High Fructose Corn 10.0 Syrup (42%) Butter Chips 12.5 Salt 2.50 Dough Relaxer 2.25 Dried Yeast 3.0 Soy Bean Oil 3.0 Monoglycerides/ 1.0 Diglycerides Dried Egg White 1.0 Sodium Stearoyl Lactylate 0.50 Calcium Propionate 0.45 Alpha Amylase Enzyme 0.32 Guar Gum 0.22 Water 60 Granulated Garlic 0.35
All dry components were mixed using low speed mixing for about 1 minute, in a horizontal mixer followed by the wet components which were mixed in using medium speed mixing for about 6 minutes, followed by the butter chips which were mixed using low speed mixing for about 1 minute. The resulting dough was then sheeted into flat sheets, cut into 4.25 in. squares with roll cutters cutting the first two parallel sides and guillotine cutters cutting the final two parallel sides. The dough squares were placed on the bottom of a pizza forming pan to obtained the desired deep dish shape. Each square contained about 44 to about 50 grams raw dough. The dough was cold-pressed in the pan via a press head that pushes and spreads the dough to evenly distribute it about the pan so that it assumes the shape of the pan.
[0043] The pizza crust dough shapes were proofed at about 85 percent relative humidity and about 110° F. Proofing was carried out for about 15 to about 20 minutes; satisfactory proofing can be determined when the pizza crusts stay indented when pressed lightly with a finger. After proofing, the proofed pizza crusts are baked at about 400° F. commercial oven for about 3 to about 4 minutes to yield a pizza crust that is fully baked and has a golden brown color. Preferably, the baked pizza crusts are immediately frozen using a −20° F. blast freezer. The pizza crusts, nested in groups of two each, were then packaged in a film pouch or bag using vacuum and then flushing with nitrogen before sealing. Preferably, the baked pizza crusts are kept frozen until offered for retail sale to maximize the product life.
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A fully baked, deep dish pizza crust is provided having a water activity in the range of about 0.9 to about 0.95. The deep dish pizza crust is ideally suited for use in a refrigerated, ready-to-eat pizza kit. The deep dish pizza crust is of a convenient size and shape (generally square and about 4 by about 4 by about 0.75 in. deep) and is especially adapted as a single serving or snack food product. Also provided is a kit for preparing ready-to-eat deep dish pizza, the kit including one or more deep dish pizza crusts, pizza sauce, cheese, and one or more pizza toppings. The deep dish pizza crusts are designed so that they can be nested so as to reduce the volume requirements in the kit. Each of the components of the pizza kit, including the deep dish pizza crusts, is hermetically sealed from the other food items to substantially retard or prevent flavor, moisture, and microbial migration from one food item to another. The deep dish pizza crusts retain a soft, desirable texture throughout their anticipated shelf lives.
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RELATED PRIORITY APPLICATION
[0001] This application claims the benefit of priority of U.S. Provisional Application No. 61/276,095, filed on Sep. 8, 2009 and entitled, “Voltage Regulating Devices in LED Lamps with Multiple Power Sources”, the entirety of which is incorporated herein by reference.
Field of the Invention
[0002] The present invention relates to driver circuits for light emitting diode illumination lamp devices powered by different types of power sources.
BACKGROUND OF THE INVENTION
[0003] There are many LED retrofit and replacement lamps in the market today. In particular, linear LED lamps are becoming more available by different manufacturers to replace fluorescent lamps using existing lampholders in fixtures. There are LED lamps that are powered by existing ballasts. There are LED lamps that are powered by direct line alternating current voltage mains power where the ballast and starter if present is bypassed or removed. There are LED lamps that are powered by a DC power supply or direct current voltage LED driver. Lastly, there are LED lamps that can be powered by electromagnetic induction. For each LED lamp and power source combination, a unique circuit is designed specifically to operate the LEDs with that particular power supply.
[0004] There becomes a need for one LED lamp with a circuit design that will work for multiple power sources. The one LED lamp will allow for reduced inventory and lower production costs. The use of voltage regulating devices along with other electrical components will allow the LED lamp to be used with ballast power, alternating current voltage or VAC mains power, direct current voltage or VDC power, and inductive transfer power.
[0005] Voltage regulating devices include the family of voltage regulators including but not limited to electromechanical regulators, DC voltage stabilizers, active regulators, linear series regulators, switching regulators, combination (hybrid) regulators, constant current regulators, DC-to-DC converter regulators, buck converter regulators, boost converter regulators, zener shunts, zener clamps, zener clippers, DC-to-AC converter regulators, inverters, etc.
[0006] The additional use of voltage reducing devices will allow the LED lamp to withstand high voltage surges from the ballast during startup, and voltage transients during normal operation of the LED lamp. These devices work with both AC and DC power. Several technologies are available to defend equipment against the damaging effects of power surges. These include devices which protect against excessive current, such as fuses and PTCs, and those that protect against excessive voltages, such as Sidactors, Tranzorbs, MOVs, glass discharge tubes, zener diodes, resistors, capacitors, inductors, varistors and spark gaps, just to name a few. No step-down transformers or capacitors in series with the power source will be used. This will allow the LED lamp device of the present invention to be used with the multiple power sources described.
[0007] The LED lamp device of the present invention can use different types of LEDs. High brightness LEDs are available in discrete radial lead lamps, or in surface mount SMD or SMT packages. Surface mount LEDs are semiconductor devices that have pins or leads that are soldered on the same side as the components. As a result there is no need for feed through holes where solder is applied on both sides of the circuit boards. Therefore, surface mount LEDs can be used on single sided boards and are mounted flat to the surface without angular offsets. They are usually smaller in package size, and the beam spreads are wider than discrete radial lead LED lamps.
[0008] OLEDs or organic light emitting diodes are an up and coming technology for illumination lamp devices. An organic light emitting diode (OLED), also light emitting polymer (LEP), and organic electro luminescence (OEL), is an LED whose emissive electroluminescent layer is composed of a film of organic compounds. The layer usually contains a polymer substance that allows suitable organic compounds to be deposited. They are deposited in rows and columns onto a flat carrier by a simple “printing” process. The resulting matrix of pixels can emit light. OLEDs can be used in light sources for general space illumination and large area light emitting elements. OLEDs typically emit less light per area than inorganic solid-state based LEDs that are usually designed for use as point-light sources.
[0009] An LED or light emitting diode is a special diode that emits light when DC power is applied. Each LED can be arranged in an anti-parallel connection with another diode or another LED as a single pair or as part of a pair of anti-parallel diode strings. Each anti-parallel serial string of at least one diode pair is in series with a current limiting device such as a resistor or a capacitor. The current limiting capacitor can be used for AC voltages, but will block DC power to the LEDs. Therefore, the resistor is a preferred device for the present invention, because it will allow both AC and DC voltages to pass to the series string of anti-parallel diode pairs.
[0010] An anti-parallel connection has at least two diodes connected to each other in opposing parallel relation, at least one or both such diodes are each an LED. The diode pairs are connected in parallel such that an anode of a first diode in the pair is electrically connected to the cathode of the other second diode in the pair, and the anode of the second diode is electrically connected to the cathode of the first diode in the pair. One of each pair of diodes is thus forward biased to produce light regardless of the instantaneous polarity of electrical current supplied to the diode pair by the power source. The anti-parallel diode pairs can also consist of at least two anti-parallel diode strings separated into two separate diode strings that can conduct in opposite electrical directions. Within each anti-parallel diode string pair, a same number of diodes are electrically connected with each number of diodes that can conduct in a different electrical direction. A current limiting resistor is connected to the anti-parallel diode string pair at one point and the value of the resistor is selected to reduce the input power to activate one of the two diode strings in the anti-parallel diode string pair one at a time. At least one or all diodes in each anti-parallel diode string pair is each an LED.
[0011] Besides using individual and discrete components in most implementation of the invention, the diodes in each pair will be normal single-die LEDs. Another aspect of the invention provides, however for a multi-die LED such that the diode pair comprises at least two LED dies mounted with reverse polarity within a single LED casing. It should be noted that “package” or “packaged” or “PCB” is defined herein as an integrated unit meant to be used as a discrete component in either of the manufacture, assembly, installation, or modification of an LED lighting device or system.
[0012] Such a package includes LEDs of desired characteristics in series with current limiting resistors sized relative to the specifications of the chosen opposing parallel diodes and with respect to a predetermined AC voltage and frequency. The Acriche Emitter type is a discrete AC LED and the Acriche PCB type is an AC LED package that is offered by Seoul Semiconductor as the world's first AC-driven semiconductor lighting sources.
DESCRIPTION OF THE RELATED ART
[0013] There are many references that contain designs for providing power to one or more LEDs in use with either a zener diode or other voltage regulating device, but none of them use the voltage regulators in combination with voltage reducing devices to work with multiple power sources as disclosed in this specification. The combination of both components offers an improvement over the references and offers an LED lamp device that can truly operate with multiple power sources.
[0014] U.S. Pat. No. 4,211,955 issued to Ray on Jul. 8, 1980 discloses a Solid State Lamp containing a rectifier and voltage regulator circuit. One embodiment of the invention includes a half wave diode rectifier and regulating means in the form of a resistor and a zener diode. His invention relies on the regulator circuit to protect against transients. In contrast, the present invention uses separate voltage reduction means to protect the electrical elements and LEDs from an overvoltage surge condition either from a ballast during startup or from voltage transients during normal operation of the LED lamp.
[0015] U.S. Pat. No. 4,460,863 issued to Conforti on Jul. 17, 1984 discloses a battery charging circuit with a zener diode and one LED in series and uses a step-down transformer to drop the higher input VAC to a lower output VAC. The present invention does not use a transformer, because it is not needed. The entire input power is utilized and VAC or VDC is used to provide power to the LEDs and other electrical components.
[0016] U.S. Pat. No. 5,939,839 issued to Robel et al. on Aug. 17, 1999 discloses circuits for protecting LEDs for illumination or signaling purposes, and uses a PTC resistor in series with a zener diode and a plurality of LEDs. The use of a PTC will cause all LEDs to turn off when there is an over-current condition, and will turn all the LEDs back on after the over-current condition is removed. This is not desirable in a lamp illumination system. The embodiments of the present invention do not use PTC resistors and therefore allows the LEDs to remain on at all times as long as input power is present. In the specification of U.S. Pat. No. 5,939,839, the zener diode together with the PTC resistor protects the LEDs against positive over voltage. In an embodiment of the present invention, a high power current limiting resistor together with at least one zener diode along with a varistor or similar voltage reducing device connected at the source of input power protects the LEDs against positive over voltage.
[0017] U.S. Pat. No. 6,150,771 issued to Perry on Nov. 21, 2000 discloses an interface circuit for a traffic signal with LEDs to replace incandescent bulbs. Their invention uses a sensing and switching circuit including conflict monitors to provide a power factor of substantially unity. In contrast, in one embodiment of the present invention, a purely resistive load is used to provide a linear current to a zener diode and the series string of LEDs load that induces no changes onto an incoming AC power line for a smoother transfer of power to the LEDs.
[0018] U.S. Pat. No. 6,203,180 issued to Fleischmann on Mar. 20, 2001 discloses a power supply unit for a lighting arrangement that includes at least one LED connected in parallel or in series to the power supply unit with a zener diode connected in parallel to each LED or to a group of LEDs. The lighting arrangement comprises a plurality of spot light sources each comprising at least one LED with each LED fixed in holders. The preferred embodiments of the present invention in contrast, use no holders for the LEDs. The LEDs are mounted directly to circuit boards. In addition, voltage reducing devices are used to protect the electrical components and LEDs from an overvoltage surge condition either from a ballast during startup or from voltage transients during normal operation of the LED lamp.
[0019] U.S. Pat. No. 6,323,598 issued to Guthrie et al. on Nov. 27, 2001 discloses an LED driver for voltage-controlled dimming of at least two LED groups and a switching circuit between the two LED groups. In contrast, an embodiment of the present invention uses only one zener diode in parallel with a single series string of LEDs. In addition, voltage reducing devices are used to protect the electrical components and LEDs from an overvoltage surge condition either from a ballast during startup or from voltage transients during normal operation of the LED lamp.
[0020] U.S. Pat. No. 6,501,084 issued to Sakai et al. on Dec. 31, 2002 discloses a UV lamp unit consisting of LEDs on a circuit board using a zener diode in parallel with a group of LED strings. However, it doesn't disclose voltage reducing devices to protect the electrical components and LEDs from an overvoltage condition either from a ballast during startup or from voltage transients during normal operation.
[0021] U.S. Pat. No. 6,577,072 issued to Saito et al. on Jun. 10, 2003 discloses a power supply and LED lamp device that primarily uses an oscillator to drive the LEDs. When a zener diode is used, the zener voltage is higher than the total of the forward voltage drops of the LEDs connected in parallel with the zener diode within a range of from 10% to 30% both inclusive. A first embodiment of the present invention uses a zener diode with a rated voltage less than 10% above the total of the forward voltage drops of the series string of LEDs, which is below the inclusive range of 10% to 30% as claimed by U.S. Pat. No. 6,577,072.
[0022] U.S. Pat. No. 6,590,343 issued to Pederson on Jul. 8, 2003 discloses a compensating circuit including a zener diode that adjusts the electrical parameters for a plurality of LEDs for inclusion within standardized specifications for the electrical system of a light fixture. Their invention further discloses a controller and software for use with the compensating circuit. In contrast, there is no controller used in the embodiments of the present invention. Input power is used to provide DC voltage to power the series string of LEDs using a constant voltage zener diode or a high voltage regulator IC.
[0023] U.S. Pat. No. 6,650,064 issued to Guthrie et al. on Nov. 18, 2003 discloses a zener diode connected in parallel with two or more sets of series connected LEDs in a reverse forward bias orientation. In contrast, the embodiments of the present invention use at least one zener diode with at least one series string of LEDs. In addition, voltage reducing devices are used to protect the electrical components and LEDs from an overvoltage surge condition either from a ballast during startup or from voltage transients during normal operation of the LED lamp.
[0024] U.S. Pat. No. 7,157,859 issued to Inoue on Jan. 2, 2007 discloses a lighting device and lighting system that use more than one zener diode each with a series resistor in parallel with respective LEDs and each LED also having a series resistor. One embodiment of the present invention uses only one zener diode with one series string of LEDs. Lastly, voltage reducing devices are used to protect the electrical components and LEDs from an overvoltage surge condition either from a ballast during startup or from voltage transients during normal operation of the LED lamp.
[0025] U.S. Pat. No. 4,939,426 issued to Menard et al. on Jul. 3, 1990; U.S. Pat. No. 5,552,678 issued to Tang et al. on Sep. 3, 1996; U.S. Pat. No. 5,914,501 issued to Antle et al. on Jun. 22, 1999; U.S. Pat. No. 6,461,019 issued to Allen on Oct. 8, 2002; U.S. Pat. No. 6,760,380 issued to Andersen on Jul. 6, 2004; U.S. Pat. No. 7,015,650 issued to McGrath on Mar. 21, 2006; U.S. Pat. No. 7,053,560 issued to Ng on May 30, 2006; U.S. Pat. No. 7,489,086 issued to Miskin et al. on Feb. 10, 2009; U.S. Pat. No. 7,618,165 issued to Kamiya et al. on Nov. 17, 2009; and U.S. Patent Application Publication Number 2006/0261362 published on Nov. 23, 2006 among others are provided for reference.
SUMMARY OF THE INVENTION
[0026] An LED lamp device is disclosed primarily for the replacement of fluorescent lamps. The LED lamp contains circuitry to allow it to be used with multiple power sources providing versatility to the end user, and reducing material and inventory costs. The LED lamp terminates primarily in G13 bi-pins on opposing end caps. However, other pin terminating lamp bases will be possible to mate with the different types of fluorescent tube lampholders. The LED lamp mates with the existing lampholders on a new or existing fluorescent fixture. The body of the LED lamp is tubular, with the LEDs and other electrical components positioned within the LED lamp housing that are in electrical communications with the bi-pins. The bi-pins ultimately transfer power from the multiple input power sources to the LEDs.
[0027] Although the patent is primarily for an LED fluorescent replacement lamp, the same circuitry can be used for other types of LED replacement lamps as well. These include LED lamp devices to replace tungsten filament, halogen, incandescent, HID, metal halide, ceramic discharge lamps, etc. in various lamp packages and housings.
[0028] A first embodiment of the present invention uses a voltage regulating zener diode to set the voltage applied to a series string of LEDs. This shunt regulator can include a zener diode, avalanche breakdown diode, or a TVS or transient voltage suppressor. A high power current limiting resistor is connected in series with the zener diode. The zener diode is connected in parallel with the series string of LEDs. More than one zener diode may be used. There may be one zener diode in parallel with one or more LEDs, or one or more series string of LEDs. This is done to maintain illumination from the LED lamp in case one or more LEDs should fail.
[0029] External power from a ballast, VAC, VDC, or electromagnetic induction power immediately passes from the bi-pins to an AC-to-DC converter. The VDC power is filtered through a capacitor and a bleeder resistor. The VDC power then passes through the high power current limiting resistor and zener diode that subsequently sets the voltage and current going to the series string of LEDs. The zener voltage is distributed evenly over each LED in the series string of LEDs.
[0030] Since the LED lamp is non-polarized, it can be installed without any direction or specific position to the mating lampholders. To accomplish this, an optional and identical AC-to-DC converter, filter capacitor, and bleeder resistor is included at the opposite end of the LED lamp with the positive and negative outputs of both AC-to-DC converters tied together respectively within the LED lamp.
[0031] A varistor or similar voltage reducing device that is positioned across the bi-pins of the LED lamp is strongly recommended. The varistor will protect the LED lamp electronics from voltage surges during ballast startup and from voltage transients during normal operation of the LED lamp.
[0032] A second embodiment of the present invention uses a high voltage regulator IC to set the voltage applied to a series string of LEDs. Such high voltage regulator ICs includes the family of TV hybrid voltage regulator ICs, DC-DC converters, buck converters, or similar voltage regulating devices. A smoothing capacitor is used at the input of the high voltage regulator IC, and a resistor bridge sets the base voltage to the high voltage regulator IC. The output of the high voltage regulator IC is connected to an optional current limiting resistor in series with a string of LEDs. More than one high voltage regulator IC may be used. There may be one high voltage regulator IC in parallel with one or more LEDs, or one or more series string of LEDs. This is done to maintain illumination from the LED lamp in case one or more LEDs should fail.
[0033] External power from a ballast, VAC, VDC, or electromagnetic induction power immediately passes from the bi-pins to an AC-to-DC converter. The VDC power enters the high voltage regulator IC. The regulated VDC is filtered through a capacitor and a bleeder resistor, and passes through the optional current limiting resistor and series string of LEDs. The high voltage regulator IC sets the voltage and current going to the series string of LEDs. The regulated high voltage DC is distributed evenly over each LED in the series string of LEDs.
[0034] Since the LED lamp is non-polarized, it can be installed without any direction or specific position to the mating lampholders. To accomplish this, an optional and identical AC-to-DC converter, and optional filter capacitor and bleeder resistor is included at the opposite end of the LED lamp with the positive and negative outputs of both AC-to-DC converters tied together respectively within the LED lamp.
[0035] A varistor or similar voltage reducing device that is positioned across the bi-pins of the LED lamp is strongly recommended. The varistor will protect the LED lamp electronics from voltage surges during ballast startup and from voltage transients during normal operation of the LED lamp.
[0036] A third embodiment of the present invention uses back-to-back voltage regulating zener diodes to set the voltage applied to a series string of paired sets of diodes each connected in an anti-parallel configuration, or to a pair of diode strings connected in an anti-parallel configuration. This clamp or clipper regulator can include two zener diodes, two avalanche breakdown diodes, or two TVS or transient voltage suppressors. A high power current limiting resistor is connected in series with the back-to-back zener diodes. The back-to-back zener diodes are connected in parallel with the series string of anti-parallel diode pairs or anti-parallel pair of diode strings. Each series string of anti-parallel diode pairs or anti-parallel pair of diode strings may contain a current limiting resistor. More than one pair of back-to-back zener diodes may be used. There may be one pair of back-to-back zener diodes in parallel with one or more anti-parallel diode pairs, or one or more series strings of anti-parallel diode pairs. One diode in each pair or one diode in each string can be an LED, or both diodes in each anti-parallel diode pair or each anti-parallel diode string pair can be LEDs. This configuration maintains illumination from the LED lamp in case one or more LEDs should fail.
[0037] External power from a ballast, VAC, VDC, or electromagnetic induction power immediately passes from the bi-pins to an optional DC-to-AC converter or an inverter. The DC-to-AC converter or an inverter is optional since both VAC and VDC will still pass onto the anti-parallel diode pairs or anti-parallel diode string pairs. The VAC power then passes through the high power current limiting resistor and the back-to-back zener diodes that subsequently set the voltage and current going to the series string of anti-parallel diode pairs or anti-parallel diode string pairs. The total back-to-back zener voltage is distributed evenly over each diode or LED in the anti-parallel diode pairs in the series string of anti-parallel diode pairs, or over each diode or LED in the anti-parallel diode strings.
[0038] Since the LED lamp is non-polarized, it can be installed without any direction or specific position to the mating lampholders. To accomplish this, an optional and identical DC-to-AC converter or inverter is included at the opposite end of the LED lamp with the positive and negative inputs of both DC-to-AC converters or inverters tied together respectively within the LED lamp. DC power and AC power will still pass to the anti-parallel diode pairs or anti-parallel diode string pairs without the DC-to-AC converter or inverter in place.
[0039] A varistor or similar voltage reducing device that is positioned across the bi-pins of the LED lamp is strongly recommended. The varistor will protect the LED lamp electronics from voltage surges during ballast startup and from voltage transients during normal operation of the LED lamp.
[0040] A fourth embodiment of the present invention uses back-to-back voltage regulating zener diodes to set the voltage applied to at least one packaged AC LED PCB connected in parallel. This clamp or clipper regulator can include two zener diodes, two avalanche breakdown diodes, or two TVS or transient voltage suppressors. A high power current limiting resistor is connected in series with the back-to-back zener diodes. The back-to-back zener diodes are connected in parallel with at least one packaged AC LED PCB. The packaged AC LED PCB may contain a current limiting resistor. More than one pair of back-to-back zener diodes may be used. There may be one pair of back-to-back zener diodes in parallel with one or more packaged AC LED PCBs. This is done to maintain illumination from the LED lamp in case one or more packaged AC LED PCBs should fail.
[0041] External power from a ballast, VAC, VDC, or electromagnetic induction power immediately passes from the bi-pins to an optional DC-to-AC converter or an inverter. The DC-to-AC converter or an inverter is optional since both VAC and VDC will still pass onto the packaged AC LED PCBs. The VAC power then passes through the high power current limiting resistor and the back-to-back zener diodes that subsequently set the voltage and current going to the packaged AC LED PCBs. The back-to-back zener voltage is the same over each packaged AC LED PCB.
[0042] Since the LED lamp is non-polarized, it can be installed without any direction or specific position to the mating lampholders. To accomplish this, an optional and identical DC-to-AC converter or inverter is included at the opposite end of the LED lamp with the positive and negative inputs of both DC-to-AC converters or inverters tied together respectively within the LED lamp. DC power and AC power will still pass to the anti-parallel diode pairs without the DC-to-AC converter or inverter in place.
[0043] A varistor or similar voltage reducing device that is positioned across the bi-pins of the LED lamp is strongly recommended. The varistor will protect the LED lamp electronics from voltage surges during ballast startup and from voltage transients during normal operation of the LED lamp.
OBJECT OF THE INVENTION
[0044] It is an object of the present invention to minimize inventory costs.
[0045] It is another object of the present invention to minimize electrical components to reduce overall material cost.
[0046] It is yet another object of the invention to provide circuitry and electrical components for a versatile LED lamp device that can be used with multiple sources of input power.
[0047] While the novel features of the invention are set forth particularly in the appended claims, the invention, both as to organization and content, will be better understood and appreciated along with other objects and features thereof, from the following detailed description taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0048] FIG. 1 shows a first embodiment of the present invention using a single resistor and zener diode as the main voltage regulating device in parallel with at least one LED.
[0049] FIG. 2 shows a second embodiment of the present invention using a high voltage regulator IC as the main voltage regulating device in parallel with at least one LED.
[0050] FIG. 3 shows an alternate embodiment of the present invention shown in FIG. 1 using more than one zener diode each in parallel with at least one LED.
[0051] FIG. 4 shows an alternate embodiment of the present invention shown in FIG. 2 using more than one high voltage regulator IC each in parallel with at least one LED.
[0052] FIG. 5 shows a third embodiment of the present invention using a single resistor and back-to-back zener diodes as the main voltage regulating device in parallel with at least one pair of diodes connected in anti-parallel in series with a resistor.
[0053] FIG. 6 shows an alternate embodiment of the present invention shown in FIG. 5 using more than one pair of back-to-back zener diodes each in parallel with at least one pair of diodes connected in anti-parallel each in series with a resistor.
[0054] FIG. 7 shows another alternate embodiment of the present invention shown in FIG. 5 using a single resistor and back-to-back zener diodes in parallel with at least one serial string of diode pairs connected in anti-parallel such that any one of the two serial string of diodes can conduct in opposite electrical directions.
[0055] FIG. 8 shows a fourth embodiment of the present invention using a single resistor and back-to-back zener diodes as the main voltage regulating device in parallel with at least one packaged AC LED PCB consisting of at least one AC LED emitter each in series with a resistor.
[0056] The foregoing has outlined rather broadly the features and technical advantages of the present invention, so that those skilled in the art may better understand the detailed description of the invention that follows. Additional features and advantages of the invention will be described hereinafter that form the subject of the claims of the invention. Those skilled in the art will appreciate that they may readily use the conception and the specific embodiment disclosed as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. Those skilled in the art will also realize that such equivalent constructions do not depart from the spirit and scope of the invention in its broadest form.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0057] Although the present invention has been described in terms of the presently preferred embodiments, it is to be understood that such 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.
[0058] FIGS. 1 to 8 , discussed below and the various embodiments used to describe the principles of the present invention in this patent document are by way of illustration only and should not be construed in any way to limit the scope of the invention. Those skilled in the art will understand that the principles of the present invention may be implemented in any suitably arranged device.
[0059] FIG. 1 shows a first embodiment of the present invention using a high power current limiting resistor 35 and a zener diode 40 as the main voltage regulating device to provide power to a series string of LEDs 45 . LED lamp 10 is shown with bi-pins 15 on opposite ends of LED lamp 10 . On both ends, bi-pins 15 are connected to the AC sides of AC-to-DC converters 20 . The positive sides of AC-to-DC converters 20 are connected together. The positive sides are also filtered through capacitors 25 and bleeder resistors 30 , and then passes through high power current limiting resistor 35 connected in series with zener diode 40 and series string of LEDs 45 . Voltage reducing devices 50 may be connected to the bi-pins 15 of LED lamp 10 .
[0060] The actual AC-to-DC converter 20 used is a full-wave bridge rectifier. The bridge rectifier circuit can consist of four separate silicon diodes or one bridge component. This bridge rectifier results in a rippled DC current and therefore serves as an example circuit only. A different rectification scheme may be employed, depending on cost considerations. For example, more capacitors or inductors and resistors may be added to further reduce ripple at a minor cost increase. A larger filter capacitor helps filter out the AC from the DC source. Because of the many possibilities and because of their insignificance, these and similar additional circuit features have been purposely omitted from FIG. 1 . The actual voltage reducing device 50 used is a varistor. A varistor or similar fusing device may be used to ensure that voltage is limited during power surges. The actual zener diode 40 can also be an avalanche breakdown diode or a voltage regulator tube. Although input power at bi-pins 15 of LED lamp 10 are rectified by AC-to-DC converters 20 , it will be noted that the LED lamp 10 will still operate with input power at only one end or across any two pins on bi-pins 15 .
[0061] When ballast power is connected to one or both ends of LED lamp 10 by way of bi-pins 15 , the ballast power is transferred to AC-to-DC converters 20 . DC voltage from AC-to-DC converters 20 is filtered by capacitors 25 and bleeder resistors 30 . DC voltage from AC-to-DC converters 20 is also connected to one side of high power current limiting resistor 35 . The other side of resistor 35 is connected in series to the cathode side of zener diode 40 and to the anode side of the first LED 45 A in the series string of LEDs 45 . The cathode side of last LED 45 B and the anode side of zener diode 40 are connected to the negative sides of AC-to-DC converters 20 . The negative sides of AC-to-DC converters 20 are connected together to DC ground. Voltage reducing devices 50 may be connected to the bi-pins 15 of LED lamp 10 .
[0062] When line voltage AC power is connected to one or both ends of LED lamp 10 by way of bi-pins 15 , the line voltage AC power is transferred to AC-to-DC converters 20 . DC voltage from AC-to-DC converters 20 is filtered by capacitors 25 and bleeder resistors 30 . DC voltage from AC-to-DC converters 20 is also connected to one side of high power current limiting resistor 35 . The other side of resistor 35 is connected in series to the cathode side of zener diode 40 and to the anode side of the first LED 45 A in the series string of LEDs 45 . The cathode side of last LED 45 B and the anode side of zener diode 40 are connected to the negative sides of AC-to-DC converters 20 . The negative sides of AC-to-DC converters 20 are connected together to DC ground. Voltage reducing devices 50 may be connected to the bi-pins 15 of LED lamp 10 .
[0063] When DC power is connected to one or both ends of LED lamp 10 by way of bi-pins 15 , the DC power is transferred to AC-to-DC converters 20 . DC voltage from AC-to-DC converters 20 is filtered by capacitors 25 and bleeder resistors 30 . DC voltage from AC-to-DC converters 20 is also connected to one side of high power current limiting resistor 35 . The other side of resistor 35 is connected in series to the cathode side of zener diode 40 and to the anode side of the first LED 45 A in the series string of LEDs 45 . The cathode side of last LED 45 B and the anode side of zener diode 40 are connected to the negative sides of AC-to-DC converters 20 . The negative sides of AC-to-DC converters 20 are connected together to DC ground. Voltage reducing devices 50 may be connected to the bi-pins 15 of LED lamp 10 .
[0064] Wireless energy transfer or wireless power transmission is the process that takes place in any system where electrical energy is transmitted from a power source to an electrical load without interconnecting wires. When power is transmitted by an inductive transmitter (not shown) located by the mating lampholders (not shown) to an inductive receiver or antenna (not shown) located in LED lamp 10 , the electromagnetic induction power is transferred to AC-to-DC converters 20 . DC voltage from AC-to-DC converters 20 is filtered by capacitors 25 and bleeder resistors 30 . DC voltage from AC-to-DC converters 20 is also connected to one side of high power current limiting resistor 35 . The other side of resistor 35 is connected in series to the cathode side of zener diode 40 and to the anode side of the first LED 45 A in the series string of LEDs 45 . The cathode side of last LED 45 B and the anode side of zener diode 40 are connected to the negative sides of AC-to-DC converters 20 . The negative sides of AC-to-DC converters 20 are connected together to DC ground. In this manner, LED lamp 10 is powered without a direct electrical connection. Voltage reducing devices 50 may be connected to the bi-pins 15 of LED lamp 10 .
[0065] Exemplary values for the relevant electrical components depicted in FIG. 1 are: AC-to-DC converters 20 =1 ampere diodes each rated 600 volts; capacitors 25 =10 uF; resistors 30 =1 mega ohm; resistor 35 =300 ohms; zener diode 40 =120 volts; and LEDs 45 , 45 A- 45 B each LED having forward voltage drops in the range 3.1-3.6 VDC.
[0066] FIG. 2 shows a second embodiment of the present invention using a high voltage regulator IC 75 as the main voltage regulating device to provide power to a series string of LEDs 125 . LED lamp 60 is shown with bi-pins 65 on opposite ends of LED lamp 60 . On both ends, bi-pins 65 are connected to the AC sides of AC-to-DC converters 70 . The positive sides of AC-to-DC converters 70 are connected together. The positive sides of AC-to-DC converters 70 are also connected to a smoothing capacitor 80 and then to a resistor bridge consisting of resistor 85 and resistor 90 . The positive sides of AC-to-DC converters 70 connect to one side of resistor 85 and to the input voltage side of high voltage regulator IC 75 . The other side of resistor 85 is connected to one side of resistor 90 to base pin 100 of high voltage regulator IC 75 and to one side of capacitor 95 . The other side of capacitor 95 connects to the negative sides of AC-to-DC converters 70 and to ground pin 105 of high voltage regulator IC 75 . The output voltage side of high voltage regulator IC 75 is filtered through capacitor 110 and bleeder resistor 115 , and then passes through optional current limiting resistor 120 connected to series string of LEDs 125 . Voltage reducing devices 130 may be connected to the bi-pins 65 of LED lamp 60 .
[0067] The actual AC-to-DC converter 70 used is a full-wave bridge rectifier. The bridge rectifier circuit can consist of four separate silicon diodes or one bridge component. This bridge rectifier results in a rippled DC current and therefore serves as an example circuit only. A different rectification scheme may be employed, depending on cost considerations. For example, more capacitors or inductors and resistors may be added to further reduce ripple at a minor cost increase. A larger filter capacitor helps filter out the AC from the DC source. Because of the many possibilities and because of their insignificance, these and similar additional circuit features have been purposely omitted from FIG. 2 . The actual voltage reducing device 130 used is a varistor. A varistor or similar fusing device may be used to ensure that voltage is limited during power surges. The actual high voltage regulator IC 75 used is a TV hybrid voltage regulator IC, DC-DC converter, buck converter, or similar high voltage DC voltage regulating device. Although input power at bi-pins 65 of LED lamp 60 are rectified by AC-to-DC converters 70 , it will be noted that the LED lamp 60 will still operate with input power at only one end or across any two pins on bi-pins 65 .
[0068] When ballast power is connected to one or both ends of LED lamp 60 by way of bi-pins 65 , the ballast power is transferred to AC-to-DC converters 70 . DC voltage from AC-to-DC converters 70 is then connected to a smoothing capacitor 80 and then to a resistor bridge consisting of resistor 85 and resistor 90 . The positive sides of AC-to-DC converters 70 connect to one side of resistor 85 and to the input voltage side of high voltage regulator IC 75 . The other side of resistor 85 is connected to one side of resistor 90 to base pin 100 of high voltage regulator IC 75 and to one side of capacitor 95 . The other side of capacitor 95 and the other side of resistor 90 connect to the negative sides of AC-to-DC converters 70 and to ground pin 105 of high voltage regulator IC 75 . The output voltage side of high voltage regulator IC 75 is filtered through capacitor 110 and bleeder resistor 115 to DC ground. DC voltage from the output voltage side of high voltage regulator IC 75 is also connected to one side of optional current limiting resistor 120 . The other side of optional current limiting resistor 120 is connected in series to the anode side of the first LED 125 A in the series string of LEDs 125 . The cathode side of last LED 125 B is connected to the negative sides of AC-to-DC converters 70 to DC ground. Voltage reducing devices 130 may be connected to the bi-pins 65 of LED lamp 60 .
[0069] When line voltage AC power is connected to one or both ends of LED lamp 60 by way of bi-pins 65 , the line voltage AC power is transferred to AC-to-DC converters 70 . DC voltage from AC-to-DC converters 70 is then connected to a smoothing capacitor 80 and then to a resistor bridge consisting of resistor 85 and resistor 90 . The positive sides of AC-to-DC converters 70 connect to one side of resistor 85 and to the input voltage side of high voltage regulator IC 75 . The other side of resistor 85 is connected to one side of resistor 90 to base pin 100 of high voltage regulator IC 75 and to one side of capacitor 95 . The other side of capacitor 95 and the other side of resistor 90 connect to the negative sides of AC-to-DC converters 70 and to ground pin 105 of high voltage regulator IC 75 . The output voltage side of high voltage regulator IC 75 is filtered through capacitor 110 and bleeder resistor 115 to DC ground. DC voltage from the output voltage side of high voltage regulator IC 75 is also connected to one side of optional current limiting resistor 120 . The other side of optional current limiting resistor 120 is connected in series to the anode side of the first LED 125 A in the series string of LEDs 125 . The cathode side of last LED 125 B is connected to the negative sides of AC-to-DC converters 70 to DC ground. Voltage reducing devices 130 may be connected to the bi-pins 65 of LED lamp 60 .
[0070] When DC power is connected to one or both ends of LED lamp 60 by way of bi-pins 65 , the DC power is transferred to AC-to-DC converters 70 . DC voltage from AC-to-DC converters 70 is then connected to a smoothing capacitor 80 and then to a resistor bridge consisting of resistor 85 and resistor 90 . The positive sides of AC-to-DC converters 70 connect to one side of resistor 85 and to the input voltage side of high voltage regulator IC 75 . The other side of resistor 85 is connected to one side of resistor 90 to base pin 100 of high voltage regulator IC 75 and to one side of capacitor 95 . The other side of capacitor 95 and the other side of resistor 90 connect to the negative sides of AC-to-DC converters 70 and to ground pin 105 of high voltage regulator IC 75 . The output voltage side of high voltage regulator IC 75 is filtered through capacitor 110 and bleeder resistor 115 to DC ground. DC voltage from the output voltage side of high voltage regulator IC 75 is also connected to one side of optional current limiting resistor 120 . The other side of optional current limiting resistor 120 is connected in series to the anode side of the first LED 125 A in the series string of LEDs 125 . The cathode side of last LED 125 B is connected to the negative sides of AC-to-DC converters 70 to DC ground. Voltage reducing devices 130 may be connected to the bi-pins 65 of LED lamp 60 .
[0071] Wireless energy transfer or wireless power transmission is the process that takes place in any system where electrical energy is transmitted from a power source to an electrical load without interconnecting wires. When power is transmitted by an inductive transmitter (not shown) located by the mating lampholders (not shown) to an inductive receiver or antenna (not shown) located in LED lamp 10 , the electromagnetic induction power is transferred to AC-to-DC converters 70 . DC voltage from AC-to-DC converters 70 is then connected to a smoothing capacitor 80 and then to a resistor bridge consisting of resistor 85 and resistor 90 . The positive sides of AC-to-DC converters 70 connect to one side of resistor 85 and to the input voltage side of high voltage regulator IC 75 . The other side of resistor 85 is connected to one side of resistor 90 to base pin 100 of high voltage regulator IC 75 and to one side of capacitor 95 . The other side of capacitor 95 and the other side of resistor 90 connect to the negative sides of AC-to-DC converters 70 and to ground pin 105 of high voltage regulator IC 75 . The output voltage side of high voltage regulator IC 75 is then filtered through capacitor 110 and bleeder resistor 115 to DC ground. DC voltage from the output voltage side of high voltage regulator IC 75 is also connected to one side of optional current limiting resistor 120 . The other side of optional current limiting resistor 120 is connected in series to the anode side of the first LED 125 A in the series string of LEDs 125 . The cathode side of last LED 125 B is connected to the negative sides of AC-to-DC converters 70 to DC ground. Voltage reducing devices 130 may be connected to the bi-pins 65 of LED lamp 60 .
[0072] Exemplary values for the relevant electrical components depicted in FIG. 2 are: AC-to-DC converters 70 =1 ampere diodes each rated 600 volts; capacitors 110 =10 uF; resistors 115 =1 mega ohm; LEDs 125 , 125 A- 125 B each LED having forward voltage drops in the range 3.1-3.6 VDC; high voltage regulator IC 75 is an NTE1796 or equivalent IC with a fixed output at 114.5 volts; capacitor 80 =220 uF; resistor 85 =10 kilo ohms; resistor 90 =180 kilo ohms; and capacitor 95 =100 uF.
[0073] FIG. 3 shows an alternate embodiment of the present invention shown in FIG. 1 using a high power current limiting resistor 165 and a zener diode 170 A and zener diode 1708 as the main voltage regulating device to provide power to a series string of LEDs 175 . Now, two separate circuits are shown with same resistor 165 and a zener diode 170 A in series with zener diode 170 B each in parallel with and powering a separate series string of LEDs 175 . A separate resistor (not shown) may be used for the second circuit. The two separate circuits allow at least one series string of LEDs 175 to remain lit in the event one of the two circuits should fail. LED lamp 140 is shown with bi-pins 145 on opposite ends of LED lamp 140 . On both ends, bi-pins 145 are connected to the AC sides of AC-to-DC converters 150 . The positive sides of AC-to-DC converters 150 are connected together. The positive sides are also filtered through capacitors 155 and bleeder resistors 160 , and then passes through resistor 165 connected in series with zener diode 170 A and parallel with a string of LEDs 175 , and then in series with zener diode 170 B and parallel with a string of LEDs 175 . Voltage reducing devices 180 may be connected to the bi-pins 145 of LED lamp 140 .
[0074] The actual AC-to-DC converter 150 used is a full-wave bridge rectifier. The bridge rectifier circuit can consist of four separate silicon diodes or one bridge component. This bridge rectifier results in a rippled DC current and therefore serves as an example circuit only. A different rectification scheme may be employed, depending on cost considerations. For example, more capacitors or inductors and resistors may be added to further reduce ripple at a minor cost increase. A larger filter capacitor helps filter out the AC from the DC source. Because of the many possibilities and because of their insignificance, these and similar additional circuit features have been purposely omitted from FIG. 3 . The actual voltage reducing device 180 used is a varistor. A varistor or similar fusing device may be used to ensure that voltage is limited during power surges. The actual zener diodes 170 A and 170 B can also be an avalanche breakdown diode or a voltage regulator tube. Although input power at bi-pins 145 of LED lamp 140 are rectified by AC-to-DC converters 150 , it will be noted that the LED lamp 140 will still operate with input power at only one end or across any two pins on bi-pins 145 .
[0075] When ballast power is connected to one or both ends of LED lamp 140 by way of bi-pins 145 , the ballast power is transferred to AC-to-DC converters 150 . DC voltage from AC-to-DC converters 150 is filtered by capacitors 155 and bleeder resistors 160 . DC voltage from AC-to-DC converters 150 is also connected to one side of high power current limiting resistor 165 . The other side of resistor 165 is connected in series to the cathode side of zener diode 170 A and to the anode side of the first LED 175 A in the first series string of LEDs 175 . The cathode side of last LED 175 B and the anode side of zener diode 170 A are connected in series to the cathode side of zener diode 170 B and to the anode side of the first LED 175 C in the second series string of LEDs 175 . The cathode side of last LED 175 D and the anode side of zener diode 170 B are connected to the negative sides of AC-to-DC converters 150 . The negative sides of AC-to-DC converters 150 are connected together to DC ground. Voltage reducing devices 180 may be connected to the bi-pins 145 of LED lamp 140 .
[0076] When line voltage AC power is connected to one or both ends of LED lamp 140 by way of bi-pins 145 , the line voltage AC power is transferred to AC-to-DC converters 150 . DC voltage from AC-to-DC converters 150 is filtered by capacitors 155 and bleeder resistors 160 . DC voltage from AC-to-DC converters 150 is also connected to one side of high power current limiting resistor 165 . The other side of resistor 165 is connected in series to the cathode side of zener diode 170 A and to the anode side of the first LED 175 A in the first series string of LEDs 175 . The cathode side of last LED 175 B and the anode side of zener diode 170 A are connected in series to the cathode side of zener diode 170 B and to the anode side of the first LED 175 C in the second series string of LEDs 175 . The cathode side of last LED 175 D and the anode side of zener diode 170 B are connected to the negative sides of AC-to-DC converters 150 . The negative sides of AC-to-DC converters 150 are connected together to DC ground. Voltage reducing devices 180 may be connected to the bi-pins 145 of LED lamp 140 .
[0077] When DC power is connected to one or both ends of LED lamp 140 by way of bi-pins 145 , the DC power is transferred to AC-to-DC converters 150 . DC voltage from AC-to-DC converters 150 is filtered by capacitors 155 and bleeder resistors 160 . DC voltage from AC-to-DC converters 150 is also connected to one side of high power current limiting resistor 165 . The other side of resistor 165 is connected in series to the cathode side of zener diode 170 A and to the anode side of the first LED 175 A in the first series string of LEDs 175 . The cathode side of last LED 175 B and the anode side of zener diode 170 A are connected in series to the cathode side of zener diode 170 B and to the anode side of the first LED 175 C in the second series string of LEDs 175 . The cathode side of last LED 175 D and the anode side of zener diode 170 B are connected to the negative sides of AC-to-DC converters 150 . The negative sides of AC-to-DC converters 150 are connected together to DC ground. Voltage reducing devices 180 may be connected to the bi-pins 145 of LED lamp 140 .
[0078] Wireless energy transfer or wireless power transmission is the process that takes place in any system where electrical energy is transmitted from a power source to an electrical load without interconnecting wires. When power is transmitted by an inductive transmitter (not shown) located by the mating lampholders (not shown) to an inductive receiver or antenna (not shown) located in LED lamp 140 , the electromagnetic induction power is transferred to AC-to-DC converters 150 . DC voltage from AC-to-DC converters 150 is filtered by capacitors 155 and bleeder resistors 160 . DC voltage from AC-to-DC converters 150 is also connected to one side of high power current limiting resistor 165 . The other side of resistor 165 is connected in series to the cathode side of zener diode 170 A and to the anode side of the first LED 175 A in the first series string of LEDs 175 . The cathode side of last LED 175 B and the anode side of zener diode 170 A are connected in series to the cathode side of zener diode 170 B and to the anode side of the first LED 175 C in the second series string of LEDs 175 . The cathode side of last LED 175 D and the anode side of zener diode 170 B are connected to the negative sides of AC-to-DC converters 150 . The negative sides of AC-to-DC converters 150 are connected together to DC ground. In this manner, LED lamp 140 is powered without a direct electrical connection. Voltage reducing devices 180 may be connected to the bi-pins 145 of LED lamp 140 .
[0079] Exemplary values for the relevant electrical components depicted in FIG. 3 are: AC-to-DC converters 150 =1 ampere diodes rated 600 volts; capacitors 155 =10 uF; resistors 160 =1 mega ohm; resistor 165 =300 ohms; zener diodes 170 A, 170 B=60 volts; and LEDs 175 , 175 A, 175 B, 175 C, and 175 D each LED having forward voltage drops in the range 3.1-3.6 VDC.
[0080] FIG. 4 shows an alternate embodiment of the present invention shown in FIG. 2 using a high voltage regulator IC 205 as the main voltage regulating device to provide power to a series string of LEDs 255 . Now, two separate circuits are shown each with a separate high voltage regulator IC 205 each to power a separate series string of LEDs 255 . The two separate circuits allow at least one series string of LEDs 255 to remain lit in the event one of the two circuits should fail. LED lamp 190 is shown with bi-pins 195 on opposite ends of LED lamp 190 . On both ends, bi-pins 195 are connected to the AC sides of AC-to-DC converters 200 . The positive sides of AC-to-DC converters 200 are connected together. The positive sides of AC-to-DC converters 200 are also connected to a smoothing capacitor 210 and then to a resistor bridge consisting of resistor 215 and resistor 220 . The positive sides of AC-to-DC converters 200 connect to one side of resistor 215 and to the input voltage side of high voltage regulator IC 205 . The other side of resistor 215 is connected to one side of resistor 220 to base pin 230 of high voltage regulator IC 205 and to one side of capacitor 225 . The other side of capacitor 225 connects to the negative sides of AC-to-DC converters 200 and to ground pin 235 of high voltage regulator IC 205 . The output voltage side of high voltage regulator IC 205 is filtered through capacitor 240 and bleeder resistor 245 , and then passes through optional current limiting resistor 250 connected to series string of LEDs 255 . Voltage reducing devices 260 may be connected to the bi-pins 195 of LED lamp 190 .
[0081] The actual AC-to-DC converter 200 used is a full-wave bridge rectifier. The bridge rectifier circuit can consist of four separate silicon diodes or one bridge component. This bridge rectifier results in a rippled DC current and therefore serves as an example circuit only. A different rectification scheme may be employed, depending on cost considerations. For example, more capacitors or inductors and resistors may be added to further reduce ripple at a minor cost increase. A larger filter capacitor helps filter out the AC from the DC source. Because of the many possibilities and because of their insignificance, these and similar additional circuit features have been purposely omitted from FIG. 4 . The actual voltage reducing device 260 used is a varistor. A varistor or similar fusing device may be used to ensure that voltage is limited during power surges. The actual high voltage regulator IC 205 used is a TV hybrid voltage regulator IC, DC-DC converter, buck converter, or similar high voltage DC voltage regulating device. Although input power at bi-pins 195 of LED lamp 190 are rectified by AC-to-DC converters 200 , it will be noted that the LED lamp 190 will still operate with input power at only one end or across any two pins on bi-pins 195 .
[0082] When ballast power is connected to one or both ends of LED lamp 190 by way of bi-pins 195 , the ballast power is transferred to AC-to-DC converters 200 . DC voltage from AC-to-DC converters 200 is then connected to a smoothing capacitor 210 and then to a resistor bridge consisting of resistor 215 and resistor 220 . The positive sides of AC-to-DC converters 200 connect to one side of resistor 215 and to the input voltage side of high voltage regulator IC 205 . The other side of resistor 215 is connected to one side of resistor 220 to base pin 230 of high voltage regulator IC 205 and to one side of capacitor 225 . The other side of capacitor 225 and the other side of resistor 220 connect to the negative sides of AC-to-DC converters 200 and to ground pin 235 of high voltage regulator IC 205 . The output voltage side of high voltage regulator IC 205 is filtered through capacitor 240 and bleeder resistor 245 to DC ground. DC voltage from the output voltage side of high voltage regulator IC 205 is also connected to one side of optional current limiting resistor 250 . The other side of optional current limiting resistor 250 is connected in series to the anode side of the first LED 255 A in each series string of LEDs 255 . The cathode side of last LED 255 B in each series string of LEDs 255 is connected to the negative sides of AC-to-DC converters 200 to DC ground. Voltage reducing devices 260 may be connected to the bi-pins 195 of LED lamp 190 .
[0083] When line voltage AC power is connected to one or both ends of LED lamp 190 by way of bi-pins 195 , the line voltage AC power is transferred to AC-to-DC converters 200 . DC voltage from AC-to-DC converters 200 is then connected to a smoothing capacitor 210 and then to a resistor bridge consisting of resistor 215 and resistor 220 . The positive sides of AC-to-DC converters 200 connect to one side of resistor 215 and to the input voltage side of high voltage regulator IC 205 . The other side of resistor 215 is connected to one side of resistor 220 to base pin 230 of high voltage regulator IC 205 and to one side of capacitor 225 . The other side of capacitor 225 and the other side of resistor 220 connect to the negative sides of AC-to-DC converters 200 and to ground pin 235 of high voltage regulator IC 205 . The output voltage side of high voltage regulator IC 205 is filtered through capacitor 240 and bleeder resistor 245 to DC ground. DC voltage from the output voltage side of high voltage regulator IC 205 is also connected to one side of optional current limiting resistor 250 . The other side of optional current limiting resistor 250 is connected in series to the anode side of the first LED 255 A in each series string of LEDs 255 . The cathode side of last LED 255 B in each series string of LEDs 255 is connected to the negative sides of AC-to-DC converters 200 to DC ground. Voltage reducing devices 260 may be connected to the bi-pins 195 of LED lamp 190 .
[0084] When DC power is connected to one or both ends of LED lamp 190 by way of bi-pins 195 , the DC power is transferred to AC-to-DC converters 200 . DC voltage from AC-to-DC converters 200 is then connected to a smoothing capacitor 210 and then to a resistor bridge consisting of resistor 215 and resistor 220 . The positive sides of AC-to-DC converters 200 connect to one side of resistor 215 and to the input voltage side of high voltage regulator IC 205 . The other side of resistor 215 is connected to one side of resistor 220 to base pin 230 of high voltage regulator IC 205 and to one side of capacitor 225 . The other side of capacitor 225 and the other side of resistor 220 connect to the negative sides of AC-to-DC converters 200 and to ground pin 235 of high voltage regulator IC 205 . The output voltage side of high voltage regulator IC 205 is filtered through capacitor 240 and bleeder resistor 245 to DC ground. DC voltage from the output voltage side of high voltage regulator IC 205 is also connected to one side of optional current limiting resistor 250 . The other side of optional current limiting resistor 250 is connected in series to the anode side of the first LED 255 A in each series string of LEDs 255 . The cathode side of last LED 255 B in each series string of LEDs 255 is connected to the negative sides of AC-to-DC converters 200 to DC ground. Voltage reducing devices 260 may be connected to the bi-pins 195 of LED lamp 190 .
[0085] Wireless energy transfer or wireless power transmission is the process that takes place in any system where electrical energy is transmitted from a power source to an electrical load without interconnecting wires. When power is transmitted by an inductive transmitter (not shown) located by the mating lampholders (not shown) to an inductive receiver or antenna (not shown) located in LED lamp 190 , the electromagnetic induction power is transferred to AC-to-DC converters 200 . DC voltage from AC-to-DC converters 200 is then connected to a smoothing capacitor 210 and then to a resistor bridge consisting of resistor 215 and resistor 220 . The positive sides of AC-to-DC converters 200 connect to one side of resistor 215 and to the input voltage side of high voltage regulator IC 205 . The other side of resistor 215 is connected to one side of resistor 220 to base pin 230 of high voltage regulator IC 205 and to one side of capacitor 225 . The other side of capacitor 225 and the other side of resistor 220 connect to the negative sides of AC-to-DC converters 200 and to ground pin 235 of high voltage regulator IC 205 . The output voltage side of high voltage regulator IC 205 is then filtered through capacitor 240 and bleeder resistor 245 to DC ground. DC voltage from the output voltage side of high voltage regulator IC 205 is also connected to one side of optional current limiting resistor 250 . The other side of optional current limiting resistor 250 is connected in series to the anode side of the first LED 255 A in each series string of LEDs 255 . The cathode side of last LED 255 B in each series string of LEDs 255 is connected to the negative sides of AC-to-DC converters 200 to DC ground. Voltage reducing devices 260 may be connected to the bi-pins 195 of LED lamp 190 .
[0086] Exemplary values for the relevant electrical components depicted in FIG. 4 are: AC-to-DC converters 200 =1 ampere diodes each rated 600 volts; capacitors 240 =10 uF; resistors 245 =1 mega ohm; LEDs 255 , 255 A- 255 B each LED having forward voltage drops in the range 3.1-3.6 VDC; high voltage regulator IC 205 is an voltage regulator IC NTE 1841 with a fixed output at 43.8 volts; capacitors 210 =220 uF; resistors 215 ˜10 kilo ohms; resistors 220 ˜180 kilo ohms; and capacitors 225 =100 uF.
[0087] FIG. 5 shows a third embodiment of the present invention using a high power current limiting resistor 280 and back-to-back zener diodes 285 as the main voltage regulating device to provide power to a series string of anti-parallel diode pairs 290 . LED lamp 270 is shown with bi-pins 275 on opposite ends of LED lamp 270 . Voltage reducing devices 300 may be connected to the bi-pins 275 of LED lamp 270 .
[0088] The actual voltage reducing device 300 used is a varistor. A varistor or similar fusing device may be used to ensure that voltage is limited during power surges. The actual back-to-back zener diodes 285 can also be a back-to-back avalanche breakdown diodes or back-to-back TVS. Each anti-parallel diode pair 290 can consist of one diode and one LED, or both diodes can be LEDs. LED lamp 270 shows two LEDs in each anti-parallel diode pair 290 . It will be noted that the LED lamp 270 will still operate with input power at only one end or across any two pins on bi-pins 275 .
[0089] When ballast power is connected to one or both ends of LED lamp 270 by way of bi-pins 275 , the ballast power is connected to one side of high power current limiting resistor 280 . The other side of resistor 280 is connected in series to the cathode side of one side of the back-to-back zener diodes 285 and to the first anti-parallel LED pair 290 A in the series string of anti-parallel LED pairs 290 . The last anti-parallel LED pair 290 B is then connected to one side of resistor 295 . The other side of resistor 295 and the cathode side of the other side of back-to-back zener diodes 285 are connected back to bi-pins 275 . Voltage reducing devices 300 may be connected to the bi-pins 275 of LED lamp 270 .
[0090] When line voltage AC power is connected to one or both ends of LED lamp 270 by way of bi-pins 275 , the line voltage AC power is connected to one side of high power current limiting resistor 280 . The other side of resistor 280 is connected in series to the cathode side of one side of the back-to-back zener diodes 285 and to the first anti-parallel LED pair 290 A in the series string of anti-parallel LED pairs 290 . The last anti-parallel LED pair 290 B is then connected to one side of resistor 295 . The other side of resistor 295 and the cathode side of the other side of back-to-back zener diodes 285 are connected back to bi-pins 275 . Voltage reducing devices 300 may be connected to the bi-pins 275 of LED lamp 270 .
[0091] When DC power is connected to one or both ends of LED lamp 270 by way of bi-pins 275 , the DC power is connected to one side of high power current limiting resistor 280 . The other side of resistor 280 is connected in series to the cathode side of one side of the back-to-back zener diodes 285 and to the first anti-parallel LED pair 290 A in the series string of anti-parallel LED pairs 290 . The last anti-parallel LED pair 290 B is then connected to one side of resistor 295 . The other side of resistor 295 and the cathode side of the other side of back-to-back zener diodes 285 are connected back to bi-pins 275 . Voltage reducing devices 300 may be connected to the bi-pins 275 of LED lamp 270 .
[0092] Wireless energy transfer or wireless power transmission is the process that takes place in any system where electrical energy is transmitted from a power source to an electrical load without interconnecting wires. When power is transmitted by an inductive transmitter (not shown) located by the mating lampholders (not shown) to an inductive receiver or antenna (not shown) located in LED lamp 270 , the electromagnetic induction power is connected to one side of high power current limiting resistor 280 . The other side of resistor 280 is connected in series to the cathode side of one side of the back-to-back zener diodes 285 and to the first anti-parallel LED pair 290 A in the series string of anti-parallel LED pairs 290 . The last anti-parallel LED pair 290 B is then connected to one side of resistor 295 . The other side of resistor 295 and the cathode side of the other side of back-to-back zener diodes 285 are connected back to bi-pins 275 . Voltage reducing devices 300 may be connected to the bi-pins 275 of LED lamp 270 .
[0093] Exemplary values for the relevant electrical components depicted in FIG. 5 are: resistor 280 =300 ohms; each zener diodes=120 volts; anti-parallel LED pairs 290 , 290 A- 290 B each LED having forward voltage drops in the range 3.1-3.6 VDC; and resistor 295 =800 ohms.
[0094] FIG. 6 shows an alternate embodiment of the present invention shown in FIG. 5 using high power current limiting resistors 320 A, 320 B and back-to-back zener diodes 325 A, 325 B as the main voltage regulating devices to provide power to a series string of anti-parallel diode pairs 330 . Each anti-parallel diode pair 330 can consist of one diode and one LED, or both diodes can be LEDs. LED lamp 310 shows one diode and one LED in each anti-parallel diode pair 330 . Now, two separate circuits are shown. The first circuit has high power current limiting resistor 320 A in series with back-to-back zener diodes 325 A to power a series string of anti-parallel diode pairs 330 A- 330 B in series with current limiting resistor 335 A. The second circuit has high power current limiting resistor 320 B in series with back-to-back zener diodes 325 B to power a series string of anti-parallel diode pairs 330 C- 330 D in series with current limiting resistor 335 B. The two separate circuits allow at least one series string of anti-parallel diode pairs 330 to remain lit in the event one of the two circuits should fail. LED lamp 310 is shown with bi-pins 315 on opposite ends of LED lamp 310 . Voltage reducing devices 340 may be connected to the bi-pins 315 of LED lamp 310 .
[0095] When ballast power is connected to one or both ends of LED lamp 310 by way of bi-pins 315 , the ballast power is connected to one side of high power current limiting resistor 320 A and 320 B. The other side of resistors 320 A and 320 B respectively is connected in series to the cathode side of one side of the back-to-back zener diodes 325 A and 325 B respectively, and to the first anti-parallel LED pair 330 A and 330 C respectively in the series string of anti-parallel LED pairs 330 . The last anti-parallel LED pair 330 B and 330 D is then connected to one side of resistors 335 A and 335 B respectively. The other side of resistors 335 A and 335 B, and the cathode side of the other side of back-to-back zener diodes 325 A and 325 B respectively are connected back to bi-pins 315 respectively. Voltage reducing devices 340 may be connected to the bi-pins 315 of LED lamp 310 .
[0096] When line voltage AC power is connected to one or both ends of LED lamp 310 by way of bi-pins 315 , the line voltage AC power is connected to one side of high power current limiting resistor 320 A and 320 B. The other side of resistors 320 A and 320 B respectively is connected in series to the cathode side of one side of the back-to-back zener diodes 325 A and 325 B respectively, and to the first anti-parallel LED pair 330 A and 330 C respectively in the series string of anti-parallel LED pairs 330 . The last anti-parallel LED pair 330 B and 330 D is then connected to one side of resistors 335 A and 335 B respectively. The other side of resistors 335 A and 335 B, and the cathode side of the other side of back-to-back zener diodes 325 A and 325 B respectively are connected back to bi-pins 315 respectively. Voltage reducing devices 340 may be connected to the bi-pins 315 of LED lamp 310 .
[0097] When DC power is connected to one or both ends of LED lamp 310 by way of bi-pins 315 , the DC power is connected to one side of high power current limiting resistor 320 A and 320 B. The other side of resistors 320 A and 320 B respectively is connected in series to the cathode side of one side of the back-to-back zener diodes 325 A and 325 B respectively, and to the first anti-parallel LED pair 330 A and 330 C respectively in the series string of anti-parallel LED pairs 330 . The last anti-parallel LED pair 330 B and 330 D is then connected to one side of resistors 335 A and 335 B respectively. The other side of resistors 335 A and 335 B, and the cathode side of the other side of back-to-back zener diodes 325 A and 325 B respectively are connected back to bi-pins 315 respectively. Voltage reducing devices 340 may be connected to the bi-pins 315 of LED lamp 310 .
[0098] Wireless energy transfer or wireless power transmission is the process that takes place in any system where electrical energy is transmitted from a power source to an electrical load without interconnecting wires. When power is transmitted by an inductive transmitter (not shown) located by the mating lampholders (not shown) to an inductive receiver or antenna (not shown) located in LED lamp 310 , the electromagnetic induction power is connected to one side of high power current limiting resistors 320 A and 320 B. The other side of resistor 320 A and 320 B respectively is connected in series to the cathode side of one side of the back-to-back zener diodes 325 A and 325 B respectively, and to the first anti-parallel LED pair 330 A and 330 C respectively in the series string of anti-parallel LED pairs 330 . The last anti-parallel LED pair 330 B and 330 D is then connected to one side of resistors 335 A and 335 B respectively. The other side of resistors 335 A and 335 B, and the cathode side of the other side of back-to-back zener diodes 325 A and 325 B respectively are connected back to bi-pins 315 respectively. Voltage reducing devices 340 may be connected to the bi-pins 315 of LED lamp 310 .
[0099] Exemplary values for the relevant electrical components depicted in FIG. 6 are: resistors 320 A, 320 B=680 ohms; each zener diodes=60 volts; anti-parallel LED pairs 330 , 330 A- 330 D each LED having forward voltage drops in the range 3.1-3.6 VDC; and resistors 335 A, 335 B=400 ohms.
[0100] FIG. 7 shows an alternate embodiment of the present invention shown in FIG. 5 using high power current limiting resistor 360 and back-to-back zener diodes 365 as the main voltage regulating device to provide power to anti-parallel diode string pairs 370 . Each diode string 370 A and 370 B can consist of diodes and LEDs, or the diodes can all be LEDs. LED lamp 350 shows all LEDs in anti-parallel diode string pairs 370 . Now, three separate diode string pairs 370 are shown. Three diode strings 370 A operate when power flows away from high power current limiting resistor 360 in series with back-to-back zener diodes 365 , and three diode strings 370 B operate when power flows towards high power current limiting resistor 360 in series with back-to-back zener diodes 365 . An anti-parallel diode string pair 370 consists of one diode string 370 A and one diode string 370 B allowing for the three anti-parallel diode string pairs 370 . Each anti-parallel diode string pair 370 in turn is connected to an optional current limiting resistor 375 . The three separate anti-parallel diode string pairs 370 , consisting of three diode strings 370 A and three diode strings 370 B allow at least one series string of anti-parallel diode pairs 370 to remain lit in the event any one of the six diode strings 370 A or 370 B should fail. LED lamp 350 is shown with bi-pins 355 on opposite ends of LED lamp 350 . Voltage reducing devices 380 may be connected to the bi-pins 355 of LED lamp 350 .
[0101] When ballast power is connected to one or both ends of LED lamp 350 by way of bi-pins 355 , the ballast power is connected to one side of high power current limiting resistor 360 . The other side of resistor 360 is connected in series to the cathode side of one side of the back-to-back zener diodes 365 , and to the anodes of the first LEDs in diode strings 370 A and the cathodes of the first LEDs in diode strings 370 B that form anti-parallel LED string pairs 370 . The cathodes of the last LEDs in diode strings 370 A and the anodes of the last LEDs in diode strings 370 B of anti-parallel LED string pairs 370 are each tied together and connected to one side of resistors 375 . The other side of resistor 375 and the cathode side of the other side of back-to-back zener diodes 365 are connected back to bi-pins 355 . Voltage reducing devices 380 may be connected to the bi-pins 355 of LED lamp 350 .
[0102] When line voltage AC power is connected to one or both ends of LED lamp 350 by way of bi-pins 355 , the line voltage AC power is connected to one side of high power current limiting resistor 360 . The other side of resistor 360 is connected in series to the cathode side of one side of the back-to-back zener diodes 365 , and to the anodes of the first LEDs in diode strings 370 A and the cathodes of the first LEDs in diode strings 370 B that form anti-parallel LED string pairs 370 . The cathodes of the last LEDs in diode strings 370 A and the anodes of the last LEDs in diode strings 370 B of anti-parallel LED string pairs 370 are each tied together and connected to one side of resistors 375 . The other side of resistor 375 and the cathode side of the other side of back-to-back zener diodes 365 are connected back to bi-pins 355 . Voltage reducing devices 380 may be connected to the bi-pins 355 of LED lamp 350 .
[0103] When DC power is connected to one or both ends of LED lamp 350 by way of bi-pins 355 , the DC power is connected to one side of high power current limiting resistor 360 . The other side of resistor 360 is connected in series to the cathode side of one side of the back-to-back zener diodes 365 , and to the anodes of the first LEDs in diode strings 370 A and the cathodes of the first LEDs in diode strings 370 B that form anti-parallel LED string pairs 370 . The cathodes of the last LEDs in diode strings 370 A and the anodes of the last LEDs in diode strings 370 B of anti-parallel LED string pairs 370 are each tied together and connected to one side of resistors 375 . The other side of resistor 375 and the cathode side of the other side of back-to-back zener diodes 365 are connected back to bi-pins 355 . Voltage reducing devices 380 may be connected to the bi-pins 355 of LED lamp 350 .
[0104] Wireless energy transfer or wireless power transmission is the process that takes place in any system where electrical energy is transmitted from a power source to an electrical load without interconnecting wires. When power is transmitted by an inductive transmitter (not shown) located by the mating lampholders (not shown) to an inductive receiver or antenna (not shown) located in LED lamp 350 , the electromagnetic induction power is connected to one side of high power current limiting resistor 360 . The other side of resistor 360 is connected in series to the cathode side of one side of the back-to-back zener diodes 365 , and to the anodes of the first LEDs in diode strings 370 A and the cathodes of the first LEDs in diode strings 370 B that form anti-parallel LED string pairs 370 . The cathodes of the last LEDs in diode strings 370 A and the anodes of the last LEDs in diode strings 370 B of anti-parallel LED string pairs 370 are each tied together and connected to one side of resistors 375 . The other side of resistor 375 and the cathode side of the other side of back-to-back zener diodes 365 are connected back to bi-pins 355 . Voltage reducing devices 380 may be connected to the bi-pins 355 of LED lamp 350 .
[0105] Exemplary values for the relevant electrical components depicted in FIG. 7 are: resistor 360 =237 ohms; each zener diodes=60 volts; anti-parallel LED string pairs 370 , 370 A- 370 B each LED having forward voltage drops in the range 3.1-3.6 VDC; and resistor 375 =400 ohms.
[0106] FIG. 8 shows a fourth embodiment of the present invention using a high power current limiting resistor 400 and back-to-back zener diodes 405 as the main voltage regulating device to provide power to packaged AC LED PCBs 410 connected in parallel. LED lamp 390 is shown with bi-pins 395 on opposite ends of LED lamp 390 . Voltage reducing devices 425 may be connected to the bi-pins 395 of LED lamp 390 .
[0107] The actual voltage reducing device 425 used is a varistor. A varistor or similar fusing device may be used to ensure that voltage is limited during power surges. The actual back-to-back zener diodes 405 can also be a back-to-back avalanche breakdown diodes or a back-to-back TVS or transient voltage suppressors. Each anti-parallel diode pair 415 can consist of one diode and one LED, or both diodes can be LEDs. LED lamp 390 shows two LEDs in each anti-parallel diode pair 415 . Anti-parallel diode pair 415 represents AC LED emitters with an external resistor 420 . The combination of anti-parallel diode pairs 415 and resistors 420 represent the packaged AC LED PCBs 410 . It is possible for the anti-parallel diode pairs 415 also to be an anti-parallel string of diode pairs (not shown) similar to the configuration shown in FIG. 7 . For the sake of exposition, only four anti-parallel diode pairs 415 are shown in each packaged AC LED PCB 410 . There will be at least one anti-parallel diode pair 415 in each series string connected to resistor 420 within each packaged AC LED PCB 410 . It will be noted that the LED lamp 390 will still operate with input power at only one end or across any two pins on bi-pins 395 .
[0108] When ballast power is connected to one or both ends of LED lamp 390 by way of bi-pins 395 , the ballast power is connected to one side of high power current limiting resistor 400 . The other side of resistor 400 is connected in series to the cathode side of one side of the back-to-back zener diodes 405 and to the first anti-parallel diode pairs 415 located in each packaged AC LED PCB 410 . The last anti-parallel diode pair 415 is then connected to one side of resistor 420 in each packaged AC LED PCB 410 . The other sides of resistors 420 and the cathode side of the other side of back-to-back zener diodes 405 are all connected back to bi-pins 395 . Voltage reducing devices 425 may be connected to the bi-pins 395 of LED lamp 390 .
[0109] When line voltage AC power is connected to one or both ends of LED lamp 390 by way of bi-pins 395 , the line voltage AC power is connected to one side of high power current limiting resistor 400 . The other side of resistor 400 is connected in series to the cathode side of one side of the back-to-back zener diodes 405 and to the first anti-parallel diode pairs 415 located in each packaged AC LED PCB 410 . The last anti-parallel diode pair 415 is then connected to one side of resistor 420 in each packaged AC LED PCB 410 . The other sides of resistors 420 and the cathode side of the other side of back-to-back zener diodes 405 are all connected back to bi-pins 395 . Voltage reducing devices 425 may be connected to the bi-pins 395 of LED lamp 390 .
[0110] When DC power is connected to one or both ends of LED lamp 390 by way of bi-pins 395 , the DC power is connected to one side of high power current limiting resistor 400 . The other side of resistor 400 is connected in series to the cathode side of one side of the back-to-back zener diodes 405 and to the first anti-parallel diode pairs 415 located in each packaged AC LED PCB 410 . The last anti-parallel diode pair 415 is then connected to one side of resistor 420 in each packaged AC LED PCB 410 . The other sides of resistors 420 and the cathode side of the other side of back-to-back zener diodes 405 are all connected back to bi-pins 395 . Voltage reducing devices 425 may be connected to the bi-pins 395 of LED lamp 390 .
[0111] Wireless energy transfer or wireless power transmission is the process that takes place in any system where electrical energy is transmitted from a power source to an electrical load without interconnecting wires. When power is transmitted by an inductive transmitter (not shown) located by the mating lampholders (not shown) to an inductive receiver or antenna (not shown) located in LED lamp 390 , the electromagnetic induction power is connected to one side of high power current limiting resistor 400 . The other side of resistor 400 is connected in series to the cathode side of one side of the back-to-back zener diodes 405 and to the first anti-parallel diode pairs 415 located in each packaged AC LED PCB 410 . The last anti-parallel diode pair 415 is then connected to one side of resistor 420 in each packaged AC LED PCB 410 . The other sides of resistors 420 and the cathode side of the other side of back-to-back zener diodes 405 are all connected back to bi-pins 395 . Voltage reducing devices 425 may be connected to the bi-pins 395 of LED lamp 390 .
[0112] Exemplary values for the relevant electrical components depicted in FIG. 8 are: resistor 400 =300 ohms; each zener diode=120 volts; AC LED emitter diode pairs 415 =AW3240; resistors 420 =750 ohms; or packaged AC LED PCBs 410 =AW3241.
[0113] It will be understood that various changes in the details, materials, types, values, and arrangements of the components that have been described and illustrated in order to explain the nature of this invention may be made by those skilled in the art without departing from the principle and scope of the invention as expressed in the following claims.
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LED driver circuits containing voltage reducing devices, voltage regulating devices, and voltage converting devices are disclosed as the main components to provide power to LEDs. The LED driver circuits are designed to work with a ballast, mains alternating current voltage, direct current voltage, and electromagnetic induction power. The voltage regulating devices can be a resistor in series with at least one zener diode or a voltage regulator both in parallel with and providing power to the LEDs. The LEDs can also be anti-parallel diode pairs consisting of one diode and one LED or two LEDs, or the LEDs can be anti-parallel diode string pairs consisting of diodes and LEDs or all LEDs. The LED driver circuits will be incorporated into LED replacement lamps, and in particular to LED lamps to replace fluorescent lamps for use with existing ballasts and other power sources where the ballast may be removed or bypassed.
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FIELD OF THE INVENTION
[0001] The present invention relates to a three-phase buck-boost power factor correction (PFC) circuit and a controlling method thereof. More particularly, it relates to a three-phase buck-boost PFC circuit employing three independent single-phase three-level buck-boost PFC circuits to improve the total harmonic distortion (THD) of the three-phase buck-boost PFC circuit and to increase the efficiency of the same.
BACKGROUND OF THE INVENTION
[0002] In the recent twenty years, the power electronic technology has obtained a quickly development, and has been widely applied to the fields of electrical power, chemical engineering and communications. The electrical power apparatuses are mostly going through the rectifiers and the electrical power network interfaces, a typical rectifier is a nonlinear circuit including diodes or thyristors, and the nonlinear circuit generates lots of current harmonics and reactive powers in the electrical power network, pollutes the electrical power network, and becomes a public nuisance of the electrical power. The electrical power apparatuses have become the main harmonic sources of the electrical power network. The main method to restrain the harmonics is the active approach, i.e. designing a new generation of high-performance rectifiers with features of having sinusoidal input current, containing low amount of harmonics and having high power factor, namely, it has the power factor correction function. Recently, the PFC circuits have attained a great development, and have become an important research direction of the power electronics.
[0003] The single-phase PFC technology currently approaches increasingly mature in circuit topology and in control, and the frequently used single-phase PFC circuit is the boost circuit. It has the advantages of having simple configuration, requiring smaller EMI filter etc. But this kind of configuration could only apply to the occasions while the output voltage is larger than the peak value of the input voltage. For the input voltage having a broad range, sometimes the input voltage is higher than the output voltage, namely the input voltage needs to be decreased and guaranteed that the input current tracks the input voltage nicely so as to gain a lower THD. At the moment, the boost circuit could not accomplish this function, and a buck configuration is used for this occasion. As shown in FIG. 1 , it is a topology of a single-phase buck-boost PFC circuit applied to a broad range of input voltage in the prior art. It has diodes B 1 -B 4 and D 1 -D 2 , switches S 1 -S 2 , inductor L 1 , input power source Vin and output capacitor C 1 , and outputs a voltage Vo.
[0004] The working modes of this kind of conversion circuit are as follows:
[0000] V o >√{square root over (2)}V in a.
[0005] Wherein, Vo is the output voltage, and Vin is the input voltage. Under this kind of operation conditions, a waveform diagram of the input voltage Vin and the output voltage Vo is shown in FIG. 2 , the output voltage is always higher than the input voltage, the converter must operate under the boost mode, switch S 1 is turned on, diode D 1 is turned off, and under this circumstances, the converter is the conventional boost PFC circuit.
[0000] V o ≦√{square root over (2)}V in b.
[0006] It is easy to find from FIG. 3 , the converter operates under the buck and the boost working modes. Between periods π−α and π+α, the output voltage is larger than the input voltage, switch S 1 is always turned on, D 1 is always turned off, and the converter works under the boost mode. Between periods α and π−α, the output voltage is smaller than the input voltage, switch S 2 is always turned off, D 2 is always turned on, and the converter works under the buck mode.
[0007] This kind of circuit is only suitable for the condition of single-phase input, for certain occasions, we need to use the three-phase input voltage, and thus this kind of single-phase circuit could not fulfill the requirements of the system. In the three-phase input voltage application occasions, there are many other conventional methods used to decrease the THD of the input current. A relatively frequently used method is shown in FIG. 4 . In which, it includes diodes, D 1 -D 14 , capacitor Co and C 1 -C 3 , switches S 1 -S 4 , inductors L 1 -L 5 and AC power sources Vi 1 -Vi 3 .
[0008] The topology of FIG. 4 could be divided into two parts: the front part is the input buck part (buck input stage), and the rear part is the output boost part (boost output stage). This PFC circuit could be employed in rectification for the three-phase three-line configuration, has a simple configuration, and has relatively less elements. But it also has drawbacks: due to that the neutral point of the three-phase three-line configuration is formed by the three-phase AC input voltage connecting to three capacitors, which is not the absolute zero potential point, in the three-phase three-line condition, the three-phase inputs are coupled to each other, thus the three-phase current control is relatively harder and the THD is relatively higher. This kind of topology has a lower efficiency due to that the current flows through a higher amount of elements. Especially, due to that the three-phase inputs are electrically coupled, this system can not be parallel-connected unless a transformer is used for isolation. However, if it is parallel-connected, the current of one phase will become a reverse-current of another phase, which will result in unbalance among circuit currents of different phases, and it is difficult to make redundant system with high reliability.
[0009] Keeping the drawbacks of the prior arts in mind, and employing experiments and research full-heartily and persistently, the applicant finally conceived a three-phase buck-boost PFC circuit and a controlling method thereof.
SUMMARY OF THE INVENTION
[0010] It is therefore an object of the present invention to provide a three-phase buck-boost PFC circuit and a controlling method thereof, this circuit includes three independent single-phase three-level buck-boost PFC circuit, the first, the second and the third single-phase three-level buck-boost PFC circuits would not influence each other due to having a neutral line, operate independently from each other, could be used to improve the THD of the three-phase buck-boost PFC circuit and to increase the efficiency of the same. The three-phase buck-boost PFC circuit provided by the present invention relatively has the higher efficiency, decreases the quantity of elements, raises the utilization ratio of elements and the power density of the system at the same time, and decrease costs of the system. Besides, it has the advantages of being easy to accomplish the parallel-connected system, and the integrated circuit of the PFC circuit and the DC/DC converter, and it is especially suitable for the UPS due to that each phase current is independently controlled.
[0011] According to the first aspect of the present invention, a three-phase buck-boost power factor correction (PFC) circuit includes a first single-phase buck-boost PFC circuit receiving a first phase voltage of a three-phase voltage and having a first and a second output terminals and a neutral-point for outputting a first and a second output voltages, a second single-phase buck-boost PFC circuit receiving a third phase voltage of the three-phase voltage and coupled to the first and the second output terminals and the neutral-point, a first to a fourth thyristors, each of which has an anode and a cathode, wherein the anodes of the first and the third thyristors and the cathodes of the second and the fourth thyristors receive a second phase voltage of the three-phase voltage, the cathode of the first thyristor and the anode of the second thyristor are coupled to the first single-phase buck-boost PFC circuit, and the cathode of the third thyristor and the anode of the fourth thyristor are coupled to the second single-phase buck-boost PFC circuit, a first output capacitor coupled to the first output terminal and the neutral-point, a second output capacitor coupled to the neutral-point and the second output terminal and a neutral line coupled to the neutral-point.
[0012] Preferably, each of the first and the second single-phase buck-boost PFC circuits is a single-phase three-level buck-boost PFC circuit, and each the single-phase three-level buck-boost PFC circuit further includes a first to a sixth diodes, each of which has an anode and a cathode, wherein the first and the second diodes are used in rectification, the anode of the first diode is coupled to the cathode of the second diode, and the cathode of the fourth diode is coupled to the anode of the third diode, a first to a fourth switches, each of which has a first and a second terminals, wherein the first terminal of the first switch is coupled to the cathode of the third diode, the second terminal of the first switch is coupled to the cathode of the first diode, the first terminal of the second switch is coupled to the anode of the second diode, the second terminal of the second switch is coupled to the anode of the fourth diode, the first terminal of the third switch is coupled to the cathode of the fourth diode, the second terminal of the third switch is coupled to the anode of the fifth diode, the first terminal of the fourth switch is coupled to the cathode of the sixth diode, the second terminal of the fourth switch is coupled to the first terminal of the third switch, the cathode of the fifth diode is coupled to the first output terminal, the anode of the sixth diode is coupled to the second output terminal, and the neutral point is coupled to the first terminal of the third switch and a first and a second inductors, each of which has a first and a second terminals, wherein the first terminal of the first inductor is coupled to the cathode of the third diode, the second terminal of the first inductor is coupled to the second terminal of the third switch, the first terminal of the second inductor is coupled to the anode of the fourth diode, and the second terminal of the second inductor is coupled to the first terminal of the fourth switch.
[0013] Preferably, the circuit further includes a first to a third input capacitors, wherein each the input capacitor and the neutral line have a first and a second terminals, the second terminal of the neutral line is coupled to the neutral point, the first terminal of the first input capacitor receives the first phase voltage, the second terminal of the first input capacitor is coupled to the first terminal of the neutral line, the first terminal of the second input capacitor receives the second phase voltage, the second terminal of the second input capacitor is coupled to the second terminal of the first input capacitor, the first terminal of the third input capacitor receives the third phase voltage, and the second terminal of the third input capacitor is coupled to the second terminal of the second input capacitor.
[0014] Preferably, the circuit further includes a fifth to a eighth thyristors and a first and a second batteries, wherein each the thyristor has an anode and a cathode, each the battery has a positive and a negative terminals, the neutral line has a first and a second terminals, the second terminal of the neutral line is coupled to the neutral point, the anodes of the fifth and the sixth thyristors are coupled to the positive terminal of the first battery, the cathodes of the fifth and the sixth thyristors are respectively coupled to the cathodes of the first diodes of the first and the second single-phase buck-boost PFC circuits, the positive terminal of the second battery is coupled to the negative terminal of the first battery, the cathodes of the seventh and the eighth thyristors are coupled to the negative terminal of the second battery, the anodes of the seventh to the eighth thyristors are respectively coupled to the anodes of the second diodes of the second and the first single-phase buck-boost PFC circuits, and the positive terminal of the second battery is coupled to the first terminal of the neutral line.
[0015] According to the second aspect of the present invention, a three-phase buck-boost power factor correction (PFC) circuit includes a first single-phase buck-boost PFC circuit receiving a first phase voltage of a three-phase voltage and having a first and a second output terminals and a neutral-point for outputting a first and a second output voltages, a second single-phase buck-boost PFC circuit receiving a second phase voltage of the three-phase voltage and coupled to the first and the second output terminals and the neutral-point, a third single-phase buck-boost PFC circuit receiving a third phase voltage of the three-phase voltage and coupled to the first and the second output terminals and the neutral-point, a first output capacitor coupled to the first output terminal and the neutral-point, a second output capacitor coupled to the neutral-point and the second output terminal and a neutral line coupled to the neutral-point.
[0016] Preferably, the first, the second and the third phase voltages are a phase A, a phase B and a phase C voltages respectively, and the first and the second output voltages have a positive voltage and a negative voltage values respectively.
[0017] Preferably, each the single-phase buck-boost PFC circuit is a single-phase three-level buck-boost PFC circuit and further includes a first to a sixth diodes, each of which has an anode and a cathode, wherein the first and the second diodes are used in rectification, the anode of the first diode is coupled to the cathode of the second diode, and the cathode of the fourth diode is coupled to the anode of the third diode, a first to a fourth switches, each of which has a first and a second terminals, wherein the first terminal of the first switch is coupled to the cathode of the third diode, the second terminal of the first switch is coupled to the cathode of the first diode, the first terminal of the second switch is coupled to the anode of the second diode, the second terminal of the second switch is coupled to the anode of the fourth diode, the first terminal of the third switch is coupled to the cathode of the fourth diode, the second terminal of the third switch is coupled to the anode of the fifth diode, the first terminal of the fourth switch is coupled to the cathode of the sixth diode, the second terminal of the fourth switch is coupled to the first terminal of the third switch, the cathode of the fifth diode is coupled to the first output terminal, the anode of the sixth diode is coupled to the second output terminal, and the neutral point is coupled to the first terminal of the third switch and a first and a second inductors, each of which has a first and a second terminals, wherein the first terminal of the first inductor is coupled to the cathode of the third diode, the second terminal of the first inductor is coupled to the second terminal of the third switch, the first terminal of the second inductor is coupled to the anode of the fourth diode, and the second terminal of the second inductor is coupled to the first terminal of the fourth switch.
[0018] Preferably, the circuit further includes a first to a sixth thyristors and a first and a second batteries, wherein each the thyristor has an anode and a cathode, each the battery has a positive and a negative terminals, the neutral line has a first and a second terminals, the second terminal of the neutral line is coupled to the neutral point, the anodes of the first to the third thyristors are coupled to the positive terminal of the first battery, the cathodes of the first to the third thyristors are respectively coupled to the cathodes of the first diodes of the first to the third single-phase buck-boost PFC circuits, the positive terminal of the second battery is coupled to the negative terminal of the first battery, the cathodes of the fourth to the sixth thyristors are coupled to the negative terminal of the second battery, the anodes of the fourth, the fifth and the sixth thyristors are respectively coupled to the anodes of the second diodes of the third, the second and the first single-phase buck-boost PFC circuits, and the positive terminal of the second battery is coupled to the first terminal of the neutral line.
[0019] According to the third aspect of the present invention, a controlling method for a three-phase buck-boost power factor correction (PFC) circuit, wherein the circuit includes a first single-phase buck-boost PFC circuit receiving a first phase voltage of a three-phase voltage, includes steps of: causing the first single-phase buck-boost PFC circuit to proceed a boost operation and output an amplitude of a first output voltage accordingly when an amplitude of a positive-half cycle of the first phase voltage is smaller than the amplitude of the first output voltage; causing the first single-phase buck-boost PFC circuit to proceed a buck operation and output the amplitude of the first output voltage accordingly when the amplitude of the positive-half cycle of the first phase voltage is larger than the amplitude of the first output voltage; causing the first single-phase buck-boost PFC circuit to proceed the boost operation and output an amplitude of a second output voltage accordingly when an amplitude of a negative-half cycle of the first phase voltage is smaller than the amplitude of the second output voltage; and causing the first single-phase buck-boost PFC circuit to proceed the buck operation and output the amplitude of the second output voltage accordingly when the amplitude of the negative-half cycle of the first phase voltage is larger than the amplitude of the second output voltage.
[0020] Preferably, the circuit further includes a first and a second output terminals, a neutral-point, a neutral line coupled to the neutral point and a second single-phase buck-boost PFC circuit receiving a second phase voltage of the three-phase voltage and coupled to the first and the second output terminals, the neutral-point and the neutral line for outputting the first and the second output voltages, and the method further includes steps of: causing the second single-phase buck-boost PFC circuit to proceed a boost operation and output the amplitude of the first output voltage accordingly when an amplitude of a positive-half cycle of the second phase voltage is smaller than the amplitude of the first output voltage; causing the second single-phase buck-boost PFC circuit to proceed a buck operation and output the amplitude of the first output voltage accordingly when the amplitude of the positive-half cycle of the second phase voltage is larger than the amplitude of the first output voltage; causing the second single-phase buck-boost PFC circuit to proceed the boost operation and output the amplitude of the second output voltage accordingly when an amplitude of a negative-half cycle of the second phase voltage is smaller than the amplitude of the second output voltage; and causing the second single-phase buck-boost PFC circuit to proceed the buck operation and output the amplitude of the second output voltage accordingly when the amplitude of the negative-half cycle of the second phase voltage is larger than the amplitude of the second output voltage.
[0021] According to the fourth aspect of the present invention, a three-phase buck-boost power factor correction (PFC) circuit includes a first capacitor having a first voltage output terminal, a second capacitor having a second voltage output terminal and electrically connected to the first capacitor in series at a neutral-point, a neutral line electrically connected to the neutral-point, three PFC converters each receiving a three-phase AC input voltage and outputting a DC output voltage having a predetermined voltage value, wherein the predetermined voltage value is smaller than a peak value of the three-phase AC input voltage, each the PFC converter includes a rectifying bridge rectifying the three-phase AC input voltage and outputting a first and a second rectifying voltages through a first and a second rectifying output terminals respectively, a first buck-boost circuit coupled to the first rectifying output terminal and the neutral line, regulating the first rectifying voltage and outputting the predetermined voltage value to the first voltage output terminal of the first capacitor and a second buck-boost circuit coupled to the second rectifying output terminal and the neutral line, regulating the second rectifying voltage and outputting the predetermined voltage value to the second voltage output terminal of the second capacitor.
[0022] Preferably, the circuit further includes a battery apparatus, wherein each the rectifying bridge includes a controllable switch, and the battery apparatus electrically connects to each the rectifying bridge via the corresponding controllable switch and provides an electrical energy when the three-phase AC input voltage is abnormal.
[0023] According to the fifth aspect of the present invention, a three-phase buck-boost power factor correction (PFC) circuit includes a first capacitor having a first voltage output terminal, a second capacitor having a second voltage output terminal and electrically connected to the first capacitor in series at a neutral-point, a neutral line electrically connected to the neutral-point, a first and a second PFC converters each receiving a first phase and a second phase AC input voltages, and outputting a predetermined voltage value to the first and the second capacitors, wherein each the PFC converter includes a rectifying bridge rectifying the first phase and the second phase AC input voltages and outputting a first and a second rectifying voltages through a first and a second rectifying output terminals respectively, a first buck-boost circuit coupled to the first rectifying output terminal and the neutral line, regulating the first rectifying voltage and outputting the predetermined voltage value to the first voltage output terminal of the first capacitor and a second buck-boost circuit coupled to the second rectifying output terminal and the neutral line, regulating the second rectifying voltage and outputting the predetermined voltage value to the second voltage output terminal of the second capacitor, wherein each the rectifying bridge includes at least one controllable rectifying switch, the first and the second PFC converters receive a third phase AC input voltage via the corresponding controllable rectifying switch.
[0024] According to the sixth aspect of the present invention, a three-phase buck-boost power factor correction (PFC) circuit includes a first single-phase buck-boost PFC circuit, a second single-phase buck-boost PFC circuit, a third single-phase buck-boost PFC circuit and a neutral line electrically coupled to the first, the second and the third single-phase buck-boost PFC circuits.
[0025] Preferably, the circuit further includes a first and a second output capacitors, wherein the first single-phase buck-boost PFC circuit receives a first phase voltage of a three-phase voltage and has a first and a second output terminals and a neutral-point for outputting a first and a second output voltages, the second single-phase buck-boost PFC circuit receives a second phase voltage of the three-phase voltage and is coupled to the first and the second output terminals and the neutral-point, the third single-phase buck-boost PFC circuit receives a third phase voltage of the three-phase voltage and is coupled to the first and the second output terminals and the neutral-point, the first output capacitor is coupled to the first output terminal and the neutral-point, the second output capacitor is coupled to the neutral-point and the second output terminal, and the neutral line is coupled to the neutral point.
[0026] The present invention may best be understood through the following descriptions with reference to the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 shows a circuit diagram of a single-phase buck-boost PFC circuit in the prior art;
[0028] FIG. 2 shows a waveform diagram of an input and an output voltages under a boost operation mode in the prior art;
[0029] FIG. 3 shows a waveform diagram of an input and an output voltages under a boost and a buck operation modes in the prior art;
[0030] FIG. 4 shows a circuit diagram of a three-phase three-line buck-boost PFC circuit in the prior art;
[0031] FIG. 5 shows a circuit diagram of a three-phase four-line buck-boost PFC circuit according to the first preferred embodiment of the present invention; and
[0032] FIG. 6 shows a waveform diagram of a three-phase input voltage in the prior art;
[0033] FIG. 7 shows a circuit diagram of the working mode 1 of the three-phase four-line buck-boost PFC circuit according to the first preferred embodiment of the present invention;
[0034] FIG. 8 shows a circuit diagram of a three-phase four-line buck-boost PFC circuit according to the second preferred embodiment of the present invention;
[0035] FIGS. 9-20 respectively show a circuit diagram of the working modes 1 to 12 of the three-phase four-line buck-boost PFC circuit according to the second preferred embodiment of the present invention;
[0036] FIG. 21 shows a circuit diagram of a three-phase four-line buck-boost PFC circuit according to the third preferred embodiment of the present invention;
[0037] FIG. 22 shows a circuit diagram of a three-phase four-line buck-boost PFC circuit according to the fourth preferred embodiment of the present invention; and
[0038] FIG. 23 shows a circuit diagram of a three-phase four-line buck-boost PFC circuit according to the fifth preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0039] To overcome the drawbacks of the conventional three-phase three-line buck boost PFC circuit, the present invention proposed a three-phase four-line buck-boost PFC circuit (the input power source has a natural neutral point) employing three independent single-phase three-level buck-boost PFC circuits combined to control the three-phase input current as shown in FIG. 5 . In which, it has diodes Ba 1 -Ba 2 , Bb 1 -Bb 2 , Bc 1 -Bc 2 , Da 1 -Da 2 , Db 1 -Db 2 , Dc 1 -Dc 2 , Da 3 -Da 4 , Db 3 -Db 4 and Dc 3 -Dc 4 , switches Sa 1 -Sa 4 , Sb 1 -Sb 4 and Sc 1 -Sc 4 , inductors La 1 -La 2 , Lb 1 -Lb 2 and Lc 1 -Lc 2 , capacitors C 1 -C 2 and a neutral line N causing the neutral point of the power source electrically connected to the neutral point of the PFC circuit, and the neutral point of the PFC circuit is the connecting node of the capacitors C 1 and C 2 . And the three-phase four-line buck boost PFC circuit receives a three-phase input voltage having a first phase voltage Va, a second phase voltage Vb and a third phase voltage Vc and generates a first output voltage +Vo and a second output voltage −Vo.
[0040] For this kind of circuit, the first, the second and the third single-phase three-level buck-boost PFC circuit would not influence each other due to having a neutral line, and are independent from each other, i.e. the three-phase voltage of phase A voltage, phase B voltage and phase C voltage could operate independently through three modes. Thus, the controlling method is relatively simple, and the THD of the circuit could reach a satisfied effect, and the efficiency could reach a relatively higher level. Due to that the potential of the neutral point of the bus capacitors is constant, and the parallelized control of several modes are easy to achieve. The concrete working principles are described as the following analyses.
[0041] FIG. 6 shows a waveform diagram of a three-phase input voltage in the prior art, here we assume that the amplitude of the output voltage Vo is exactly half the peak value of the input voltage Vin. We divided the above-mentioned FIG. 6 into twelve regions:
[0000]
0
~
π
6
,
π
6
~
π
3
,
π
2
~
π
2
,
π
2
~
2
π
3
,
2
π
3
~
5
π
6
,
5
π
6
~
π
,
π
~
7
π
6
,
7
π
6
~
4
π
3
,
4
π
3
~
3
π
2
,
3
π
2
~
5
π
3
,
5
π
3
~
11
π
6
and
11
π
6
~
2
π
.
[0000] The working principles of the first region are analyzed in detail as follows.
[0000]
0
~
π
6
working
region
(
1
)
[0042] The working mode of the first working region is shown in FIG. 7 . Phase A voltage is larger than zero and the amplitude of which is smaller than the output voltage in the first region, thus diode Ba 1 is turned on, phase A voltage is implemented in the boost mode, switch Sa 1 is turned on, diode Da 1 is turned off, switch Sa 3 is chopping towards the phase A voltage, and inductor La 1 is used in charging and discharging of the phase A voltage. When switch Sa 3 is turned on, current of phase A flows through sub-circuit of Va→Ba 1 →Sa 1 →La 1 →Sa 3 →N and charges inductor La 1 . When switch Sa 3 is turned off, current of phase A flows through sub-circuit of Va→Ba 1 →Sa 1 →La 1 →Da 3 →C 1 →N and charges capacitor C 1 . Phase C voltage is larger than zero and the amplitude of which is larger than the output voltage in the first region, thus diode Bc 1 is turned on, phase C voltage is implemented in the buck mode, switch Sc 3 is turned off, diode Dc 3 is turned on, switch Sc 1 is chopping against the phase C voltage, and inductor Lc 1 is used in charging and discharging of the phase C voltage. When switch Sc 1 is turned on, current of phase C flows through sub-circuit of Vc→Bc 1 →Sc 1 →Lc 1 →Dc 3 →C 1 →N and charges inductor Lc 1 . When switch Sc 1 is turned off, current of phase C flows through sub-circuit of Dc 1 →Lc 1 →Dc 3 →C 1 →N, and inductor Lc 1 releases energy. Phase B voltage is less than zero and the amplitude of which is larger than the output voltage in the first region, thus current of phase B is implemented in buck mode, diode Bb 2 is turned on. When switch Sb 2 is turned on, current of phase B flows through sub-circuit of N→C 2 →Db 4 →Lb 2 →Sb 2 →Bb 2 →Vb and charges inductor Lb 2 . When switch Sb 2 is turned off, current of phase B flows through sub-circuit of C 2 →Db 4 →Lb 2 →Db 2 , and inductor Lb 2 releases energy.
[0043] (2) The working principles of the remaining regions are similar to those of region 1 , and would not be described in detail.
[0044] Through the above-mentioned analyses, one could know that the present invention could rectify the three-phase input voltage, and there is only one switch is switching during the buck mode or the boost mode, and the switch losses are largely decreased than those of the present technology. And due to that the output voltage is lower than the conventional output voltage, the requirements of the voltage stress on the switch are lower, electronic elements of lower specification can be selected, and at the same time the conduction resistance of the switch having lower voltage stress requirements is smaller and results in a great raise of the whole operational efficiency and a lower input current THD. Due to the existence of the neutral line, the three single-phase three-level buck-boost PFC circuits would not influence each other, are independent from each other, and the controlling method of which are relatively simpler.
[0045] An improvement of the present invention
[0046] The proposed circuit according to the aforementioned FIG. 5 has drawbacks, i.e. the utilization rate of its elements is lower. Taking phase A as example, diodes Da 2 and Da 4 , and switch Sa 2 and Sa 4 are not utilized when phase A voltage is positive, and diodes Da 1 and Da 3 , and switches Sa 1 and Sa 3 are not utilized when phase A voltage is negative. Furthermore, this circuit includes three single-phase buck-boost PFC circuits such that the quantity of employed elements is plenty, the cost is higher, and the power density is lower.
[0047] To raise the utilization rate of the elements, and to decrease the quantity of system's elements and costs, the present invention provides another three-phase buck-boost PFC circuit as shown in FIG. 8 .
[0048] Observing from FIG. 8 , the three-phase input voltage is converted by two single-phase buck-boost PFC modes. D 1 A, D 2 A, D 1 C and D 2 C are diodes, wherein D 1 A and D 2 A are used for rectifying the current of phase A, and D 1 C and D 2 C are used for rectifying the current of phase C. D 1 B, D 2 B, D 3 B and D 4 B are thyristors using for rectifying the current of phase B. S 11 , S 12 , S 13 , S 14 , S 21 , S 22 , S 23 and S 24 are power switches, engage in chopping according to the required duty ratio, and cause the system to output the required voltage. In this kind of integrated circuit, the thyristors accomplish the rectifying function and achieve the switching function too. The detail working principles are described as the following descriptions.
[0000]
0
~
π
6
working
region
(
1
)
[0049] Referring to FIG. 9 , it shows the working mode 1 in the first working region. Phase A voltage is larger than zero and the amplitude of which is smaller than the output voltage in the first region, thus diode D 1 A is turned on, phase A voltage is implemented in the boost mode, switch S 11 is turned on, diode D 11 is turned off, switch S 13 is chopping towards the phase A voltage, and inductor L 11 is used in charging and discharging of the phase A voltage. When switch S 13 is turned on, current of phase A flows through sub-circuit of Va→D 1 A→S 11 →L 11 →S 13 →N and charges inductor L 11 . When switch S 13 is turned off, current of phase A flows through sub-circuit of Va→D 1 A→S 11 →L 11 →D 13 →C 1 →N and charges capacitor C 1 . Phase C voltage is larger than zero and the amplitude of which is larger than the output voltage in the first region, thus diode D 1 C is turned on, phase C voltage is implemented in the buck mode, switch S 23 is turned off, diode D 23 is turned on, switch S 21 is chopping towards the phase C voltage, and inductor L 21 is used in charging and discharging of the phase C voltage. When switch S 21 is turned on, current of phase C flows through sub-circuit of Vc→D 1 C→S 21 →L 21 →D 23 →C 1 →N and charges inductor L 21 . When switch S 21 is turned off, current of phase C flows through sub-circuit of D 21 →L 21 →D 23 →C 1 →N, and inductor L 21 releases energy. Phase B voltage is less than zero and the amplitude of which is larger than the output voltage in the first region, thus current of phase B is in buck mode. Through the above-mentioned analyses, one would know that switches S 12 and S 22 are not taking effect towards phase A and phase C, we could use switches S 1 2 and S 22 to proceed buck mode control towards current of phase B, switches S 14 and S 24 turn off and diodes D 23 and D 24 turn on at this moment. Inductors L 12 and L 22 are used in charging and discharging of the phase B voltage. Especially as illustrated, we could use only switch S 12 to engage chopping towards phase B voltage in this region, diode D 2 B turns on, and diode D 4 B turns off at this moment. When switch S 12 is turned on, current of phase B flows through sub-circuit of N→C 2 →D 14 →L 12 →S 12 →D 2 B→Vb and charges inductor L 12 . When switch S 12 turns off, current of phase B flows through sub-circuit of C 2 →D 14 →L 12 →D 12 , and inductor L 12 releases energy. We could also use only switch S 22 to engage chopping towards phase B voltage in this region, diode D 4 B turns on, and diode D 2 B turns off at this moment. When switch S 22 turns on, current of phase B flows through sub-circuit of N→C 2 →D 24 →L 22 →S 22 →D 4 B→Vb and charges inductor L 22 . When switch S 22 turns off, current of phase B flows through sub-circuit of C 2 →D 24 →L 22 →D 22 and inductor L 22 releases energy. We could also use switches S 12 and S 22 commonly operated and chopping towards current of phase B, both thyristors D 2 B and D 4 B turn on, and current of phase B flows into two sub-circuits.
[0050] The working principles of the remaining regions are similar to those of region 1 , and would not be described in detail. The respective simplified topology of the working mode of the converter of each region is shown as follows.
[0000]
π
6
~
π
6
working
region
(
2
)
[0051] Similarly, referring to FIG. 10 , it shows the working mode 2 in the second working region.
[0000]
π
3
~
π
2
working
region
(
3
)
[0052] Referring to FIG. 11 , it shows the working mode 3 locating at the third working region.
[0000]
π
2
~
2
π
3
working
region
(
4
)
[0053] Referring to FIG. 12 , it shows the working mode 4 in the fourth working region.
[0000]
2
π
3
~
5
π
6
working
region
(
5
)
[0054] Referring to FIG. 13 , it shows the working mode 5 in the fifth working region.
[0000]
5
π
6
~
π
working
region
(
6
)
[0055] Similarly, referring to FIG. 14 , it shows the working mode 6 in the sixth working region.
[0000]
π
~
7
π
6
working
region
(
7
)
[0056] And then, referring to FIG. 15 , it shows the working mode 7 in the seventh working region.
[0000]
7
π
6
~
4
π
3
working
region
(
8
)
[0057] As for the working mode 8 in the eighth working region, it is shown in FIG. 16 .
[0000]
4
π
3
~
3
π
2
working
region
(
9
)
[0058] As for the working mode 9 locating at the ninth working region, it is shown in FIG. 17 .
[0000]
3
π
2
~
5
π
3
working
region
(
10
)
[0059] As shown in FIG. 18 , it is the working mode 10 of its tenth working region.
[0000]
5
π
3
~
11
π
6
working
region
(
11
)
[0060] The working mode 11 in the eleventh working region is shown in FIG. 19 .
[0000]
11
π
6
~
2
π
working
region
(
12
)
[0061] Regarding the working mode 12 in the twelfth working region, it is shown in FIG. 20 .
[0062] Observing from the aforementioned analyses, the present invention has the following features:
[0063] 1. Having three-phase buck-boost PFC function, low THD and high efficiency; and
[0064] 2. The improved buck-boost PFC circuit only employing two single-phase buck-boost PFC circuits to rectify the three-phase input voltage so as to decrease the quantity of system's elements, increase the utilization rate of the elements, increase the system's power density at the same time and decrease the system's costs;
[0065] 3. Controlling each phase current independently so as to accomplish the parallel-connected system easily; and
[0066] 4. Accomplishing the integrated circuit of PFC circuit and DC/DC converter easily, especially suitable for occasions of UPS, and described in detail according to the following preferred embodiments.
[0067] The third to the fifth preferred embodiments of the present invention are described as follows.
[0068] The above-mentioned analyses towards the circuit are all using circuit of FIG. 8 as example, and the three-phase AC power source is the three-phase four-line type. But in the real application, if the three-phase AC power source is the three-phase three-line type, then three capacitors having Y-type connection C 3 -C 5 are employed to form a floating neutral point at the input terminal so as to change the three-phase three-line type into a three-phase four-line type as shown in FIG. 21 . In which, N is the formed neutral point, and this belongs to the scope of the third preferred embodiment of the present invention.
[0069] When the input voltage is cut off, we need to use the battery to provide the electrical power to the system continuously to guarantee the normal operation of the system. FIG. 22 shows a mode having two sets of batteries Bi 1 and Bi 2 through six thyristors D 11 to D 61 and a neutral line N being electrically connected to the three single-phase buck-boost PFC circuits, the two set of batteries Bi 1 and Bi 2 respectively provide the electrical power to the positive-half cycle and the negative-half cycle of the three-phase four-line mode, and this belongs to the scope of the fourth preferred embodiment of the present invention.
[0070] FIG. 23 shows a mode having two sets of batteries Bi 1 and Bi 2 through four thyristors D 11 -D 21 and D 41 -D 51 , and a neutral line N being electrically connected to the two single-phase buck-boost PFC circuits, the two set of batteries Bi 1 and Bi 2 respectively provide the electrical power to the positive-half cycle and the negative-half cycle of the three-phase four-line mode, and this belongs to the scope of the fifth preferred embodiment of the present invention.
[0071] Thus, the aforementioned several topologies as shown in FIGS. 21 to 23 are also belonging to the scope of the preferred embodiments of the present invention.
[0072] According to the aforementioned descriptions, the present invention provides a three-phase buck-boost PFC circuit and a controlling method thereof, this circuit includes three independent single-phase three-level buck-boost PFC circuit, the first, the second and the third single-phase three-level buck-boost PFC circuit would not influence each other due to having a neutral line, operate independently from each other, could be used to improve the THD of the three-phase buck-boost PFC circuit and to increase the efficiency of the same. The three-phase buck-boost PFC circuit provided by the present invention relatively has the higher efficiency, decreases the quantity of elements, raises the utilization ratio of elements and the power density of the system at the same time, and decrease costs of the system. Besides, it has the advantages of being easy to realize the parallel-connected system, the integrated circuit of the PFC circuit and the DC/DC converter, and it is especially suitable for the UPS due to that each phase current is independently controlled, which indeed possesses the non-obviousness and the novelty.
[0073] While the invention has been described in terms of what are presently considered to be the most practical and preferred embodiments, it is to be understood that the invention need 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. Therefore, the above description and illustration should not be taken as limiting the scope of the present invention which is defined by the appended claims.
|
The configurations of a three-phase buck-boost power factor correction (PFC) circuit and a controlling method thereof are provided in the present invention. The proposed circuit includes a first single-phase buck-boost PFC circuit receiving a first phase voltage and having a first and a second output terminals and a neutral-point for outputting a first and a second output voltages, a second single-phase buck-boost PFC circuit receiving a second phase voltage and coupled to the first and the second output terminals and the neutral-point, a third single-phase buck-boost PFC circuit receiving a third phase voltage and coupled to the first and the second output terminals and the neutral-point, a first and a second output capacitors coupled to the first and the second output terminals respectively, and to the neutral-point also and a neutral line coupled to the neutral-point.
| 7
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to improved thermoset polymers modified with certain fluorocarbon additives.
[0003] 2. Description of the Prior Art
[0004] It has recently been proposed to modify thermoplastic polymers by incorporating therein various oils, gums, etc.
[0005] U.S. Pat. No. 3,485,787 discloses that certain block copolymers may be extended by incorporating mineral oil therein.
[0006] U.S. Pat. No. 3,830,767 teaches that bleeding of the extending oil from the block copolymer may be prevented by incorporating a petroleum hydrocarbon wax therein.
[0007] U.S. Pat. No. 4,123,409 relates to block copolymers having thermoplastic terminal blocks and an elastomeric intermediate block. The patent discloses blending with the copolymer a high molecular weight oil which is compatible with the elastomeric block portion of the copolymer. Where the elastomeric portion is a hydrocarbon, the oil employed is a mineral oil. Where the elastomeric block is a polysiloxane, a silicone oil is blended therewith.
[0008] U.S. Pat. No. 3,034,509 discloses the addition of silicone oil to polyethylene for use as surgical tubing.
[0009] U.S. Pat. No. 4,386,179 discloses the dispersion of a polysiloxane throughout an elastomeric thermoplastic hydrocarbon block copolymer.
[0010] Japanese Patent No. 60-104,161 describes an anti-friction composite material comprising certain resins and more than 1 . 0 % by weight of a fluorocarbon oil which have been injected molded together in a manner such that the oil exudes onto the molded surfaces of the resin due to poor compatibility of the oil with the resin and differences in viscosity between the resin and oil to produce an anti-friction surface.
[0011] European Patent Application No. 222,201 published May 20, 1987, discloses the use of certain perfluoropolyethers as additives in rubber blends vulcanizable with peroxides.
[0012] U.S. Pat. Nos. 5,143,963, 5,128,773 and 5,912,291 disclose compositions of matter formed by melt-blending a thermoplastic polymer and from 0.01% to <1.0% of a fluorocarbon additive.
[0013] In application Ser. No. 09/978,302, filed Oct. 17, 2001, there is disclosed a mixture comprising (1) a cross-linkable thermosetting resin providing composition and intimately admixed therewith, (2) from about 0.01 to about <1.0%, by weight, based on the weight of the mixture, of a fluorocarbon additive selected from the group consisting of a fluorocarbon oil, a fluorocarbon gum, a fluorocarbon grease and mixtures thereof, the fluorocarbon additive having a lower surface energy than that of the thermoset resin formed by cross-linking the composition.
[0014] There is continuing research leading to the development of novel polymeric materials, the properties of which are tailored by incorporating therein various additives.
[0015] It is an object of the present invention to provide novel improved thermoset polymer compositions having unique properties and which find utility in a wide variety of applications.
[0016] It is another object of the invention to provide a novel improved method for preparing thermoset polymer compositions having properties and characteristics heretofore unattainable.
SUMMARY OF THE INVENTION
[0017] These and other objects are realized by the present invention, one embodiment of which relates to a mixture comprising a cross-linkable thermosetting resin, excluding phenol and unsaturated polyester resins, providing composition and intimately admixed therewith, (2) from 1.0% to about 8%, by weight, based on the weight of the mixture, of a fluorocarbon additive which is substantially non-chemically reactive with said thermoset resin selected from the group consisting of a fluorocarbon oil, a fluorocarbon gum, a fluorocarbon grease and mixtures thereof, said fluorocarbon additive having a lower surface energy than that of the thermoset resin formed by cross-linking said composition.
[0018] A second embodiment of the invention concerns a method of forming a composition of matter comprising a cross-linked thermoset resin, excluding phenol and unsaturated polyester resins, and from about 1.0% to about 8%, by weight, of a fluorocarbon additive selected from the group consisting of a fluorocarbon oil, a fluorocarbon gum, a fluorocarbon grease and mixtures thereof, said fluorocarbon additive having a lower surface energy than that of said resin, said method comprising intimately admixing said fluorocarbon additive with a cross-linkable thermosetting resin providing composition (I) for a time sufficient to produce a substantially homogeneous admixture comprising said resin and said fluorocarbon additive, followed by subjecting said mixture to conditions which provide a cross-linked thermoset solid resin wherein the concentration of said fluorocarbon additive through a cross-section of said solid resin composition is lower in the interior thereof and higher at the surfaces thereof.
[0019] A still further embodiment of the invention is a composition of matter comprising (1) a cross-linked thermoset resin, excluding phenol and unsaturated polyester resins, and (2) from about 1.0% to about 8%, by weight, by weight, based on the weight of the composition, of a fluorocarbon additive which is substantially non-chemically reactive with said thermoset resin selected from the group consisting of an oil, gum, grease and mixtures thereof, said additive having a lower surface energy than that of said resin, wherein the concentration of said additive through a cross-section of said solid resin composition is lower in the interior thereof and higher at the surfaces thereof.
[0020] A further embodiment of the invention relates to articles of manufacture constructed from the compositions described above.
DETAILED DESCRIPTION OF THE INVENTION
[0021] Although most non-fluorinated polymers are not compatible with fluorocarbon oils and gums and are also not readily blended therewith because of the high specific gravity of the fluorocarbons, the present invention is predicated on the discovery that thermosetting resin providing compositions, when efficiently and thoroughly intimately admixed with the above-noted amounts of a fluorocarbon oil, gum or mixture thereof such that the fluorocarbon additive is homogeneously distributed throughout the composition, yield, upon subjecting the composition to conditions which result in a thermoset resin, solid compositions which, because of the differences in thermodynamic compatibility and surface energy between the fluorocarbon additive and the resin, develop higher concentrations of the additive at the surface than throughout the interior thereof.
[0022] In the phrase “concentration of fluorocarbon additive in a gradient through a cross-section from a lower value at the interior thereof to a higher value at the surfaces,” the term “gradient” is not intended to suggest that the concentration varies uniformly from the center or interior of the composition to the surface. Although this may be the case with respect to some combination of polymers and additive, typically a much higher concentration of the additive is at the surfaces of the composition with a much smaller amount in the interior or bulk of the polymer.
[0023] This higher concentration of fluorocarbon additive at the surface of the polymer enables the provision of a polymer composition having heretofore unattainable properties. Thus, using very low concentrations of fluorocarbon additive, relatively high concentrations are attainable at the surface.
[0024] The high concentrations of fluorocarbon additive at the surfaces provide compositions having the advantages of fluorocarbon-like surface properties, i.e., greater hydrophobicity, lower surface energy, non-adherent surface characteristics, more chemically inert, lower friction, smoother, etc. In addition, the presence of the fluorocarbon additive enhances molding operations since it reduces “sticking” of the composition to the mold surfaces and enhances mold release. Also, the additive will, because of the lubricant properties thereof, permit higher speed processing of extruded objects, i.e., films, fibers and other objects formed therefrom and with smoother surfaces, with the added benefits of shorter injection molding cycles and higher extrusion rates.
[0025] For biological or biomedical applications of the polymer compositions, the fluorocarbon surfaces are especially advantageous since they exhibit superior biocompatibility in contact with tissue surfaces, cells, physiological fluids and blood as compared with most thermoset polymers.
[0026] For the most part, the basic bulk mechanical, physical and chemical properties of the thermoset polymer employed are retained or even enhanced for the compositions of the present invention, but acquire the fluorocarbon surface properties of the additive due to the above-noted gradient concentration of the fluorocarbon additive through a cross-section of the composition from a lower value in the bulk to a higher value at the surface. This makes the compositions of this invention also advantageous for molds such as those used for optical and electronic parts and for electro-optical or electro-mechanical devices which require lower surface energy and low friction surfaces.
[0027] The lower concentrations of fluorocarbon additive in the interior portion of the thermoset polymer can also advantageously modify the bulk mechanical, physical and chemical properties of the polymer, however, particularly with respect to the classes of thermoset polymers discussed hereinbelow.
[0028] A unique advantage associated with the compositions of the invention is that if cut into plural sections, the fluorocarbon additive in the interior will migrate to the new surfaces formed by the cutting operation.
[0029] A wide variety of polymers may be utilized in the practice of the invention. Preferred among the suitable resins are:
[0030] Unsaturated crosslinkable alkyl and aryl polyesters and polycarbonates, e.g., diallyl phthalate and diallyl isophthalate polymers; diethylene glycol bis(allyl carbonate); bis(phenol) A bis(allyl carbonate).
[0031] 1. Bismaleimides, e.g., methylene dianiline-based bismaleimide.
[0032] 2. Epoxy resins, e.g., bisphenol A—epichlorohydrin; polyglycidyl ethers of 1,4-butanediol; neopentyl glycol, trimethylolpropane or higher functionality polyols; epoxy phenol and cresol novolacs; cycloaliphatic epoxy resins.
[0033] 3. Phenolic resins, e.g., phenol-formaldehyde resins.
[0034] 4. Unsaturated polyesters, e.g., maleic anhydride/glycol (ethylene, propylene, diethylene, dipropylene or neopentyl glycols).
[0035] 5. Crosslinkable Polyimides.
[0036] 6. Crosslinkable Polyurethanes, e.g., polyisocyanate/polyol condensation products.
[0037] 7. Silicones, elastomers and semi-rigid polymers based on crosslinkable alkyl and aryl silicones.
[0038] 8. Urea and melamine formaldehyde resins.
[0039] 9. Synthetic and natural rubbers, e.g., polyisobutylene, cis-1,4-polyisoprene, cis-1,4-polybutadiene, styrene-butadiene random copolymer, styrene-butadiene block copolymer, polychloroprene, butadiene-acrylonitrile random copolymers, all of which may be vulcanized.
[0040] 10. Crosslinked Polyaryletherketones.
[0041] 11. Thermoset Furan resins.
[0042] It is preferred to employ fluorocarbon additives having a surface energy substantially lower than that of the polymer with which it is compounded in order to ensure the high surface fluorine concentration described above.
[0043] Suitable fluorocarbon oils, gums and greases include fluorinated hydrocarbons and fluorinated hydrocarbon-polyether oils, i.e., Aflunox™ and Krytox™ oils and greases, including such oils, gums and greases as perfluoropolyethylene oxide, perfluoropolypropylene oxide, polytetrafluoroethylene oligomers, perfluoropolyethylene-propylene, perfluoropolybutadiene oligomers, polyvinylidene fluoride oligomers and their copolymers, and perfluorohydrocarbon oils such as perfluorocyclohexane, perfluorohexane, perfluorododecane and higher molecular weight homologous linear or branched perfluorohydrocarbons, and perfluorinated cyclic hydrocarbons.
[0044] The preferred fluorocarbon oils, gums and greases of this invention are characterized by having viscosities in the range of 20 to more than 50,000 centistokes at 20□ C, and the preferred fluorocarbon greases useful in this invention are characterized by having consistencies (as determined by ASTM D-217) in the range of NLGI grades 0-6. Preferred greases include those made by mixing or blending fluoropolyether oils with perfluorohydrocarbons, such as those preferred from mixtures of Krytox™ fluoroether oils with Vydax™ fluorotelomers.
[0045] The selection of a particular oil, gum or grease will depend, of course, on the intended applications of the resultant composition.
[0046] Generally, it is preferred that the fluorocarbon additive have a lower surface energy, by more than about 5 dynes/cm, as compared with the polymer with which it is compounded.
[0047] It is a particularly advantageous feature of the present invention that extremely small amounts of fluorocarbon additive may be incorporated in the thermoset polymer to achieve the highly unusual and desirable properties associated with the compositions of the invention.
[0048] By ensuring that the mixing step results in an initially homogeneous admixture of the ingredients, one is able to obtain, upon forming the thermoset resin composition, a solid composition having the above-described gradient concentration. If the ingredients are not homogeneously admixed, the product will comprise a composition wherein a substantial amount of unmixed free fluorocarbon additive simply coats the surface of the polymer. Because of the incompatibility of the F-additive and the difference in surface energies between the polymers and the fluorocarbon additive, the latter will not readily diffuse into and penetrate the polymer to any appreciable extent. Relatively uniform dispersion of the additive throughout the polymer during preparation requires homogeneous blending.
[0049] To facilitate admixing of the fluorocarbon additive with the resin forming composition where the latter is in solid form, it is preferred to mix the fluorocarbon additive into fluid premixers of prepolymers or cross-linkable resin composition. Cross-linkable prepolymers, i.e., phenolics or expoxies in the form of small particles such as pellets or powders may be used advantageously. This ensures uniform dispersion of the additive in the fluid prepolymer or efficient wetting of polymer particle surfaces prior to curing, thereby accomplishing efficient dispersion of the additive throughout the polymer.
[0050] In a preferred embodiment, the fluorocarbon additive is premixed with a fraction of fluid or pelletized prepolymer and then admixed with the remainder of the polymer and subsequently intimately admixed therewith.
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A mixture comprising (1) a cross-linkable thermosetting resin, excluding phenol and unsaturated polyester resins, providing composition and intimately admixed therewith, (2) from about 1.0% to about 8%, by weight, based on the weight of the mixture, of a fluorocarbon additive which is substantially non-chemically reactive with the thermoset resin selected from the group consisting of a fluorocarbon oil, a fluorocarbon gum, a fluorocarbon grease and mixtures thereof, the fluorocarbon additive having a lower surface energy than that of the thermoset resin formed by cross-linking the composition.
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TECHNICAL FIELD
[0001] The technical field relates to small connection ports, known in the art as feedthroughs, which may be used in subcutaneous active medical devices. A feedthrough element may include a conductor placed in a small opening in an electrically insulating material.
BACKGROUND
[0002] Many implantable devices use feedthrough elements to connect a hermetically enclosed electronic board to an implanted device such as a measuring and/or a stimulating electrode and/or an electromechanical actuator. A feedthrough comprises an electrical connection between a hermtically closed enclosure and the outside surrounded by insulating material, which allows electrical signals to pass between the surroundings and the hermetical enclosure while maintaining the integrity of the hermetic enclosure.
[0003] Implantable housings can be made from titanium. In the case of titanium housing, feedthroughs for the entire housing unit may be assembled into one main titanium body. The manufacturing of the titanium body thus requires a large number of welds, often at least one weld for each feedthrough.
[0004] Sometimes, each feedthrough is directly brazed onto a titanium body and requires a complex machined titanium part.
[0005] Sometimes the housing is made from alumina (aluminum oxide) which is a ceramic. Such a housing may have feedthroughs all around the outer perimeter of the ceramic. One of the technical difficulties with this design is the machining of very small holes (e.g., 0.4 mm diameter) all around the diameter of ceramic housing, which is made from a very hard material. Another issue is the cost of machining such small and precise holes, which have to be ground with diamond tools.
SUMMARY
[0006] The disclosure describes an implantable device that may be used as a cochlear implant that overcomes the challenges noted above, providing ease of manufacturing and assembly and also a unique shape of the casing that facilitates routing of connecting electrodes to the feedthrough elements through a void created between the implanted device and the tissue of a user.
[0007] In an embodiment, a device implantable under skin includes a sealed housing containing electronics for at least stimulation or collection of data and at least one antenna for communicating with an external device. The device also includes a magnet configured to hold the external device in proximity to the sealed housing. The sealed housing includes an upper cover being closest to the skin when the device is implanted and a lower cover that is hermetically connected to the upper cover, the lower cover including an elevated region, a recessed region, and at least one feedthrough element formed in the recessed region of the lower cover.
[0008] In an embodiment, the at least one feedthrough element includes a plate shaped base with one or more holes, and the at least one feedthrough element is configured to connect an electrode, providing electric connection to the electronics housed within the sealed housing through conductive pins in the one or more holes.
[0009] In an embodiment, the plate shaped base of the at least one feedthrough element is hermetically joined to the lower cover of the external housing.
[0010] In an embodiment, the lower cover has a circular disc outer perimeter shape, and the lower cover includes an elevated part located radially adjacent to the at least one feedthrough element.
[0011] In an embodiment, the elevated part is aligned radially with the at least one feedthrough element, and the elevated part is positioned farther away from a center of the lower cover.
[0012] In an embodiment, the elevated region of the lower cover has a crescent shape spanning more than 50% of the lower cover, the at least one feedthrough element is surrounded on two sides by ends of the crescent shape.
[0013] In an embodiment, the implantable device includes two feedthrough elements, each feedthrough element of the two feedthrough elements having a rectangular shape with rounded corners and having 14 connector pins.
[0014] In an embodiment, the implantable device includes two feedthrough elements, each feedthrough element of the two feedthrough elements having a circular shape and having 4 connector pins.
[0015] In an embodiment, the implantable device includes an electrically conducting lead connected to the at least one connector pin of the feedthrough element, and thereby electrically connected to the electronics in the sealed housing, a silicone overmolding surrounding the conducting lead, wherein the lead passes through a recessed region, to reach the outer circumference of the lower cover. Here the lead may connect or continue to a spirally coiled wire.
[0016] In an embodiment, the upper cover has a hollow crown made of a biocompatible material and permeable to electromagnetic waves including magnetic fields.
[0017] In an embodiment, the hollow crown includes an external wall forming an external radial periphery of the sealed housing, and an internal wall oriented towards a center of the sealed housing, and the external wall and the internal wall form an opening of an annular U-shaped groove.
[0018] In an embodiment, the biocompatible material is aluminum oxide. It is well known that other ceramics such as zirconia toughened alumina, high purity alumina, or pure zirconia could be used for this purpose but aluminum oxide has been found to be preferable.
[0019] In an embodiment, the lower cover is made of titanium. Titanium in this application denotes any titanium alloy or titanium like alloy suitable for implantation. That is any alloy which may be processed like titanium and inserted in the body without causing reaction or being degraded.
[0020] In an embodiment, the sealed housing is a cochlear implant configured to be implanted under the skin of a human user and above the user's skull bone.
[0021] The disclosure further describes a method of manufacturing an implantable device, whereby a number of manufacturing steps are performed:
form a ceramic upper cover with a circumferential flange; form a ceramic feedthrough element with a circumferential flange and a plurality of feedthrough pins; braze a feedthrough titanium welding flange leak tight onto the circumferential flange of the ceramic feedthrough element and braze an upper cover titanium welding flange leak tight onto the circumferential flange of the ceramic upper cover; form a titanium lower cover by stamping a titanium plate into a desired shape with a circumference an at least one opening with an edge; weld the feedthrough titanium welding flange to the edge of the at least one opening of the titanium lower cover; and weld the titanium lower cover onto the upper cover titanium welding flange to form a hermetically sealed enclosure with a plurality of insulated electric connections.
With this method a hermetic sealed enclosure may be made with very few steps and a high yield is ensured as especially the feedthrough element may be leak tested prior to the welding thereof onto the titanium lower cover. The welding between welding flanges and titanium lower cover may be performed by laser welding to minimize heat load on nearby elements such as the feedthrough pins and the electronics within the housing. The forming of the upper cover may comprise the formation of a hollow crown including an external wall forming an external radial periphery of the upper cover, and an internal wall oriented towards a center of the upper cover, and the external wall and the internal wall thus forming an opening of an annular U-shaped groove. In this case, the brazing of an upper cover titanium welding flange onto the circumferential flange of the ceramic upper cover comprises both of the brazing of one welding flange to the internal wall and the brazing of one further welding flange to an external wall. Also the welding of the upper cover titanium weld flanges to the titanium lower cover comprises welding of both internal and external upper cover weld flanges to the lower cover.
[0028] In an embodiment of the method, forming the titanium lower cover comprises stamping elevated parts and regions and providing a recessed region relative thereto and generating the at least one opening in a recessed region. As the elevated parts and regions are intended to abut the skull of the user in the implanted state, the opening in the recessed region will be spaced apart from the skull bone of the user. This allows for feedthrough pins to extend from the feedthrough element without interfering with the skull bone.
[0029] An embodiment, the method comprise the further step of electrically connecting at least one electric lead to at least one of the metal pins outside of the hermetically sealed enclosure and cause the lead to extend in a recessed area from the pin to the outer circumference of the implantable device. At the outer circumference the leads may be joined in a spirally coiled multi-wire conductor. Thus leads may pass from the feedthrough pins to the outer regions of the housing without being subject to pressure in case the implanted housing inadvertently is pressed towards the skull bone.
[0030] An embodiment of the method comprises the further step of connecting the pins inside the implantable device to a circuit board having a plurality of interconnected electronic components thereon. This processing step may be performed prior to the closing of the hermetically sealed enclosure.
[0031] An embodiment of the method comprises the following additional steps:
place the implantable device in a mould, hold the leads in place in the recessed area, inject hardenable fluid material into the mould in order to form an overmould which fixates the leads.
Preferably the hardenable fluid is a silicone, which will set into a flexible but resilient protective substance, which may absorb mechanical shocks as well as insulate the leads from the corrosive nature of body fluids.
[0035] An embodiment of the method comprises the following additional step: attach in a releasable manner a magnet to an exterior part of the exterior upper cover. Preferably the magnet is provided with a casing, which interfaces with a silicone intermediate part and this intermediate part ensures a connection with the hermetically sealed housing.
BRIEF DESCRIPTION OF DRAWINGS
[0036] FIG. 1 illustrates a partial cross section view of an example of a cochlear implant housing with an external antenna related to the disclosure.
[0037] FIG. 2A illustrates a partial cross section view of an example of a cochlear implant housing according to an embodiment of the disclosure.
[0038] FIG. 2B illustrates a bottom view of an example of cochlear implant housing with a multipolar feedthrough element according to an embodiment of the disclosure.
[0039] FIG. 2C illustrates a bottom view of an example of a feedthrough element with 4 connection poles in a housing according to an embodiment of the disclosure.
[0040] FIG. 2D illustrates a detailed view of an example of a feedthrough element with 4 connection poles according to an embodiment of the disclosure.
[0041] FIG. 2E illustrates an example of construction details of a cochlear implant housing according to an embodiment of the disclosure.
[0042] FIG. 3A illustrates a cross section view of an example of a cochlear implant according to an embodiment of the disclosure.
[0043] FIG. 3B illustrates an enlarged portion of the cross section view of an example of a cochlear implant according to an embodiment of the disclosure.
[0044] FIG. 3C illustrates a cross section view of an example of a cochlear implant according to an embodiment of the disclosure.
[0045] FIG. 3D illustrates a cross sectional view corresponding to FIG. 3B , but now with the a mold over silicone shealding.
DETAILED DESCRIPTION
[0046] Neurostimulation implants can be used to stimulate and/or measure electrophysiological signals. An example of a neurostimulation implant is a cochlear implant as illustrated in FIG. 1 .
[0047] The cochlear implant includes an internal portion 100 which is surgically implanted in a patient (e.g., under the skin on the skull) and an external portion 120 which attaches externally above the implanted portion. In the example of FIG. 1 , the cochlear implant includes an implantable hermetic housing 101 and an external antenna 108 . The implantable hermetic housing 101 includes electronics 102 , a receiving/transmitting antenna 103 , and a magnet 104 that holds the external portion 120 with the antenna 108 in position. The external antenna 108 can thus communicate with the electronics 102 in the implantable hermetic housing. The antennas 103 , 108 may be coils, whereby magnetic energy and information may be transferred from the one coil to the other.
[0048] The design of housing 101 is based on a main body 105 made from a ceramic, such as alumina, hermetically closed with a flat titanium cover 106 . The device can be implanted under a user's skin with the main body 105 oriented toward the skin (toward the outside of the user) and titanium cover oriented toward inside of the user. The titanium cover could be adjacent to the skull bone.
[0049] The main body 105 includes a plurality of feedthroughs 107 and provides mechanical protection for electronics 102 , an air-tight and fluid-tight seal (hermetic seal) and electric insulation of the feedthroughs. As shown in FIG. 1 , a feedthrough includes a pin made of conductive material 117 inserted into a small hole 118 formed in the main body 105 . The feedthroughs 107 are arranged radially around the outer circumference of main body 105 .
[0050] FIGS. 2A and 2B illustrate another example of a cochlear implant shown without the corresponding external device. In FIG. 2A the right hand side is a sectional view, whereas the left hand side is a side-view and in FIG. 2B the section line and side view are indicated. Thus the implant is shaped as an annular object with a central hole 218 or opening. This central hole 218 serves to receive a magnet 314 as shown in FIG. 3C , which serves the same purpose as the prior art magnet 104 . The implant includes a subcutaneous hermetic housing 201 , which has a ceramic surface 202 on the side which faces the skin of the user, in order to allow receiving of energy by electromagnetic coupling of a coil of an external device (not shown). The implant also includes a U-shaped main body 203 , made of biocompatible ceramic. The U-shaped main body 203 has a U-shaped cross sectional profile, as shown in FIG. 2A . This shape creates space within the main body to accommodate various components such as electronics board 208 . The U-shaped main body 203 can be manufactured with a Ceramic Injection Molding (CIM) process and offers a solid and strong shape against multiple external constrains such as pressure, impact and shock. According to FIG. 2A , the U-shaped body is annularly shaped to circumvent the central hole 218 , wherein the magnet 314 is insertable, however the magnet 314 (see FIG. 3C ) could well, in an alternative thereto, be placed to circumvent the U-shaped body, in which case no central hole would be provided. Also both a centrally placed and a circumferential magnetic means could be employed.
[0051] FIG. 2B shows a view from the bottom of the cochlear implant, and displays the bottom surface of stamped titanium cover 206 . The titanium cover 206 can be manufactured by stamping to obtain the desired shape.
[0052] Apart from stamping from a rolled plate item, other ways of processing the disc like item are possible, such as shaping by machining out of a solid body or by metal powder techniques. A well known powder processing techniques comprises a first step of pressing a metal powder and a binder into a semi solid body which is later heat treated or sintered into a solid metal body of the desired shape. Possibly a final machining step is necessary to achieve desired tolerances. A further powder technique uses a laser beam which melts titanium power in a layer. By repetition of layers, the part is built (like fast prototyping with polymer). A step of high temperature sintering is needed to obtain the final density on the part
[0053] As shown in FIG. 2B , the stamped titanium cover 206 includes elevated parts 210 and an elevated region 211 . These elevations 210 , 211 are elevated relative to the plane of the cover to abut a common plane indicated by dashed line 228 seen in FIG. 3A , and thus create a recessed region 220 . When the cochlear implant is implanted in a user, between skin and bony tissue (such as on the skull of the user), the elevated parts 210 and elevated region 211 abuts against the bony tissue, while there remains a void between the bone tissue and the recessed region 220 . This void is useful for routing leads of electrodes from remote locations on the user's body to the implanted device. The leads can thus pass through the recessed region 220 and are protected from shock and impact by the cochlear implant supported on the elevated parts 210 and elevated region 211 . As seen in FIG. 2A connection pins 205 extend out of a plate 225 and into, but not beyond the region between plane 228 and the recessed region 220 .
[0054] In an embodiment, elevated parts 210 may be left out of the stamped titanium cover 206 , but instead support on the skull bone may be created by the addition of a silicone distance mat, which is added on top of the recessed region of the stamped titanium cover 206 . In this case the stamped cover 206 would be flat in the entire recessed region without elevated parts. The protection of the leads would be created by the silicone mat being interposed between the leads and the recessed area in that particular region. Thus, the same functionality may be provided and create a secure path for electrodes without actually shaping elevated parts 210 in the titanium cover.
[0055] FIG. 2B illustrates an embodiment with two multipolar feedthrough elements 204 . In this embodiment each multipolar feedthrough element 204 includes 14 pins 205 , whereby each pin forms a connection pole. The feedthrough element 204 may comprise a base shaped as a plate 225 . The number of pins and the shape of the feedthrough elements are not limited to the illustrated embodiment.
[0056] Each multipolar feedthrough element 204 may be made and the holes 227 created with the use of classic processing technique for implantable devices: a ceramic plate 225 with a first and a second flat side is initially made and provided with circular holes 227 directly connecting the first and the second sides, a platinum iridium pin 205 is inserted into each hole 227 , a feedthrough metal welding flange 216 B preferably made from titanium is added to a circumference flange of the ceramic plate 225 , and a gold brazing metal is used in a brazing process to fuse the inserted pins 205 and the titanium welding flange 216 B to the ceramics of the plate 225 . By this process an air and fluid tight electrically insulating plate 225 is provided with a multitude of electrical connections from the first to the second side.
[0057] By creating feedthrough elements 204 separately from the stamped titanium cover 206 , it is possible to manufacture the titanium cover 206 through a stamping process and the multipolar feedthrough elements may be assembled onto the stamped titanium cover 206 by laser welding due to the feedthrough titanium welding flange 216 B on the feed-through ceramic plate 225 . This example of multipolar feedthrough elements 204 has a rectangle shape with rounded edges 207 which allows a continuous laser welding process in the assembly of the ceramic plate and the titanium cover 206 . In this way, feedthrough elements 204 and their connections to measuring and/or stimulation electrode leads are protected against direct constraints from the environment such as pressure, impact or shock.
[0058] Assembly of multipolar feedthrough element 204 may well be achieved by a direct mounting process such as used in surface mounted devices (SMD) where there is already a well laid out and well established process road for manufacturing in both large and smaller numbers. In the above assembly process steps, it is the process steps up to and including the fusing of the ceramic plate with the pins and metal flange which are most error prone, however, each feedthrough element comprising ceramic plate 225 with the metal pins 205 and feedthrough welding flange 216 B may be tested prior to installment in the titanium cover 206 , and nonfunctional parts, such as parts not being leak proof may be discarded. This is opposed to the prior art feedthrough generation, where the holes 118 are generated along the circumference of the ceramic main body 105 , and in case one hole with inserted pin 117 comes out not leak proof, the entire main body has to be discarded, as an individual pin 117 is not exchangeable. This is at a time where a lot of processing hours and expensive material has been incorporated into the main body, and the result is poor yield.
[0059] FIG. 2A illustrates some internal components including electronics board 208 . Electronics board 208 is mounted by the pins 205 that enter into holes of electronics board 208 before they are soldered to gain contact with the circuitry embedded in the electronic board. These pins 205 pass also through the sealed holes 227 of the feedthrough elements 204 . FIG. 2E provides additional detail through an enlarged view of a cross section of the cochlear implant.
[0060] FIG. 2E illustrates an example of the construction of the implantable hermetic housing 201 . Inner and outer titanium welding flanges 216 A may be placed between the U-shaped main body 203 and the stamped titanium cover 206 . A titanium feedthrough welding flange 216 B may be placed between the feedthrough element 204 and the stamped titanium cover 206 . The components may initially be brazed at brazing locations 217 in an oven to fuse the welding flanges 216 A, 216 B to the ceramic plate 225 and main body 203 respectively. The laser weld process finalizes the hermetically sealed hosing 201 . A laser weld 211 runs along the entire circumference of the main body 203 and has a weld intersection parallel to the common plane 228 . A laser weld 212 runs along the inner circumference of the main body 203 and has a weld intersection which is perpendicular to the common plane 228 , and leaser welds 215 runs aloin the perimeter of each ceramic plate 225 of every feedthrough element and also here the weld intersection is perpendicular to the common plane 228 . The advantages of the laser welds are that they are leak tight seams which may be generated without any production of fumes or gasses, and at the same time heat dissipation to brazed areas nearby or to the electronic components inside the housing 201 is manageable due to the short heating time and very limited metal melt zone. The laser welding may be performed in a controlled atmosphere to ensure that the atmosphere inside the housing 201 , which will be sealed off in an airtight manner by the welding process, has well known and pre-defined properties. Preferably the gas inside the hermetic chamber is a mix of argon and helium. The argon part provides for a protective atmosphere, where as the helium gas allows for leakage test.
[0061] FIGS. 2C and 2D illustrate an example of a multipolar feedthrough element that is a quad polar feedthrough element 209 having four pins 205 . The round shape of feedthrough element 209 facilitates laser welding of the feedthrough element to the stamped titanium cover 206 .
[0062] An implantable connector (not shown) could be connected to the feedthrough pins 205 in order to connect leads for neuromodulation electrodes, cochlear electrode array, measuring electrodes for ECAP measures, an electromechanical actuator or antennas among others.
[0063] FIGS. 3A-C illustrates an example of additional details of components within the implantable hermetic housing 201 . As shown in FIG. 3A , a voluminous area of the housing is formed between the inside of the U-shaped body 203 and the inside surface of the elevated region 211 of the stamped titanium cover 206 . Arrow 307 shows the height of this area, and as seen in FIG. 3A this height allows integration of components on both sides of board 208 , namely on the ceramic side 308 and on the lid side 309 .
[0064] A tight area indicated by arrow 311 is defined between the ceramic plate 225 and the inside surface of the U-shaped body 203 . In this area, components can be integrated only on the ceramic side 308 as the lid side 309 is reserved for the feedthrough element.
[0065] The ceramic side 308 may house an antenna 310 in order to be closest to the skin and the corresponding external antenna. The antenna 310 may be a coil. The lid side 309 can house the thickest components such as signal processors as it has the largest sectional depth 307 . The coil 310 couples wirelessly with a coil provided externally of the implanted housing, and energy as well as information is transmitted, through the magnetic coupling of the two coils, from the external part to the internal part, and an information signal may pass from the coil 310 of the implanted part to the external antenna. Possibly the implanted device comprises a rechargeable battery to facilitate the transmission of a wireless signal from the implanted part to an external receiver antenna and also to supplement the energy consumed by the electrodes in times of high demand.
[0066] Alternatively or as a supplement to the antenna 310 , energy harvesting by movement may be implemented as known from mechanical wrist watches: a half-circle shaped disk rotates around its centre, caused by the unbalance and the movements of the watch by the arm. This rotation winds the clock spring. Such a system may be added into the implanted device, together with the housing. Here the rotation from the half-disk is used to drive a small generator, designed to produce power and able to charge a small rechargeable battery—designed to supply the cochlear implant. The energy harvester could be designed in many ways: another example is a magnet in a tube with a coil around it, able to move back and forth according to the movement of the head. This principle is known from the battery-free so-called shake flashlights. To facilitate the smaller size of the implant, the rotating system may be placed in a separate cabinet, implanted elsewhere in the head and connected to the cochlear implant through a wire. If the implant is placed right under the skin, a solar cell in the unit could add energy for charging during the day. However, the skilled person would appreciate that the energy harvester may also be placed at a different location in-vivo.
[0067] As shown in FIG. 3B , the recessed region 220 forms a space between the stamped titanium cover 206 and the skull bone tissue 302 . The wires or leads 303 which connect the pins in the feed-through to a device external to the housing 201 , such as to electrodes, sensors, antennas or transducers pass in this space wherein they are protected against shock and impact by a silicone overmolding 304 as seen in FIG. 3C and by the elevated parts and regions.
[0068] As seen better in FIG. 3C , the leads 303 pass out from the region of the housing and form a spiral 305 which is able to absorb forces that could be applied to the lead 303 . The spiral 305 is able to be stretched, folded and bend and can thus adapt to the individual surgery and the shape of the mastoidectomy as well as adapt to cranial growth and other changes which may take place after surgical implant of the device. The spiraled coil is wound around a pin, which is then drawn out to leave a void 310 at the center of the spiraled coil. Along the spiral, placed inside the void 310 left by the pin, or outside it such as along the ground electrode an antenna lead for FM communication may be placed. Also possibly any of the ground electrode, a measuring electrode, a stimulation electrode, or a lead passing over the top of the head to an implant at an opposed side of the head, may be used additionally as a radio antenna. Any inside or outside surface of the implanted housing or the circuitry board 208 may serve as a carrier for a radio frequency antenna such as a patch antenna or a rod antenna. Such antennas could allow the implanted part to communicate with external units by Bluetooth or similarly coded protocols, which could provide a wider band-width of the communication between external part and implanted part, than what is obtainable by means of the coil 310 . This requires an additional radio to be incorporated into the internal part. The higher frequencies used in usual RF transmission of information lead to a high degree of attenuation when transmitted through human tissue, however, the external antenna part and the implanted part are placed in very close proximity and are also located in well known positions with respect to each other, which allows for antenna designs with a high degree of directionality to be used, and also their closeness to each other situates the external and internal antennas within the near field of each other, and these two fact may ensure very good coupling between such two antennas, and this may overcome the problems of attenuation of the RF frequency signals transmitted through the tissues of the user. A similar argument goes for RF frequency transmission of signals between two implanted devices placed at each side of the head, whether the signals are transmitted directly from implanted part to implanted part, or signals are exchanged from one external part to the other, or from one external part to both of two implanted parts being placed at each side of the head of a user. One particular frequency band which would be open to such communication RF signals would be the band around 2.4 G Hz used for Bluetooth and Bluetooth low energy transmission. A patch antenna with a directional characteristic is disclosed in WO2007019855 and such an antenna could be used.
[0069] The potential mix-up of the two BTE and antenna parts for the respective left and right ear can cause problems for users with an implant at each ear, because of differences in the two implants and/or stimulation schemes for the left and right ears. Also in school classes with many pupils carrying similar implant and external parts, such a mix-up may take place between pupils. An ID-chip, such as an RFID chip in each implanted part for identification is available and need only to communicate a short distance to the BTE (Behind The Ear) part or to the antenna part and to such a purpose only limited power and a small antenna is needed. A simple hand-shake procedure between external part and implant may be instigated prior to on-set of transmission of sound signals, to ensure that it is the correct external part, and not a part belonging to the other ear or a school friend. The identification hand shake may take place by means of the coil antennas in the external and internal parts, however here the communication is not so fast. In US2005/0255843A such an identification scheme is disclosed, which allows proprietary communication using magnetically coupled coils between two separate devices, such as a first and a second hearing aid sitting on each one of a users ears. This technique could also be implemented and used between an implanted part and an external part, provided the internal part has some energy storage capacity, eg a battery, which would allow it to transmit its own identification code to the external part when prompted.
[0070] FIG. 3D shows how the overmold with a hardenable substance such as silicone encapsulates the housing 201 . The silicone fills the void made under the housing by the recesses and elevated parts of the titanium cover 206 whereby all leads in the area are fixated and protected both against shock and tissue fluids of the body. Also al the pins of each feed-through are completely embedded in the silicone and thereby protected.
[0071] While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.
LIST OF ELEMENTS
[0000]
100 internal portion
101 implantable hermetic housing
102 electronics
103 receiving antenna
104 magnet
105 main body from ceramic
106 flat titanium cover
107 feedthrough
108 external antenna
117 conductive material pin
118 small hole
120 external portion
201 subcutaneous hermetic housing
202 ceramic surface
203 u-shaped main body
204 multipolar feedthroughs
205 pin(s)
206 stamped titanium cover
207 rounded edge
208 electronics board
209 quad polar feedthrough
210 elevated part
211 elevated region
212 outer laser weld
213 inner laser weld
215 feed through laser welds
216 A upper cover titanium welding flange
216 B feedthrough titanium welding flange
217 brazing locations
218 central hole
220 recessed region
225 ceramic plate
227 hole
228 common plane
302 skull
303 wires
304 silicone overmolding
305 spiral
306 lead
307 voluminous area arrow
308 ceramic side
309 lid side
310 antenna
311 tight area arrow
314 exchangeable magnet
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A cochlear implant includes a sealed housing containing electronics for at least stimulation or collection of data and at least one antenna for communicating with an external device and a magnet configured to hold the external device in proximity to the sealed housing. The sealed housing includes an upper cover being closest to the skin when the device is implanted, and a lower cover that is hermetically connected to the upper cover. The lower cover includes an elevated region, a recessed region, and at least one feedthrough element formed in the recessed region of the lower cover. The recessed region provides space for a lead to connect to the feedthrough element and protects it from shock and other environmental risks.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention is directed toward an improved method of forming resin-based articles and the articles formed therefrom. In particular, the present invention provides an efficient, low cost method of forming human body prosthetics, such as external breast prostheses as well as various pads and cushions for healthcare related items.
[0003] 2. Background Information
[0004] Many human prosthetics are made of a synthetic silicone resin cured to a gelatinous state with the outer surface of the prosthesis molded to simulate the shape of the particular replacement body part. For instance, external breast prostheses are formed by a process of adding uncured silicone gel to the cavity of a mold modeled in the shape of a human breast and appropriately curing to obtain the look, shape and feel of an actual human breast.
[0005] As disclosed in U.S. Pat. No. 5,035,758 issued to Degler, a distinction is made between film-free breast prostheses and prostheses encapsulated or sheathed in film. Film-free breast prostheses have the disadvantage that silicone oil often seeps from the prosthesis because the silicone resin composition often does not crosslink completely, and it is this uncrosslinked silicone that leaks out. This leakage leaves an undesirable sticky or tacky residue on the surface of the prosthesis.
[0006] In order to overcome this disadvantage, breast prostheses are typically sheathed in thermoplastic films, such as polyurethane films. In general, such breast prostheses are produced by placing the uncrosslinked silicone resin composition together with a crosslinking agent and a catalyst between two flat films that form an envelope for the prosthesis. The films are welded together along this edge except for a small opening reserved for filling the envelope. The films are then fixed at the edge of a cavity in the area of the welded edge in a die that corresponds to the shape of a human breast. Silicone resin composition is added until the films are pressed against the walls of the die cavity; the film edges are then welded together in the area of the filling opening, and the silicone resin composition is cured to form a gelatinous mass.
[0007] However, welding the film edges together especially in the area of the filling opening, poses problems when residues of the injected silicone resin composition are between the films. These residues prevent satisfactory welding of the film edges so the weld seam easily tears open and the silicone resin composition easily escapes during the curing process as well as after the curing process, even when only a slight pressure is applied to the prosthesis. Furthermore the dies must be heated to a relatively high temperature in the welding and crosslinking operation and must be cooled between each step, which is very time consuming and expensive.
[0008] As disclosed in U.S. Pat. No. 5,370,688 issued to Schulz et al on Dec. 6, 1994, an example of the typical, time-consuming method of forming an external breast prosthesis is as follows. First, a flexible film of thermoplastic material is heated and placed on a male (convex) vacuum forming tool or mold in order to form the outer skin of the prosthesis. The most commonly used thermoplastic materials are polyurethane based. The male vacuum forming mold is shaped to simulate the natural shape of the female breast and may be of various shapes and sizes in order to produce various sized prostheses. The heated film is then placed over the vacuum forming mold to produce the outer skin of the prosthesis.
[0009] The inner skin of an external breast prosthesis is also typically formed by heating and placing a flexible thermoplastic film over a male vacuum forming mold. The inner skin and the outer skin are then sealed together along their peripheries by a method as known in the art, such as a high frequency electronic sealing method of welding the thermoplastic films.
[0010] Next, the empty capsule is filled with a gel-forming liquid composition through an opening to form a filled capsule. The opening may be formed by puncturing a small hole in the wall of the capsule or by leaving a small segment of the respective peripheries of the inner skin and outer skin unsealed. Any trapped air in the filled capsule is removed before sealing the opening by the use of a vacuum chamber or other mechanical means. After the trapped air is substantially removed the opening is sealed.
[0011] The filled capsule is then placed into a heat chamber where the gel-forming composition is cured to form a gel which comprises the body of the prosthesis. After the gel-forming composition has been cured, the excess film is trimmed from the peripheral edges, producing the completed prosthesis.
[0012] In view of the limitations associated with the prior art, a substantial need exists for a method of forming a resin-based article that is less expensive and less time consuming than current methods while retaining the benefits of a prosthesis sheathed in film. Applicant's invention, through a novel combination steps and materials, provides such a method.
SUMMARY OF THE INVENTION
[0013] The general purpose of the present invention, which will be described subsequently in greater detail, is to provide a method for forming resin-based articles, such as human prosthetics or medical cushions, which contains many of the advantages of the prior art along with significant novel features that result in a method that is not anticipated, rendered obvious, suggested, or even implied by any of known method, either alone or in combination.
[0014] In view of the foregoing, it is an object of the present invention to provide a method of forming a resin-based article that is less expensive than existing methods.
[0015] It is another object of the present invention to provide a method of forming a resin based article that is less time consuming than existing methods.
[0016] It is another object of the present invention to provide a method of forming a resin-based article that reduces cycle time of forming said article.
[0017] It is another object of the present invention to provide a method of forming a resin-based article that retains the benefits of a resin-based article sheathed in film.
[0018] In satisfaction of these and other related objectives, the present invention provides a method for forming a resin-based article, such as human prostheses or cushions and pads for medical products. As will be discussed in the specification to follow, practice of the present invention provides a method, which eliminates the steps of forming and welding thermoplastic sheathing, while retaining the benefits associated with resin-based articles sheathed in film.
[0019] The preferred embodiment of the present invention provides a resin-based elastomer, which can be sprayed onto the cavity of the mold itself, thus eliminating thermoplastic sheathing in its entirety. The process of the present invention is as follows. First the appropriate (concave) mold is selected for the application. For example, if the article being manufactured is an external breast prosthesis, the mold should be shaped in the form of a human breast. Next, the appropriate resin-based elastomer is selected for the application. For instance, a spray silicone-based elastomer would be selected for a silicone gel filled external breast prosthesis. The resin-based elastomer is appropriately diluted and prepared into a sprayable form. Next, the elastomer is sprayed onto the mold over a time period to provide adequate coverage of the mold, i.e. for a thicker surface film, the elastomer should be sprayed longer than for a thinner surface film. Once the mold is adequately coated, the mold is placed into a heat chamber at an appropriate temperature for an adequate time period to cure the elastomer into an external ‘skin’ or sheathing for the article. The mold is then removed, and a resin-based gel or foam is added to the mold. The gel or foam must be allowed to completely ‘air out’, ensuring undesired air bubbles are removed prior to curing. The mold is then placed back into the heat chamber for a brief period in order to allow the gel or foam to cure to a gelatinous state. Once, the gel or foam has cured, the mold is removed from the heat chamber, and an additional coating of elastomer is sprayed onto the rear of the article. The mold is then placed back into the heat chamber for a final cure of the second layer of elastomer ‘skin’.
[0020] In summary, then, an embodiment of the present invention provides a highly cost-effective and time-saving method of forming resin-based articles, such as human prosthetics or medical product cushions or pads, while retaining the performance of a resin-based article formed with thermoplastic sheathing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Applicant's invention may be further understood from a description of the accompanying drawing.
[0022] FIG. 1 is a cross-sectional view of the article of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] At the outset, it should be understood that the present invention encompasses a method for forming any number of resin-based articles. Such articles may be composed of various materials, examples of which shall be included in the specification to follow. In addition, the resin-based articles which may be formed by said process are envisioned to fall primarily in the medical industry, examples of which shall be included in the specification to follow as well. However, in each case the embodiments and materials expressed are intended as examples only, and should not be viewed in a limited sense.
[0024] An embodiment of the present invention that may be most easily understood is with reference to the formation of a gelatinous, human prosthetic, such as an external breast prosthesis. The first step in the formation of an external breast prosthesis begins with the formation or selection of a suitable concave, open faced mold fashioned in a shape that realistically mimics a female breast. Such a mold may be formed in various shapes and sizes as desirable for the final product. Additionally, such molds may be fashioned from epoxy, aluminum, styrene, or any number of other materials, as known in the art.
[0025] Next, a suitable resin-based compound is selected to create the skin or covering of the prosthesis itself. The compound selected must be of such a nature and material characteristic as to create a sufficient bond with the filler material selected to form the body of the article itself. For instance, if the material selected to form the body of the external breast prosthesis is a silicone gel, then the elastomer selected to form the skin should also be silicone based. However, if the article being formed is a medical cushion, a foam, such as a polyurethane foam may compose the body of the cushion. In such a case, the elastomer selected should be a polyurethane-based elastomer. Additionally, it is desirable that the materials selected have a similar cure temperature as well to add efficiency to the process. Whatever the composition, this compound must be prepared into a dilute liquid form such that it can be easily painted or sprayed. In the preferred embodiment, the compound is a clear, pourable, two-component silicone rubber compound designed for making flexible parts, having a low durometer and excellent flexibility. In the preferred embodiment, the elastomer is mixed with a crosslinker; then, a solvent such as toluene, xylene, or mineral spirits is added to the elastomer mix in an amount necessary for proper dilution into a paintable or sprayable form.
[0026] The next step in the process of forming the prosthesis is to apply the diluted elastomer onto the concave surface of the mold itself in a uniform manner for the appropriate duration to provide proper coverage of the mold. Application of the elastomer to the cavity of the mold may be accomplished by painting or spraying the diluted elastomer directly onto the surface of the mold. This process may be accomplished remotely, robotically, or by hand (observing appropriate safety procedures as dictated by the composition of the elastomer), and the duration of the spray necessary directly corresponds with the desired thickness of the outer ‘skin’ of the prosthesis. For instance, a longer spray duration will obviously result in a thicker layer of elastomer than a shorter spray duration. Additionally, although the preferred embodiment presents a uniform spray of the mold, embodiments are also envisioned wherein, the duration of the spray is more concentrated in specific areas of the mold in order to provide a thicker ‘skin’ in certain areas of the prosthesis than in other areas, a trait which is difficult, if not impossible, using methods derived from the prior art.
[0027] At this point, the elastomer must be appropriately cured in order to properly form the ‘skin’ of the prosthesis. For example, most silicone rubber elastomers should be cured with heat; therefore, the elastomer covered mold would be placed into a heat chamber pre-heated to the appropriate temperature and allowed to cure for an appropriate time for the elastomer to cure to the desired state. An example of a proper curing temperature and time for a silicone elastomer is 85° C. for five minutes.
[0028] After the elastomer has cured, the mold is removed from the oven, and the resin-based filler material is added. As previously mentioned, this material should not only be selected for its structural characteristics to give the desired look and feel to the article, but it must also be of a composition that will bond with the elastomer selected as well. In the present example of an external breast prosthesis, the filler material might be a standard density silicone gel or a reduced density silicone gel with microspheres added. Regardless or the material selected, the filler material is poured into the mold and allowed to sit for an appropriate duration to allow any undesired voids or air bubbles to dissipate. At this point, the mold is again placed into the heat chamber to cure, preferable at the same temperature as that of the elastomer. An example for the external breast prosthesis would be at 85° C. for an additional ten minutes.
[0029] After the resin-based filler material has cured, the mold is again removed from the oven. At this point, another coating of the resin-based elastomer is sprayed onto the back surface of the article (corresponding with the open face of the mold) to create the outer ‘skin’ or film on the rear side of the product. For instance, on the surface of the external breast prosthesis that would fit against the wearer's body. Again, the elastomer is sprayed by an appropriate method and for an appropriate duration to give the desired thickness of the ‘skin’ of the article. At this point, the mold is place back into the heat chamber for the final cure of the most recently applied elastomer. For example, the mold for an external breast prosthesis may be placed into the heat chamber for an additional five minutes at a temperature of 85° C.
[0030] Finally, after the article is completely cured, the mold is removed from the heat chamber and allowed to cool. The external breast prosthesis, or whatever the formed resin-based article may be, is then removed from the mold, and any excess elastomer sheathing is trimmed from the article.
[0031] In the external breast prosthesis embodiment, this process eliminates the time and expense of forming and using thermoplastic films to sheathe the gelatinous prosthesis, while retaining the benefits of a prosthesis sheathed in film. Those benefits being a fully crosslinked article that is not susceptible to seepage of the resin based material.
[0032] Although the specific example disclosed throughout the specification mainly deals with external breast prostheses, and number of other prostheses, cushions, and pads are contemplated to fall within embodiments of the present invention, including, but not limited to facial prostheses, other soft tissue prostheses, wheel-chair cushions, ergonomic wrist pads, and other pads and cushions for various medical devices.
[0033] An article so derived from the process of the present invention is shown in FIG. 1 and generally denoted by the numeral 10 . Referring to FIG. 1 , a first resin-based sheathing ( 12 ) is shown, cured and chemically bonded to cured, resin-based filler material ( 14 ). Finally, a second resin-based sheathing ( 16 ) is shown, cured and chemically bonded to cured, resin-based filler material ( 14 ) as well. Additionally, as can be seen in FIG. 1 , first resin-based sheathing ( 12 ) is bonded to second resin-based filler material ( 16 ) about the perimeter of article ( 10 ).
[0034] Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limited sense. Various modifications of the disclosed embodiments, as well as alternative embodiments of the inventions will become apparent to persons skilled in the art upon reference to the description of the invention. It is, therefore, contemplated that the appended claims will cover such modifications that fall within the scope of the invention.
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The present invention is directed toward an improved method of forming resin based articles and the articles formed therefrom. In particular, the present invention provides an efficient, low cost method of forming human body prosthetics, such as external breast prostheses as well as various pads and cushions for healthcare related items. The method uses a resin-based elastomer diluted into a form which can be sprayed onto an open mold cavity. This first layer of elastomer is cured. Then a resin-based filler material is applied to the first layer of elastomer and cured. Finally, a second layer of elastomer is applied to the filler material and cured. The resulting article being a gelatinous or foam resin-based article sheathed in an elastomeric skin.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a door apparatus and more particularly, to a novel door apparatus of the type wherein one door rotates while moving horizontally to the right and left when it is opened, then becomes in parallel with the sidewall of an entrance, thereby being opened fully, and moves once again to the original direction and is closed.
2. Description of the Prior Art
Conventional doors in general have a structure when the right or left side portion of the door are pivotally fitted to the sidewall of an entrance by hinges. Therefore, when one opens the door, the door swings greatly with the hinges being the support point. Since the door swings greatly and opens, one must take a step backward when he pulls the door towards him. Generally, one does not open fully the door but passes through it. In such a case, one must pass while turning sideways.
Since the conventional door has the structure described above, the door cannot be opened and closed smoothly particularly by the handicapped or those who use a wheelchair and they have difficulty in opening and closing the door.
SUMMARY OF THE INVENTION
In order to eliminate the problems with the conventional door described above, the present invention contemplates to provide a novel door apparatus of the type wherein one door rotates while moving horizontally to the right or left, opens fully when it becomes parallel to the sidewall of an entrance, moves horizontally while reversing to the original direction and is thereafter closed, and which eliminates the trouble of taking a step backward or turning sideways when opening the door.
The above and other objects and novel features of the present invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an overall perspective view of the door apparatus in accordance with the present invention;
FIG. 2 is an enlarged, longitudinal sectional front view at the center of the door apparatus;
FIG. 3 is an enlarged sectional view taken along line A--A of FIG. 1;
FIG. 4 is an enlarged sectional view taken along line B--B of FIG. 3;
FIG. 5 is a partial enlarged front view of a door support shaft portion;
FIG. 6 is a sectional view taken along line C--C of FIG. 5;
FIG. 7 is a sectional view taken along line D--D of FIG. 4;
FIG. 8 is a sectional view taken along line E--E of FIG. 4;
FIG. 9 is a partial enlarged sectional view of a frame;
FIG. 10 is a front view of an operation rod;
FIG. 11 is an enlarged sectional view taken along line F--F of FIG. 10;
FIGS. 12 to 14 are explanatory views, each useful for explaining the door operation; and
FIG. 15 is an explanatory view useful for explaining the moving orbit of the door.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the drawings, reference numeral 1 represents one door having a predetermined width. Reference numeral 2 represents a frame for supporting the door 1. It consists of a rectangular main frame 2a incorporating therein main shaft and door operation shaft and sub-frames 2b, 2b move integrally back and forth from the upper and lower portions of the main frame 2a and incorporating therein horizontal rocking rod, disc, and so forth. An arcuate groove 3 is formed on the sub-frame 2b along the moving orbit of a door support shaft 4 which will later be described.
Substantially the center 2a' of the main frame 2a on the side where a later-appearing operation shaft is stored is cut in a predetermined length so as to expose partly the operation shaft.
Reference numerals 4, 4 represent door support shafts which project vertically from the upper and lower center of the door 1 in the transverse direction. The tip of each door support shaft 4 is supported rotatably by the tip of a later-appearing support arm. Part of the circumferential surface of each door support shaft is cut off in such a manner as to leave a shaft portion 5 having a width corresponding to a notch groove of a later-appearing rotation limit plate. The axis (P in FIG. 6) of the shaft portion 5 crosses at right angles the door 1.
Reference numerals 6, 6 represent support arms which support rotatably the door support shafts 4, 4, respectively. Each support arm moves horizontally from the upper or lower end of a later-appearing main shaft and rocks horizontally with the main shaft being the support point.
Reference numeral 7 represents the main shaft described above. It is stored in the vertical portion of the main frame 2a and is supported rotatably by suitable bearing members 8 and 9.
Reference numerals 10, 10 represent support shafts which are fixed vertically inside the sub-frame 2b. Each support shaft supports rotatably the base portion of a horizontal rocking rod in the horizontal direction. The support shaft 10 is fixed at a position where lines connecting the axis of the support shaft 10, the axis of the main shaft 7 and the axis of the door support shaft 4 describe a regular triangle.
Reference numerals 11, 11 represent horizontal rocking rods, whose base portions are supported rotatably by the support shafts 10, 10 described above, respectively. Each rod is equipped with an elongated hole 11a which extends from the tip to the substantial center of the rocking rod and into which the tip of the door support shaft 4 fits slidably.
Reference numerals 12, 12 represent rotation limit plates, each of which is equipped at the tip thereof with a notch groove 12a having a predetermined width in match with the elongated hole 11a of the horizontal rocking rod 11 and at the rear end thereof with a frame portion 12b into which the horizontal rocking rod 11 fits slidably. A spring receiving portion 12c is formed projectingly on the side of each rotation limit plate 12. Incidentally, the shaft portion 5 of the door support shaft 4 is fitted into the notch groove 12a.
Reference numerals 13, 13 represent spring receiving members which are rotatably fitted to the support shaft 10.
Reference numerals 14, 14 represent bias springs which are interposed between the spring receiving members 13 and the spring receiving portions 12c of the rotation limit plates 12. Each spring normally pushes the rotation limit plate 12 to the door support shaft 4.
Reference numerals 15, 15 represent rotary shafts, each of which is disposed vertically in the sub-frame 2b on the side opposite to the support shaft 10. A first small gear 16 and a disc 17 having a predetermined diameter are fixed to each rotary shaft 15. The disc 17 rocks the support arm 6 through a later-appearing connecting rod and its diameter is such that when a pin 18 implanted thereto moves by 180°, the support arm 6 rocks by 90° with the main shaft 7 being the support point.
A pin 18 is implanted to an eccentric position of the disc 17. The position of implantation of this pin 18 is selected so that when the door 1 is closed, the pin 18 is positioned on the line connecting the center of the rotary shaft 15 to the center of a pin 19 implanted to the support arm 6.
Reference numerals 19, 19 represent the pins described above. Each pin 19 is implanted to the substantial center of each support arm 6 in its longitudinal direction. More precisely, the pin 19 is implanted to the portion which correspnds to 1/4 of the entire width of the door 1.
Reference numerals 20, 20 represent connecting rods. On of the ends of each connecting rod 20 is connected pivotally to the disc 17 through the pin 18 described above and its other end, to the support arm 6 through the pin 19 described above.
Reference numerals 21, 21 represent rotary shafts which are disposed vertically inside the sub-frame 2b. A second small gear 22 meshing with the afore-mentioned first small gear 16 is fixed to each rotary shaft 21. The diameter of the second small gear 22 is twice the diameter of the first small gear 16.
A pin 23 is implanted at an eccentric position of each second small gear 22. Incidentally, the position of implantation of this pin 23 is selected so that when the door 1 is open, it is positioned on the line connecting the center of the rotary shaft 21 to the center of a rotary shaft 24 of a later-appearing third small gear.
Reference numerals 24, 24 represent rotary shafts disposed vertically on the main frame 2a. A third small gear 25 meshing with a fourth small gear fixed to a later-appearing operation shaft and a disc 26 are fixed to each rotary shaft 24. The diameter of the third small gear 25 is equal to that of the first small gear 16 and the diameter of the disc 26 is equal to that of the second small gear 22.
A pin 27 is implanted to an eccentric position of the disc 26. the position of implantation of this pin 27 is selected so that when the door 1 is open, it is positioned on the line connecting the center of the rotary shaft 24 to the center of the rotary shaft 21 of the second small gear.
Reference numerals 28, 28 represent connecting rods. One of the ends of each connecting rod 28 is pivotally connected to the second small gear 22 through the pin 23 and its other end, to the disc 26 through the pin 27.
Reference numerals 29, 29 represent fourth small gears fixed to the upper and lower end portions of a later-appearing operation shaft. They mesh with the third small gears 25. The diameter of the fourth small gear 29 is equal to those of the first and third small gears 16 and 25.
Reference numeral 30 represents an operation shaft, which is equipped substantially at its center with a fitting hole 31 of a later-appearing operation rod and which is stored in the vertical portion of the main shaft 2a and supported rotatably by a suitable bearing member 32. A key 31a is disposed inside the fitting hole 31 of the operation rod. The fitting hole 31 of the operation rod is bored so that when the door 1 is closed, the operation rod crosses the door 1 at right angles.
Reference numeral 33 represents an operation rod, which is equipped at its both end portions with knobs 34, 34, and which is fitted slidably into the fitting hole 31 of the operation rod. A key groove 33a, into which the key 31a described above fits, is formed on the operation rod 33.
Next, the operation of the door appartus of the present invention having the above-mentioned construction will be described.
When one approaches the door 1, he pulls the operation rod 33 towards him by gripping the knob 34. When he pushes the knob 34 towards the center of the door 1 while gripping it, the operation shaft 30 rotates.
FIG. 12 shows the state at this time. In the drawing, when the operation shaft 30 rotates, the fourth small gear 29 fixed to it rotates clockwise (in the direction represented by arrow) and rotates counter-clockwise the third small gear 25 meshing with it. When the third small gear 25 rotates, the disc 26 rotates through the rotation of the rotary shaft 24 and pushes out the connecting rod 28 towards the disc 17.
When the pin 23 is pushed out by the connecting rod 28, the second small gear 22 rotates clockwise and lets the first small gear 16 meshing with it rotate counter-clockwise. When the first small gear 16 rotates, the disc 17 rotates through the rotary shaft 15 and moves the pin 18 implanted thereto in such a manner as to describe a semi-circle.
Accordingly, the connecting rod 20 is pushed towards the door 1 and its end portion pushes out the pin 19 so that the support arm 6 starts rocking horizontally in the direction represented by an arrow with the main shaft 7 being the center.
When the support arm 6 rocks as described above, the door support shaft 4 supported rotatably at the tip of the support arm 6 moves forward while describing an arcuate orbit with the main shaft 7 being the center. At this time, the door support shaft 4 moves forward gradually while sliding inside the elongated hole 11a of the horizontal rocking rod 11 but the rotation of the door support shaft 4 itself is checked by the rotation limit plate 12 which is supported movably in the axial direction by the horizontal rocking rod 11 and biased to the door support shaft 4 by the bias spring 14. In other words, the axis P of the shaft portion 5 of the door support shaft 4 is kept always in agreement with the support shaft 10.
Accordingly, with the forward movement of the door support shaft 4, the door 1 moves horizontally and outward, changes its moving direction, becomes at right angles to the original position or in parallel with the sidewall of the entrance (not shown) and is open, as shown in FIG. 15.
FIG. 13 shows this state. At this time, the operation rod 33 faces the main shaft 7 so that the operation shaft 30 rotates by 90°. The disc 26 rotates by 90° while the disc 17 which has pushed out the connecting rod 20 rotates by 180°.
When one pushes out further the operation rod 33 while passing through the entrance, the disc 26 further rotates counter-clockwise and the position of the pin 27 implanted thereto changes to the opposite side. In consequence, the connecting rod 28 is pulled, on the contrary, this time and the disc 22 further rotates. When the disc 22 rotates until the pin 18 reaches the original position, the door 1 is closed in the reverse sequence.
The door operation when one passes through the entrance from inside to outside is exactly the same as the door operation described above.
In accordance with the present invention having the construction and operation described above, one door rotates while moving horizontally to the right and left, becomes in parallel with the sidewall of the entrance, thereby being open fully, then reverses to the original direction, moves horizontally and is thereafter closed. Therefore, one need not take a step backward or turn sideways when passing through the entrance as has been necessary in the conventional swing door, but can moves straight as such. Accordingly, the handicapped or those who use a wheelchair can smoothly operate the door and pass through the entrance. Since the door is open fully while becoming in parallel with the sidewall of the entrance, the door apparatus of the present invention is most suitable for a narrow passage. Furthermore, the rhythmic door operation is indeed pleasing. One need not change the grip of the knob from opening till closing of the and the door apparatus of the present invention provides great practical values.
While the invention has been particularly shown and described in reference to preferred embodiments thereof, it will be understood by those skilled in the art that changes in form and details may be made therein without departing from the spirit and scope of the invention.
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Disclosed herein is a novel door apparatus of the type wherein one door rotates while moving horizontally to the right and left, becomes parallel to the sidewall of an entrance, thereby being opened fully, then reverses in the original direction while moving horizontally and is then closed. The door apparatus of the invention is most suitable for an entrance having a limited width or for the handicapped or those who use a wheel chair because they have difficulty in passing through conventional swing type doors.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation of prior U.S. application Ser. No. 12/229,736, filed Aug. 25, 2008, which claims the benefit of U.S. Provisional Application No. 60/966,012 filed Aug. 25, 2007, the entire contents of which are incorporated by reference in their entirety.
FIELD OF THE INVENTION
[0002] This invention relates generally to cleaning wipes, and more particularly has reference to a textured cleaning wipe for cleaning cell phones or other electronic devices.
BACKGROUND OF THE INVENTION
[0003] In the past decade cell phones have penetrated nearly 50% of the global population. It is estimated that about 4 billion people currently have a cell phone or other mobile electronic communication device such as a smartphone. Cell phone usage has also exploded during this time. As calling plans are more affordable, people are more accustomed and dependent on mobile communication, and cell phones do much more than just make calls, with many models providing web-surfing, email and gaming functions, in addition to organizer-like functions such as calendars and notepads, as well as video and image recording and playback. All this has physically resulted in a significant majority of the population, of all ages, constantly carrying around and often holding or using some type of small electronic gadget such as a cell phone, smartphone, mp3 player, digital camera, or other electronic device. These electronic devices typically have numerous buttons, slots, crevices, keys, screens and other uneven surfaces from which germs and bacteria accumulated from continuous use cannot be easily reached and cleaned with an ordinary wipe or cloth.
[0004] As a result, some scientists and microbiologists have concluded through lab tests and other studies that an average cell phone may be dirtier than a toilet seat. Even without these scientific studies, it is common sense that cell phones accumulate and harbor germs from constant use with hands, and from being pressed against the side of the face during a phone call. Women for example, suffer especially because they often get makeup on their cell phones. A need exists for a consumer cleaning article that will effectively clean the hard to reach spaces on various cell phone devices and other electronics such as game controllers, computer mice, mp3 players, etc. The present invention satisfies that need.
SUMMARY OF THE INVENTION
[0005] The present invention relates to cleaning wipes for electronic devices made from non-woven fabrics having a textured surface on one or both sides and their use as a wipe to clean and/or disinfect surfaces and crevices of electronic devices such as cell phones, keyboards, and digital cameras. In one embodiment, a cleaner and/or disinfectant solution is absorbed into the fabric. In another embodiment the cloth will have a plurality of projections that will extend across one length of the cloth without breakage. In another embodiment a plurality of projections will have triangular cross-sections and in another embodiment, a plurality of projections will have rectangular cross-sections. In one embodiment a plurality projections will be in form of pyramids, with breakage horizontally and vertically across the length and width of the cloth and will have triangular cross sections.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a simplified plan view illustration of a cleaning wipe embodying the novel features of the present invention, and showing a pattern of cone-shaped projections rising from the surface of a non-woven fabric.
[0007] FIG. 2 is a side elevational view of the cleaning wipe shown in FIG. 1 .
[0008] FIG. 3 is an enlarged, fragmentary, cross-sectional view, taken substantially along the line 3 - 3 , of FIG. 1 .
[0009] FIG. 4 is a simplified perspective view illustration of an alternative embodiment of the invention, showing a pattern of long triangular ridges extending across the surface of a non-woven fabric.
[0010] FIG. 5 is a simplified plain view illustration of yet another embodiment of the invention, showing a zig zag pattern of ridges extending across the surface of a non-woven fabric.
[0011] FIG. 6 is a simplified plan view illustration of yet another embodiment of the invention, showing a pattern of undulating ridges extending across the surface of a non-woven fabric.
[0012] FIG. 7 is a simplified plan view illustration of yet another embodiment of the invention, showing a pattern of pyramid-shaped projections rising from the surface of a non-woven fabric.
[0013] FIG. 8 is a perspective view of the wipe shown in FIG. 7 .
[0014] FIG. 9 is a simplified plan view illustration of yet another embodiment of the invention, showing another pattern of long triangular ridges extending across the surface of a non-woven fabric.
[0015] FIG. 10 is a perspective view of the wipe shown in FIG. 9 .
[0016] FIG. 11 is a cross-sectional view, taken substantially along the line 11 - 11 , of FIG. 9 .
[0017] FIG. 12 is a fragmentary, side elevational view of a roller die used to form projections on the surface of a cleaning wipe of the present invention.
[0018] FIG. 13 is an enlarged, fragmentary view of another embodiment of the invention, showing a cross-sectional view of long rectangular ridges extending across the surface of a non-woven fabric.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The present invention relates to a cleaning wipe for electronic devices made up of a non-woven fabric having a textured surface on one or both sides of the baric especially designed to clean and disinfect the surfaces of electronic devices such as cell phones, keyboards, and digital cameras.
[0020] 1. DEFINITIONS
[0021] The following terms are utilized throughout this application:
[0022] Projection or texture refer to any raised or lowered portions of a fabric with respect to the horizontal plane of the fabric. Thus, the term “projection” or “texture” includes, without limitation, a raised or depressed portion of the fabric that is surrounded by flat areas of the fabric (hereinafter “isolated projection”) and long continuous raised or depressed portions of the fabric that runs across the surface of the fabric (hereinafter “ridge”).
[0023] Triangular refers to a shape that resembles a geometric two-dimensional triangle. Triangular may cover shapes that do not have perfectly angled tips or flat surfaces of a triangle. The term triangular may include, without limitation, shapes which are wide at the base but narrows when approaching the apex.
[0024] Triangular cross section refers to the resultant triangular shape of a cross section through the middle of a projection.
[0025] Rectangular refers to a shape that resembles a geometric two-dimensional rectangle. Rectangular may cover shapes that do not have perfectly angled corners or flat surfaces of a rectangle. Rectangular may include, without limitation, shapes which are wide at the base and similarly wide at the top.
[0026] Rectangular Cross section refers to the resultant rectangular shape of a cross section through the middle of a projection.
[0027] The invention of the present application may be described by, but not necessarily limited to, the exemplary embodiments provided.
[0028] As is shown in the drawings for purposes of illustration, the invention embodies a textured cleaning wipe specially adapted for cleaning cell phones or other electronic devices. Preferably, the wipe is made of non-woven fabric that has projections on the surface of the fabric. In another embodiment, projections have a triangular or rectangular cross section.
[0029] A desirable feature of projections having a triangular cross-sectional shape is that they are adapted to effectively clean crevices and other small areas on the surface of electronic devices. The variable width from the base to the apex of a projection with a triangular cross section provides greater surface area to contact crevices and other small areas on the surface of electronic devices. This configuration allows projections to reach a plurality of hard to reach spaces on the surfaces of key pads, cell phones, or other electronic device. Projections with a triangular cross-sectional shape include, but are not limited to, conical projections, pyramidal projections, and ridges with a triangular cross section.
[0030] In a preferred embodiment, the projections have a triangular cross section as best shown in FIGS. 2-3 . The projections 2 rise from the surface 4 of a non-woven fabric 6 and have a triangular cross-section with a pointed tip 8 and wider base 10 , no matter what shape or pattern they create on the surface of the wipe (i.e. zig-zags, straight lines, S-curves, etc.)
[0031] Specific examples of suitable textures include an array of cones ( FIGS. 1-3 ) or pyramid-shaped projections ( FIGS. 7-8 ) arranged on the surface of the wipe in a series of rows and columns which forms a rectangular grid pattern, with each cone or projection being spaced from the adjacent cone or projection and being surrounded by flat areas of the surface.
[0032] Alternatively, the projections can be provided as a series of spaced-apart elongated ridges ( FIGS. 4-6 ) which run parallel to each other and extend across the surface of the wipe. The ridges can be straight ( FIG. 4 ), curved ( FIG. 6 ), or have a zigzag pattern ( FIG. 5 ). Preferably, each projection is relatively wide in cross-section as compared to its height.
[0033] The projections can be hollow (as shown), or more preferably, solid and filled with the same fabric material as the underlying substrate.
[0034] These projections with triangular cross sections can have a variety of different sizes and shapes. For example, the projections can have the shape of pyramids or cones, with square or round bases, respectively. The heights can vary from about 0.2-5.0 mm, and more preferably 0.5-2.5 mm. In a typical example, the bases (or diameters for cones) will be about 3 mm wide, and spaced about 2-4 mm apart horizontally and vertically across the surface of the non-woven fabric in a rectangular or non-rectangular grid pattern of discrete, spaced-apart projections.
[0035] Other embodiments feature long triangular ridges 12 or continuous elevations that run one length of the non-woven fabric, as best shown in FIG. 4 . One embodiment of the present invention involves utilizing triangular ridge projections between 0.5-2.5 mm in height, with a base width of about 1.0-5.0 mm spaced preferably 1.0-5.0 mm apart and having a length which is equal or substantially equal to the length of the fabric.
[0036] Other embodiments feature long rectangular ridges, 15 or continuous elevations that run one length of the non-woven fabric, as shown in a cross-sectional view in FIG. 13 . One embodiment of the present invention involves utilizing rectangular ridge projections between 0.3-2.5 mm in height, with a base width of about 1.0-5.0 mm spaced preferably 1.0-5.0 mm apart and having length which is equal or substantially equal to the length of the fabric.
[0037] Yet other embodiments modify the above ridges design by introducing vertical spaces or separations along the length-long ridges, resulting in a pattern such as the pyramid design described above, or the zig-zag pattern shown in FIG. 5 .
[0038] Yet other embodiments feature ridges that run across the wipe in zig-zag patterns ( FIG. 5 ), or S-shaped patterns ( FIG. 6 ). These produce a randomized cleaning angle, which is good for cleaning surfaces with a variety of differing sizes and shapes of crevices. Still other embodiments (not shown) feature ridges representing a mark or other figure or image, while maintaining the disclosed triangular or rectangular cross-section.
[0039] The non-woven fabric may be formed from a variety of different fiber blends and compositions. 100% split microfiber, 20-80% Polyester and 80-20% Nylon is presently preferred.
[0040] Alternatively, the fiber composition may consist of Eighty Percent (80%) Polyester and Twenty Percent (20%) Nylon. Additional, either Polyester or Nylon may be replaced with Rayon or other synthetic fiber or natural fiber. Other embodiments may be 25-95% split microfiber and 75-5% combination of synthetic or natural fibers less than 1 denier but preferably not split-able and not bi-combinant fibers. A particular fiber blend suitable for use with the present invention is One-Hundred and Fifty (150) gram fabric, 50% split microfiber (80/20% polyester/nylon blend) and 50% viscose (which gives it better body, folding ability and moisture absorption/release). Preferably, the resulting fabric is scratch-free. Examples of other fiber blends for the present invention include Microfiber 16 segmented PIR shaped rolls of fabric with central round core, star-like projections and triangular segments between each star shaped projection. In one embodiment of the present invention such fabric shall contain a Polyester core where triangles in between are Nylon, can be made with Nylon Core and protuberances and Polyester triangular segments in between. One method uses the bicombinant, drawn yarn; drawn through spinnerets however making the product with staple can be done and used if desired. Staple fiber is when the filament fiber is cut into pieces, then spun, drawn or by other method, made into a finished yarn which is then made into the non-woven substrate.
[0041] It is desirable for the projections to be sufficiently stiff or firm to resist axial compression when subjected to the range of pressures typically exerted by a person wiping a surface with a cloth. Various production methods can be used for making the non-woven fabric and the stiff projections with triangular or rectangular cross sections on the surface of the fabric.
[0042] The surface texturing can be formed in a variety of different ways, including calendaring, embossing, or embroidering, from a single piece of material. Alternatively, if desired, the projections can be formed separately from the same or different material, and attached to the wipe by adhesive or other suitable bonding methods.
[0043] For example, the non-woven webs may be created using a number of production methods common in the trade, including without limitation, needlepunch, spunlace, hydrojet or lattice methods.
[0044] The triangular or rectangular ( FIG. 13 ) ridges, cones or other projections created can be made using a heat roller with die on one or both sides and the fabric passing through the custom die(s) where with pressure and heat the projections are formed into the non-woven fabric. Examples of suitable devices include a metal, ultrasonic heated roller die 14 ( FIG. 12 ) or a hard rubber roller die with electrical coils (non shown).
[0045] A variety of different methods can be used to keep the projections firm. Thus, for example, in a production method using die, heat and pressure to create the triangular projections, the heat and pressure are also used to cause the projections created and its surrounding fabric to be pressed down, compressed using, for example, 10-1000 psi and heat of 100-225 degrees F., depending upon the fiber materials being used. The firmness also can be affected by the weight of the base fabric (e.g., 50 grams/square meter) and the fiber blend (e.g., 50% polyester/50% viscose).
[0046] In some embodiments of the present invention, a liquid solution is absorbed into the wipe. Dry fabrics generally do not remove oil and germs effectively.
[0047] In some embodiments of the present invention, a cleaning or disinfecting solution is absorbed into the wipe. Some cleaning or disinfecting solutions to be absorbed into a non-woven fabric include, but are not limited to, ethyl alcohol, Benzethonium Chloride, Alkyl, and Dimethyl Benzyl Ammonium Chloride. A variety of different cleaning or disinfecting solutions can be used. One cleaning solution is a quick-drying, alcohol-based cleaning solution to minimize the potential hazard of shorting electronic equipment. A calibrated amount of solution is used to moisten but not over saturate the non-woven fabric to minimize the potential hazard of shorting electronic equipment, while still providing effective cleaning power. Thus, for example, in at least one embodiment, the wipes are impregnated with approximately 1.5 g of liquid solution, but this amount can be affected by the size of the fabric (here, 4″×4″) and by the composition of the fabric and its absorbency (here, 50% viscose, 50% microfiber).
[0048] The wipes of the present invention can be packaged in a variety of different ways. In one embodiment, cell phone wipes will be packaged and sealed individually, allowing the users to remove one wipe from the box and take with him or her throughout the day, unwrapping and using the moist wipe when needed. Cell phone wipes are a mobile solution for a mobile device, cell phones. Thus, a tub-like dispenser or other multi-pack solutions are generally impractical because the busy cell phone user is not going to carry ten moist wipes with him or her. Single packaging allows users to take just one wipe with them on the road and use when needed, providing a more practical solution. Ideally, the wipes will be made compact (small) and convenient (disposable) so that they can travel with the device they are intended to clean. A typical size for a cell phone wipe is a rectangular sheet about 4″×4″ to 5″×5″.
[0049] While several particular forms of the invention have been illustrated and described, it will be apparent that various modifications can be made without departing from the spirit and scope of the invention.
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A cleaning wipe with a plurality of stiff triangular or rectangular-cross-sectional projections rising from the surface of a non-woven cloth is designed to clean the nooks and crannies, various crevices and other hard to reach areas of cell phones or other electronic items with a myriad of buttons and/or camera lenses, charger outputs, mouthpieces, ear receivers and keypads which are designed in countless shapes and sizes. The projections, whether in the form of cones, pyramids, length-long ridges or other embodiments are specifically designed to clean the small crevices, the mouthpiece and earpiece and between small buttons such as keypads on a cell phone or other electronic device.
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FIELD OF THE INVENTION
[0001] The present invention relates to a portable power source for a motor vehicle and, more particularly, to a method and apparatus to provide supplemental power to start internal combustion and turbine engines.
BACKGROUND OF THE INVENTION
[0002] Internal combustion and turbine engines require a power source to start. Commonly, this power source is in the form of a battery, which provides power to a starter motor, which in turn drives the engine. The crankshaft of the engine is rotated by the starter motor at a speed sufficient to start the engine. If the battery goes dead or otherwise lacks sufficient power for the starter motor to drive the engine, the engine won't start. Environmental factors, such as temperature, affect the output of the battery and power required to rotate the engine.
[0003] If the battery lacks sufficient power to start the engine, a supplemental power source is necessary to jump start the engine. Typically, jumper cables are used to connect the battery of one vehicle to the dead battery of another vehicle needing to be jumped. The batteries are connected in parallel using heavy cables (jumper cables) which are connected to the terminals of the batteries using conductive clamps.
[0004] Several potential problems arise from the use of conventional jumper cables. Batteries in motor vehicles are capable of producing from 2,500 to more than 45,000 watts of power. If the batteries are cross-connected or the clamps inadvertently contact each other when one end of the jumper cables is connected to a battery, sparking can occur resulting in damage to the battery, the electrical system of the vehicle, and injury to the user of the jumper cables. If the jumper cables are not properly connected, there is a potential for the batteries exploding and fire, which may result in injury to those in proximity to the vehicle being jumped. Furthermore, the user is not given any indication as to the reason the battery is dead, which may only cause additional problems when trying to jump start the dead battery.
SUMMARY OF THE INVENTION
[0005] The present invention provides an apparatus and method for delivering supplemental power to the electrical system of a vehicle. The apparatus and method performs real-time monitoring of all system parameters to increase the safety and effectiveness of the unit's operation while providing additional parametric and diagnostic information obtained before, during and after the vehicle starting operation.
[0006] The present invention monitors the voltage of the battery of the vehicle to be jump started and the current delivered by the jump starter batteries to determine if a proper connection has been established and to provide fault monitoring. For safety purposes, only if the proper polarity is detected can the system operate. The voltage is monitored to determine open circuit, disconnected conductive clamps, shunt cable fault, and solenoid fault conditions. The current through the shunt cable is monitored to determine if there is a battery explosion risk, and for excessive current conditions presenting an overheating condition, which may result in fire. The system includes an internal battery to provide the power to the battery of the vehicle to be jump started. Once the vehicle is started, the unit automatically electrically disconnects from the vehicle's battery.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a functional block diagram of the portable power source of the present invention.
[0008] FIGS. 2A and 2B are a schematic of the portable power source, control circuit and sensors of the present invention.
[0009] FIGS. 3-8 are flow charts of the processing steps of the portable power source of the present invention.
[0010] FIG. 9 is a flow chart of the interrupt service routine of the system of the portable power source of the present invention.
DESCRIPTION
[0011] Referring initially to FIG. 1 , the portable supplemental power source (jump starter) of the present invention is generally indicated by reference numeral 10 . Jump starter 10 includes a programmable microprocessor 12 which receives inputs 14 and produces informational outputs 16 and control outputs 18 . Microprocessor 12 provides flexibility to the system 10 to allow updates to the functionality and system parameters without changing the hardware. In the preferred embodiment, an 8-bit microprocessor with 64 k bytes of programmable flash memory is used to control the system 10 . One such microprocessor is the ATmega644P available from Atmel Corporation. The microprocessor 12 may be programmed via an internal connector 90 , or an external connector 92 (see FIG. 2 ). It should be understood that other programming ports may be included are not limited to the two shown in the figure.
[0012] A battery voltage sensor 20 monitors the voltage level of one or more jump starter batteries 22 . A reverse voltage sensor 24 monitors the polarity of the jumper cables on line 26 which are connected to the vehicle's electrical system 28 . A vehicle voltage sensor 30 monitors the voltage on line 37 (voltage of the vehicle). When the contacts are open, the solenoid voltage sensor 32 input to microprocessor 12 is used to measure the voltage of the jump starter batteries 22 , which may be configured for various jump starter voltages. When the contacts are closed, the voltage difference between the batteries 22 and the contact relay 34 is used to measure the voltage drop across a temperature-and-resistance calibrated 00 AWG shunt cable 36 in order to calculate the current being delivered by the jump starter batteries 22 to the vehicle's electrical system 28 . Although the present invention is disclosed and described as connected to a vehicle, it should be understood that it is equally applicable to a stationary engine. Additionally, the connection method to the electrical system or batteries of the engine to be started is not important and may include conductive clamps, NATO connectors, or may be permanently hardwired to the system, for example.
[0013] A battery temperature sensor 38 monitors the temperature of the jump starter's batteries 22 to detect overheating due to excess current draw from the batteries during jump starting. A shunt cable temperature sensor 40 monitors the temperature of the 00 AWG shunt cable 36 in order to compensate for resistance changes of the shunt cable due to the high current passing through the shunt cable 36 and to detect overheating conditions. The unit 10 also includes automatic 42 and manual 44 pushbutton inputs to accept user input to select either automatic or manual operation.
[0014] The microprocessor includes several outputs 16 to provide information to the user and to control the application of power to the vehicle to be jump started. An LCD display 46 may be used to display user instructions, error messages, and real-time sensor data during operation of the jump starter 10 . A reverse voltage LED 48 is illuminated when the microprocessor 12 determines that a reverse voltage jumper cable voltage is detected by reverse voltage sensor 24 . An auto mode LED 50 is illuminated when the automatic mode pushbutton 42 is depressed. A manual mode LED 52 is illuminated when the manual mode pushbutton 44 is depressed. If the voltage level of the jump starter batteries 22 drop below a value of twenty percent of the normal level, a charge battery LED 54 is illuminated. The charge battery LED 54 remains illuminated until the batteries 22 are charged to a minimum state of charge such as fifty percent, for example. A fault LED 56 is turned on anytime the microprocessor 12 detects any operational, sensor or internal fault. An audible warning may also be provided 70 . The fault LED 56 remains illuminated until the fault condition is cleared. A contact relay control output 58 operates the contact relay 34 . When the jump starter operation has been successfully initiated, the contact relay 34 is closed and the jump starter batteries 22 are connected to the starter system or batteries of the vehicle to be started 28 . The contact relay 34 is opened when a successful start cycle has been completed, a start fault has occurred or the operator interrupts the jump starter cycle. An optional key pad 72 may be included and used for entry of a passcode to operate the unit 10 , or to identify one or more users of the system which may be stored to track user operation. For example, if two different users operate the unit 10 and error conditions are recorded for one of the users, this information may be used to identify training issues that need to be addressed.
[0015] Referring to FIGS. 2A and 2B and 3 - 8 , when the jump starter 10 is initially powered on 200 , the microcontroller 12 initializes the hardware, reads all system parameters and variables, and initializes the interrupt service routine 202 (See FIG. 8 ). All stored performance history is read from the onboard, non-volatile memory 204 and a start message is displayed 206 on the LCD display 46 . The history is saved for diagnostic, unit use and safety purposes. The microcontroller 12 then performs a system self-test operation 208 where the LCD 46 , all LEDs 48 , 50 , 52 , 54 and 56 , all sensors 20 , 24 , 30 , 32 , 38 , 40 , the push buttons 42 and 44 , and the system batteries 22 are tested and their status displayed 208 on the LCD 46 . If a fault is detected 400 , an error message is displayed 402 and system operation is halted.
[0016] Once the initialization and self-test operations are completed, the system starts into a main processing loop 210 . An interrupt service routine (“ISR”) 500 ( FIG. 9 ) is also started which constantly monitors all input sensor values and user input buttons. The ISR 500 is periodically called by the microcontroller 502 . A check is made to determine if the serial input buffer flag is set 504 . If the flag is set 504 , then configuration information is read and flags set or cleared 506 . If the output flag is set 508 , the information is transmitted to an external PC and the output buffer flag is cleared 510 . Next, all input parameters are read 512 , and a moving average is calculated for each parameter 514 . If the PC remote flag is set 516 , all parameters and statuses are copied to the output buffer 518 and the output buffer flag is set 520 . The manual mode AC starting current profile is calculated 522 , all event timer counts are incremented 524 , and the status of the automatic 42 and manual 44 pushbuttons is monitored and set 526 . All calculations, timer counts, and status indications (flags) are stored in the internal memory of the microprocessor 12 .
[0017] At the start of the main process loop 210 , the flags are checked 404 beginning with the shunt calibration flag 406 . If the shunt calibration flag is set 406 , the starter contact relay 34 is closed 408 . The temperature of the shunt cable is measured 410 and the voltage drop across the shunt cable is read 412 . The temperature of the shunt cable is measured a second time and averaged with the previous reading 414 . The shunt resistance is then calculated and saved 416 and the shunt calibration flag is cleared 418 .
[0018] Next, if the flag to upload data to an external PC is set 420 , the information is copied to the output buffer 422 , the output buffer ready flag is set 424 , and the upload data flag is cleared 426 . If the download data from PC flag is set 428 , data is copied from the input buffer 430 , and the download data flag is cleared 432 .
[0019] If the PC remote control flag is set 434 , the remote control status flag is toggled 436 . If the flag is true, the unit 10 can be controlled remotely by a PC or locally by the buttons. If the flag is false, the unit can only be controlled locally.
[0020] If the system does not detect a battery charging voltage 212 , once jumper cables 60 have been connected to the vehicle to be started 28 , the voltage is measured by the reverse voltage sensor 24 to determine if the cables have been properly connected to the vehicle 214 . If the voltage measured is significantly less than the voltage of the system batteries 22 , then a reverse polarity connection of the jumper cables to the vehicle is determined and an error flag is set and the event saved in non-volatile memory 216 . A “Reverse Polarity” error message is displayed 218 on the LCD 46 , and the reverse voltage LED 48 is illuminated 216 . Any further jump starter action by the operator is ignored until the reverse polarity condition is corrected 220 , at which point processing returns to the start of the main processing loop 210 .
[0021] If the jumper cables 60 are not reverse connected 214 , then the state of charge of the system batteries 22 is determined 222 . If the voltage level of the system batteries 22 measured by the voltage sensor 30 is equal to a state of charge of eighty percent or more below a fully charged voltage level 222 , an error flag is set and the event recorded in memory 224 . The charge battery LED 54 is illuminated and the LCD 46 displays a “Charge Battery” message 225 . The system stays in this condition, which prohibits any farther jump starter action by the operator until a charging voltage is detected 226 , which is great enough to indicate that a battery charger (not shown) has been connected to the battery 22 .
[0022] If the system has detected a battery charger voltage 212 , a “Battery Charging” message is displayed 228 on the LCD 46 , and the charge LED 54 is illuminated. The voltage profile of the battery 22 is monitored to determine if the charge is complete 230 . A completed charge is determined by monitoring the charging voltage rise to a threshold value then decrease by a predetermined percentage. This voltage peaking and subsequent fall-off is a characteristic of the battery chemistry indicating that the battery has reached its maximum charge capacity. Once the charging has reached a minimum charged level or is completed 230 , the processing returns to the beginning of the main processing loop 210 . The jump starter batteries 22 only need to reach a 50% charge in order for the system to attempt to start the vehicle.
[0023] If the battery temperature measured by sensor 38 rises above a maximum safe threshold 232 , an error flag is set and the event recorded in non-volatile memory 234 . An error message “Battery Over Temperature” is displayed 236 on the LCD 46 and the Fault LED 56 is illuminated. The system prevents any further operation until the battery temperature falls below a safe level 238 . Once a safe temperature is reached, processing returns to a ready state at the beginning of the main processing loop 210 .
[0024] If the temperature of the shunt cable 36 rises above a safe threshold temperature 240 , an error flag is set and the event recorded in memory 242 . An error message “Cable over Temperature” is displayed 244 on the LCD 46 and the Fault LED 56 is illuminated. The system prevents any further operation until the shunt cable temperature falls below a minimum safe temperature 246 . Once a safe temperature is reached, the system returns to a ready state at the beginning of the main processing loop 210 .
[0025] Next, the system checks the status of the automatic 42 and manual 44 push buttons. If neither button has been pushed 248 , a “Ready” message is displayed 250 on the LCD 46 and processing returns to the main processing loop 210 . When no error conditions are detected and no user inputs are being processed, the system remains in the ready mode, and displays a “Ready” text message on the LCD 46 . Other information such as the selected jump starter voltage, the percentage change of the batteries 22 , the temperature of the batteries, and the vehicle voltage, for example, may also be displayed on LCD 46 .
[0026] If one of the push buttons 42 or 44 has been selected, the system will compare the operator-configured starter voltage against the voltage of the vehicle to be started 28 . The jump starter 10 may be configured for 12, 18, 24, 30 or 36 volts, for example, using a selector jumper 56 . If the batteries 22 are 12-volt batteries, only 12- or 24-volt configurations are shown in FIG. 2 . However, two or more batteries of the same or different voltage levels may be used to match the voltage requirements of the vehicle to be started. If the difference between the voltage selected and the voltage measured is not within a predetermined range and tolerance 252 , a “Wrong Selector Volts” message is displayed 254 on the LCD 46 and further operation is prohibited until the correct voltage is selected 256 at which point processing returns to the main processing loop 210 .
[0027] If the selected voltage is within the correct range 252 , then the system determines which button was selected 258 . If the Auto button 42 was pushed, a ninety-second count down timer is started and displayed 260 on the LCD 46 . During this time the system monitors the vehicle voltage 262 . If the system does not detect a voltage drop 264 within 90 seconds 265 , the automatic operation is cancelled and processing returns to the main processing loop 210 . The automatic operation may also be interrupted and canceled by pushing the auto button 267 . If the vehicle voltage drops by twenty percent or more from the initially measured voltage 264 , then the vehicle's starter motor is engaged and is trying to start the vehicle. If the maximum number of start attempts has not been exceeded 266 , the contact relay 34 is closed and the contact relay on timer is started 268 , connecting the jump starter's batteries 22 to the vehicle's starting system 28 . The start cycle counter is incremented 270 , a “Jump Starter On” message is displayed 272 along with the average current being drawn, and the Auto Mode LED 50 is illuminated. If the relay on timer expires indicating that the relay 34 has been closed for ninety seconds without a start complete event, the relay 34 is automatically opened by the system to reduce the probability of overheating any component in the jump starter or vehicle.
[0028] The system monitors all input sensors 14 and the current status of the jump starter for possible fault conditions. Upon detection of any fault condition, the system will open the contact relay 34 (if closed), and display a message indicating that a fault has occurred, and what action, if any, should be taken by the operator.
[0029] If the battery temperature exceeds a maximum limit 274 , a battery temperature error count is incremented 276 . The contact relay 34 is opened, a “Battery Temp” error message and temperature is displayed 278 on the LCD 46 and the fault LED 56 is illuminated. Processing returns to the main processing loop 210 .
[0030] If the shunt cable temperature exceeds a maximum limit 280 , a cable temperature error count is incremented 282 . The contact relay 34 is opened, a “Cable Temp” error message and temperature is displayed 278 on the LCD 46 and the fault LED 56 is illuminated. Processing returns to the main processing loop 210 .
[0031] If the system detects a geometric rise in the starting current 284 during the first 16 seconds after the contact relay 34 is closed, a current doubling error count is incremented 286 , a “Battery Explosion” error message is displayed 288 on the LCD 46 , the contact relay 34 is opened and the fault LED 56 is illuminated 290 . The system may be returned to the ready mode if the Automatic button 42 is pressed by the operator 292 , or automatically after five minutes 294 .
[0032] If no current flow is detected by the system 296 indicating that there is an open circuit within the system, an open circuit error count is incremented 298 , an “Open Circuit” error message is displayed 300 on the LCD 46 , the contact relay 34 is opened and the fault LED 56 is illuminated 290 . The system may be returned to the ready mode if the Automatic button 42 is pressed by the operator 292 , or automatically after five minutes 294 .
[0033] If the system detects an increase in the difference between the measured jump starter battery voltage 20 and the voltage measured 30 across the contact relay 34 indicating that one of the jump starter cables has been disconnected 302 from the vehicle's battery or starter system 28 then a jumper cable unplugged error count is incremented 304 , a “Jumper Cable Unplugged” error message is displayed 306 on the LCD 46 , the contact relay 34 is opened and the fault LED 56 is illuminated 290 . The system may be returned to the ready mode if the Automatic button 42 is pressed by the operator 292 , or automatically after five minutes 294 .
[0034] During the jump starting process if the current measured across the shunt cable 36 is greater than a preset maximum current such as 1400 amps for a short period of time such as 500 ms 308 , the over max current error count is incremented 310 , an “Over MAX Starting Current” error message is displayed 312 on LCD 46 , the contact relay 34 is opened and the fault LED 56 is illuminated 290 . The current across the shunt cable 36 is also measured to determine if it exceeds a predetermined current such as 1000 amps for more than a predetermined period of time such as 15 seconds 314 . If this over current condition is determined, an over high current error count is incremented 316 , an “Over High Crank Amps” error message is displayed 318 on the LCD 46 , the contact relay 34 is opened and the fault LED 56 is illuminated 290 . The system may be returned to the ready mode if the Automatic button 42 is pressed by the operator 292 , or automatically after five minutes 294 .
[0035] If the system detects a decrease in the jump starter battery voltage 20 , but does not detect an appreciable current flow through the jump starter, a shunt cable 36 failure is indicated 320 . The shunt cable 36 is a precisely measured and calibrated 00 AWG wire, the temperature of which is monitored 40 and used to calculate the resistance across the length of the cable 36 .
[0036] The voltage drop across the cable 36 is also measured to calculate the current through the shunt cable 36 using Ohm's Law. If the shunt cable 36 fails, the system cannot reliably measure the starting current which would present a safety hazard.
[0037] If the system detects a shunt cable failure 320 , a current shunt error count is incremented 322 , a “Current Shunt Failure” error message is displayed 324 on the LCD 46 , the contact relay 34 is opened and the fault LED 56 is illuminated 290 . The system may be returned to the ready mode if the Automatic button 42 is pressed by the operator 292 , or automatically after five minutes 294 .
[0038] If the system detects a great difference between the vehicle's voltage 30 and the contact relay 34 voltage 326 , the contact relay 34 may have failed indicating an over high starter current condition. A contact relay failure count is incremented 328 , a “Contact Relay Error” message is displayed 330 on the LCD 46 , the contact relay 34 is opened and the fault LED 56 is illuminated 290 . The system may be returned to the ready mode if the Automatic button 42 is pressed by the operator 292 , or automatically after five minutes 294 .
[0039] If manual mode is selected 258 , “Manual” is displayed 332 on the LCD 46 , the system will prompt the operator to press the manual button 44 again. If the manual button 44 is pressed a second time 334 , then the system checks the number of start attempts 266 . If the maximum number of start attempts has been exceeded 266 , an over start attempt error count is incremented 336 , a “Cool Down Unit” message is displayed 338 on the LCD 46 , and the system waits for five minutes for the system to cool 340 . Once the cool down time has expired, processing returns to the main processing loop 210 . If the total start attempts have not exceeded the limit 266 , the processing continues at block 268 as described above.
[0040] If in auto mode and the starting current decreases by 20% from the maximum measured current 342 , then the start cycle is complete. A decrease in the starting current indicates that the vehicle has started and its alternator is now generating its own current reducing the demand from the jump starter batteries 22 . If the starting current is below the threshold 342 , a “Start Cycle Complete” message is displayed 344 on LCD 46 , and the contact relay is opened 346 . This message remains displayed until the operator presses the Auto button 292 , or if there is no user activity for five minutes 294 , after which the system returns to the main processing loop 210 .
[0041] If in manual mode, the jump starter 10 may be used when the battery voltage of the vehicle is below 10 volts, or if the vehicle's battery is not connected. In the situation where the vehicle's battery is present but has a voltage of less than 10 volts, the jump starter will start to charge the vehicle's battery before any starting operation begins. If the vehicle's battery is extremely low or completely dead, once the contactor is closed, the jump starter's batteries will start to charge the batteries. The current will rise sharply and then start to decrease, but this does not indicate that a start attempt has been made or that the vehicle's starter motor has been cranked. The algorithm looks for this initial increase and then decrease in the delivered current and then waits for a minimum of three alternating current cycles indicating that the vehicle's starter has been engaged. Due to the compression/decompression cycles of the pistons, the starting current will rise and fall in a generally sinusoidal pattern. The algorithm looks for this so that it knows that the vehicle's starter motor has been activated. Once this alternating current cycle has been detected, if the current then decreases by approximately twenty percent and remains low, this indicates a start complete, the contactor is opened, the start complete message is displayed and then the system waits for the Auto button to be pushed or the 5 minute timeout.
[0042] If the vehicle's battery holds the charge, then the starting cycle in manual mode is the same as described above for automatic mode. If the battery does not hold the charge or if no battery is present, the system waits until the vehicle's starter motor is engaged. Once the vehicle's starter motor is engaged and the engine is turning over, the system 10 monitors the jump starter current flow. As the engine turns over the jump starter's current increases and decreases with the compression stroke of the engine's pistons. During a piston's compression cycle, the current from the jump starter's batteries 22 increases due to the increased power demand of the starter motor. During a piston's decompression cycle, the current flow decreases due to the decreased power demand of the starter motor. This current increase and decrease is generally sinusoidal which is recognized by the system.
[0043] Once the system has detected three more sinusoidal current flow cycles, the same 20% decrease threshold in current as set forth above for the automatic mode determination, may be used to determine when the vehicle's engine has started 348 . If the engine has started, the “Start Cycle Complete” message is displayed 344 on the LCD 46 and the contact relay opened 346 .
[0044] If the engine has not been started 348 , the system next checks the relay closed time. If the maximum time set for the contact relay to be closed has expired 350 , a “Maximum Starter On” message is displayed 352 on the LCD 46 and the contact relay is opened 346 .
[0045] If the contact relay closed time has not expired, the system checks for a cycle halt flag. Any cycle may be interrupted by the Auto button being pressed by the operator. If the Auto button is pressed 354 , a “Start Cycle Halted” message is displayed 356 on the LCD 46 , and the contact relay opened 346 .
[0046] It is to be understood that while certain forms of this invention have been illustrated and described, it is not limited thereto, except in so far as such limitations are included in the following claims and allowable equivalents thereof.
|
A method and apparatus provides supplemental power to an engine. The method and apparatus includes a pair of conductive leads for connecting the supplemental power to an engine electrical system, a batter, a relay connected to the conductive leads, a shunt cable connecting the batter to the relay and a processor for controlling the relay to selectively apply electrical power to the engine electrical system. The method and apparatus includes safety features to reduce the risk of injury to the operator and damage to the apparatus and/or engine electrical system.
| 5
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TECHNICAL FIELD
The present invention relates generally to premixed liquid monopropellant compositions and specifically to nondetonable premixed liquid monopropellant mixtures and solutions consisting of oxidizers and fuels.
BACKGROUND OF THE INVENTION
Recent requirements for “green” or substantially less toxic rocket propellants, particularly for use on space stations, have resulted in a search for suitable less toxic propellant compositions that function as effectively as available propellants. Solid rocket propellants are fast burning solids which operate only one time and are not usable in, for example, space station and similar applications where throttle control and on/off switching capability are essential. Liquid propellants provide the throttle and switching control desired for thrust vector control motors. An oxidizer of nitrogen tetroxide with a fuel of hydrazine is an excellent bipropellant combination for this purpose. Hydrazine used as a monopropellant is also attractive for this purpose. Also, catalyzed hydrazine as a monopropellant provides off/on capability. However, these propellants do not conform to the new requirements for environmentally nontoxic propellants because the constituents are extremely toxic or carcinogenic.
Most of the available liquid propellants are bipropellants similar to nitrogen tetroxide and hydrazine discussed above. The liquid oxidizer and the liquid fuel components are stored separately and then mixed when the propellant must be burned. In some cases the ingredients used in bipropellant systems are hypergolic. A hypergolic bipropellant system is one in which the constituents ignite on contact with each other. Although liquid monopropellants are simpler to use than bipropellants, liquid monopropellants that perform as w II as liquid bipropellants have heretofore not been available.
Liquid propellants, many of which have been claimed to have less toxicity, have been disclosed as green propellants, in the prior art. Zletz et al. In U.S. Pat. No. 2,896,407, for example, disclose liquid propellants useful for gas generation and rocket propulsion. The bipropellants disclosed by Zletz et al. require the hypergolic reaction of a liquid fuel and a liquid oxidizer, preferably highly concentrated hydrogen peroxide that may optionally include a dissolved water soluble inorganic salt, such as ammonium nitrate. The hypergolic fuel is an organohalothioborate, such as dimethylchlorodithioborate or its solutions in conventional hydrocarbons. Zletz et al. do not disclose or otherwise suggest premixed monopropellant mixtures or solutions containing water soluble organics, such as alcohols, or water soluble organic salts, such as amine-nitrates, in aqueous hydrogen peroxide solutions. Furthermore, it is not possible to forecast the behavior of four-component mixtures, such as H 2 O 2 /H 2 O/AN/alcohol, based on the properties of three-component mixtures such as H 2 O 2 /H 2 O/AN. Moreover, the hypergolic bipropellant formulations described by Zletz et al. are, by their nature, unsuitable for use as monopropellants.
Rowlinson. U.S. Pat. No. 3,004,842 teaches that foamed solid AN explosives are more sensitive to detonation than either unfoamed or porous beds of granules. He melt-casts compositions containing AN at the melting point of AN, and uses H 2 O 2 as a foaming agent that decomposes to steam and O 2 at the casting temperature, forming a solid foam as the temperature is lowered to ambient. His foams are detonable with only a blasting cap and do not require a booster like other AN explosives.
The present invention concerns only liquid solutions and mixtures. Rowlinson uses H 2 O 2 as a foaming agent, not as either a solute or an oxidizer. Also, preferably our monopropellants would be nondetonable.
U.S. Pat. No. 3,470,040 to Tarpley describes inorganic liquid propellant compositions that are essentially unpourable, and thus are gel-like, under storage or shear conditions. These gelled liquid propellants may use a liquid oxidizer, such as red fuming nitric acid and liquid oxygen, and contain ammonium nitrate, have a yield point and flow when pumped. The present invention discloses premixed liquid monopropellant solutions and mixtures and not gels.
Berman, in U.S. Pat. No. 3,143,446, acknowledges the disadvantages of all liquid propellant types of rocket motors and teaches encapsulating reactive liquid oxidizers, including nitrogen tetroxide, or liquid fuels, such as hydrazine, for use in solid propellants. Auxiliary solid oxidizers, such as ammonium nitrate, may be used with the encapsulated liquids. The present invention does not disclose encapsulated propellant ingredients.
Hybrid propellants consisting of a solid fuel, either RDX or HMX, and a liquid oxidizer are taught by Biddle et al. in U.S. Pat. No. 4,527,389. The liquid oxidizer preferred for this purpose is an aqueous solution of hydroxylamine nitrate (HAN) or hydroxylamine perchlorate (HAP). The solid fuel burns by itself to generate fuel-rich combustion products, and the liquid oxidizer is sprayed into the combustion products to oxidize them to completion. Biddle does not disclose premixed liquid monopropellants. Use of hydrogen peroxide as an oxidizer is stated to be unsuitable because it is corrosive. The present invention does not disclose propellants for use in a hybrid rocket motor configuration.
U.S. Pat. No. 5,292,387 to Highsmith et al. discloses ammonium nitrate-containing propellants. These propellants, however, are solid propellants wherein ammonium nitrate is phase-stabilized with a metal dinitramide, preferably potassium dinitramide by dissolving ammonium nitrate and potassium dinitramide in methanol, which is evaporated. It is not suggested that any of these components could be used to form premixed liquid monopropellant solutions and mixtures.
In U.S. Pat. No. 5,837,931, Bruenner et al. disclose solid solutions made of ammonium nitrate, hydrazinium nitrate, hydroxylammonium nitrate and/or lithium nitrate, including eutectics, that are liquid at room temperature and useful as liquid oxidizers for propellants. These propellants, which contain a metal fuel, a hydrocarbon polymer and the liquid oxidizer, form a gel structure that supports the metal fuel. Bruenner et al. does not suggest liquid propellants that do not require the formation of solid solutions or eutectics.
A need exists, therefore, for substantially nontoxic, low detonation sensitivity, environmentally friendly liquid propellants that perform effectively and provide maximum throttle control. A need particularly exists for premixed liquid monopropellant solutions and mixtures with these characteristics.
SUMMARY OF THE INVENTION
It is a primary object of the present invention, therefore, to overcome the disadvantages of the prior art and to provide substantially nontoxic, or less toxic, nondetonable, environmentally friendly liquid propellants that perform as effectively as hydrazine monopropellants and/or liquid bipropellants.
It is another object of the present invention to provide a substantially nontoxic, nondetonable or low detonation susceptible, environmentally friendly liquid monopropellant with a “start-stop-start” capability that fulfills a mission requirement as effectively as a Bipropellant system in which the oxidizer and fuel constituents are stored in separate tanks.
It is yet another object of the present invention to provide a low toxicity, non-carcinogenic, smokeless, safe liquid monopropellant useful for impulse propellants and gas generators.
It is yet a further object of the present invention to provide throttleable premixed liquid monopropellant solutions and mixtures which can be readily decomposed or combusted by contact with a catalyst pack or ignited with the use of a glow plug, spark plug, or pyrotechnic squib.
It is still another object of the present invention to provide liquid monopropellants and bipropellants useful for thrust vector control motors and reaction control systems.
It is a still further object of the present invention to provide a storage stable premixed liquid propellant solution or mixture having a freezing point of less than −10° C.
In accordance with the aforesaid objects, the present invention provides substantially nontoxic, nondetonable or low detonation susceptible, environmentally friendly liquid monopropellant solutions and mixtures that perform as effectively as conventional highly toxic and reactive mono or bipropellant. The liquid propellants of the present invention are formed of aqueous solutions of selected oxidizers and selected aqueous fuels in a stoichiometrically formulated solvent/solute ratio. Preferred solvents are aqueous hydrogen peroxide solutions and/or aqueous alcohol solutions. The preferred solutes are other oxidizers and fuels. Particularly preferred other oxidizers are ammonium dinitramide, ammonium nitrate, aminoguanidine dinitrate, hydroxylamine nitrate and hydrazine nitrate. Preferred fuels are water soluble alcohols, amines, amine nitrates, polyvinyl nitrate, hydroxyethyl hydrazines, derivatives of guanidine and aminoguanidine, and azoles such as 5-aminotetrazole. Examples of preferred guanidine and aminoguanidine derivatives include guanidine nitrate, aminoguanidine nitrate, and triaminoguanidine nitrate.
Other objects and advantages will be apparent from the following detailed description and claims.
DETAILED DESCRIPTION OF THE INVENTION
The optimum operation of certain types of rockets, for example, vernier control rockets, thrust vector control motors and the like, requires maximum thrust control. The liquid propellants of the present invention provide the requisite degree of control for these applications. The liquid propellants of the pr sent invention are designed to be “throttleable”. The propellant mass flow rate can be controlled with a throttle; therefore, the thrust can be controlled since the specific impulse times the mass flow rate is equal to the thrust. Unlike solid propellant systems, the decomposition or combustion of the liquid monopropellant mixtures and solutions of the present invention may be switched on or off to provide further control. In a rocket propulsion system or specifically a thrust vector control motor, the combustion or decomposition of the liquid monopropellant mixtures and solutions of the present invention may be controlled so thrust is throttled up gradually, and power may be switched off or on, as necessary. The premixed liquid monopropellant mixtures and solutions of the present invention are more versatile than solid propellants because of their control capability. Solid propellants burn quickly and produce maximum thrust quickly, while liquid propellants can be throttled to increase thrust gradually.
The unique composition of the premixed liquid monopropellant mixtures and solutions of the present invention is responsible for the foregoing characteristics. The novel liquid monopropellants are formulated from solutions of oxidizers and fuels. Aqueous hydrogen peroxide solutions and/or aqueous organic solutions, particularly alcohol solutions, are the solvents of choice for the present liquid propellants. Solutions with nitric acid and other water soluble nitrates may also be used, however. The solutes preferred for these propellants are solid oxidizers and fuels. Methanol and ethanol solutions are the preferred alcohol solutions. Preferred solid oxidizers include ammonium dinitramide (ADN), ammonium nitrate (AN), hydroxylamine nitrate (HAN), hydrazine nitrate (HN) and aminoguanidine binitrate. Other similar water soluble oxidizers may also be useful in this propellant formulation.
The fuels preferred for the premixed liquid monopropellant solutions and mixtures of the present invention should be aqueous hydrocarbons, aqueous nitro-organics and solutions of solid organic fuel compounds in these liquids. Additional preferred fuels include water soluble alcohols, amines, amine nitrates such as triaminoguanidine nitrate (TAGN), hydroxyethyl hydrazine, hydroxyethyl hydrazine nitrate, guanidine nitrate and, aminoguanidine nitrate, and mixtures thereof.
A premixed liquid monopropellant formulation in accordance with the present invention may be made by dissolving a selected solid oxidizer in aqueous hydrogen peroxide. A preferred solid oxidizer is ammonium dinitramide. Both methanol and ethanol are miscible in the ADN/H 2 O 2 /H 2 O solution. The solvent/solute ratio is preferably formulated to be at the stoichiometric point relative to carbon dioxide (CO 2 ) and water (H 2 O) plus or minus about 5%. Sufficient water may be added to maintain the desired flame temperature.
Equation 1 illustrates a typical premixed monopropellant oxidizer fuel mixture reaction in accordance with the present invention:
CH 3 CH 2 OH+6H 2 O 2 +3H 2 O→2CO 2 +9H 2 O
This formulation achieves the objectives of the present invention with 80% H 2 O 2 , 12% CH 3 CH 2 OH and 8% H 2 O. The H 2 O 2 is preferably at a 70% concentration in water. The low concentration of H 2 O 2 (70%) allows the use of commercially available, easily handled material. In accordance with the invention, a range of H 2 O 2 concentration from 40%–90% may be used.
The liquid propellant mixtures and solutions of the present invention are ideally nondetonable or have low detonation susceptibility and are formulated to have a flame temperature which meet the gas generator or rocket motor design requirements. The premixed liquid monopropellant mixture must ignite reliably and repeatedly when required to do so. For example, repeatable ignition of the liquid monopropellant can be achieved with decomposition on a catalyst bed such as iridium, silver, silver oxide or platinum. Other methods suitable include the use of a glow plug, spark plug, or separately stored chemical ingredient, which when mixed with the liquid monopropellant results in hypergolic ignition.
It is necessary for the freezing point of the propellants of the present invention to be less than −10° C. to perform properly.
An alternate route to improved performance is to dissolve a solid oxidizer, such as, for example, aminoguanidine nitrate, ammonium nitrate or ammonium dinitramide, in the aqueous mixture, thus increasing the specific gravity, which, in turn, increases performance. In general, it is desired that the specific gravity of the propellant be as high as possible for maximum performance, the goal being to maximize the specific gravity within the constraints imposed by the freezing point and storage stability.
The maximum desirable upper storage temperature limit is about 71° C. (160° F.). If necessary, stabilizers may be added to enable the propellant liquid to withstand storage.
An advantage presented by the premixed liquid monopropellant solutions and mixtures of the present invention is their requirement for only one storage tank, one pump and one controller as compared to the dual components necessary for the separate fuel and oxidizer solutions of a bipropellant propulsion system. High performance premixed monopropellant mixtures and solutions as disclosed in the present invention provide the capability for achieving performance levels greater than conventional monopropellants such as anhydrous hydrazine for use in gas generators, and in fact, in some cases, are comparable in performance to conventional bipropellants used in very high performance rocket systems.
Table 1 below describes the characteristics of seven liquid monopropellant compositions made in accordance with the present invention.
Premixed liquid monopropellant mixtures and solutions consisting of a variety of fuels mixed with 70% hydrogen peroxide were theoretically evaluated and compared with a baseline of anhydrous hydrazine, a conventional monopropellant. In addition to comparison with a conventional monopropellant system, examples of the premixed liquid monopropellants of the present invention were also compared with a bipropellant system consisting of nitrogen tetroxide and monomethyl hydrazine (NTO/MMH). Flame temperatures were held at 2000° K or less. A flame temperature ceiling of 2000° K was considered the upper limit for use with SOA materials used for construction of combustors and perceived catalyst beds. The basis that was used for comparison of performance is relative boost velocity, V. REL. It can be shown that the theoretical boost velocity (V Boost) of a missile is
V Boost= Ivac·gc·In[ 1 +RHO /( Mi/Vp )], (1)
where
Ivac=vacuum specific impulse @ a combustion pressure (P c ) of 125 psia and an expansion ratio (ε) of 180.
gc = Newton's constant, RHO = propellant density, Mi = mass of inert parts, and Vp = volume of propellant
Using relative boost velocity, defined as
V . REL = ( V Boost ) of candidate Propellant ( V Boost ) of baseline Propellant ( 2 )
as the figure of merit, the candidates were compared at three assigned values of Mi/Np to the baseline monopropellant, hydrazine, and baseline bipropellant (NTO/MMH).
TABLE I
Examples of Premix d Liquid Monopropellant
Solutions and Mixtures
Composition
A
B
C
D
E
F
G
70% H 2 O 2
59.86
84.00
80.00
80.00
77.00
77.00
36.67
ADN
—
—
—
—
—
—
51.20
AN
25.00
—
—
—
—
—
—
Ethanol
15.14
16.00
12.00
20.00
20.00
18.00
12.13
Water
—
—
8.00
—
3.00
5.00
—
Freezing Point ° C.
<−10
<−10
<−10
<−10
—
—
<−10
Flame Temp, ° K
2000
2000
1900
1817
1713
1756
2542
IVAC
276.0
279.6
273.1
270.0
264.8
266.9
307.7
Density (rho)
.0450
.0422
.0423
.0413
.0410
.0412
.0503
PERFORMANCE COMPARED TO NTO/MMH:
Relative Boost Velocity Compared With
Baseline Bipropellant (NTO/MMH)
mf = 0.1
0.81
0.77
—
—
0.71
0.72
1.00
mf = 0.5
0.80
0.77
—
—
0.72
0.73
0.96
mf = 0.9
0.79
0.78
—
—
0.73
0.74
0.92
PERFORMANCE COMPARED TO ANHYDROUS HYDRAZINE:
Relative Boost Velocity Compared With
Baseline Monopropellant (ANHYDROUS HYDRAZINE)
mf = 0.1
1.53
1.46
1.42
1.38
1.34
1.36
1.88
mf = 0.5
1.45
1.41
1.38
1.34
1.30
1.32
1.75
mf = 0.9
1.36
1.34
1.31
1.29
1.26
1.27
1.58
HAZARDS
(Impact, Friction,
Accept-
Accept-
Accept-
Accept-
Accept-
Electrostatic)
able
able
able
able
—
—
able
Detonation #8
yes
yes
no
yes
—
—
—
Cap
NOL card gap test
—
—
Negative
—
—
—
—
@ 70 cards
Explosive
—
—
Class 1.3
—
—
—
—
Classification
TABLE II
Monopropellant Compositions With Values of Relative Boost Velocity
Similar to High Performance NTO/MMH Bipropellant Systems
Composition, Wt%
U REL @ (m f ) N204/MMH =
Oxidizer
Fuel
Ivac
T c , ° K
RHO
0.1
0.5
0.9
44 HP 70%
56 GN
271.0*
2149
0.04953
0.87
0.84
0.80
50 HP 70%
50 GN
260.8
2018
0.04902
0.83
0.80
0.77
38 HP 90%
62 GN
287.5*
2381
0.05138
0.95
0.92
0.86
50 HP 90%
50 GN
269.3
2176
0.05122
0.89
0.86
0.81
47 HP 70%
53 AGN
276.9*
2194
0.05178
0.93
0.89
0.83
50 HP 70%
50 AGN
271.0
2132
0.05145
0.90
0.86
0.81
41 HP 90%
59 AGN
294.5*
2438
0.05451
1.03
0.98
0.90
50 HP 90%
50 AGN
279.2
2284
0.05387
0.97
0.92
0.85
50 HP 70%
50 TAGNO3
300.2*
2433
0.05061
0.98
0.94
0.90
44 HP 90%
56 TAGNO3
320.1*
2669
0.05325
1.10
1.04
0.97
50 HP 90%
50 TAGNO3
308.5
2584
0.05295
1.05
1.00
0.94
68 HP 70%
32 TAGN3
300.2*
2381
0.04811
0.94
0.91
0.88
62 HP 90%
38 TAGN3
327.8*
2709
0.05112
1.08
1.04
0.98
77 HP 70%
23 GCN
277.1*
2167
0.04738
0.85
0.83
0.81
73 HP 90%
27 GCN
308.3*
2550
0.05062
1.01
0.97
0.92
88 HP 70%
12 ETNH
299.6*
2310
0.04361
0.85
0.85
0.84
85 HP 90%
15 ETNH
334.8*
2698
0.04588
1.00
0.98
0.96
82 HP 70%
18 NO2ACANID
289.2*
2296
0.04726
0.89
0.87
0.84
78 HP 90%
22 NO2ACANID
320.1*
2669
0.05073
1.05
1.01
0.96
44 HP 70%
56 EDDN
291.4
2356
0.05182
0.98
0.93
0.88
28 HP 70%
72 EOADN
306.9
2628
0.05249
1.04
0.99
0.93
55 HP 70%
45 PVNO 3
313.2
2660
0.05094
1.03
0.99
0.94
NOTE:
*Denotes maximum Ivac @ P c = 125 PSIA & ε = 180
GN is guanidine nitrate
AGN is aminoguanidine nitrate
TAGNO3 is triaminoguanidine nitrate
GCN is cyanoguanidine
ETNH is aziridine (ethylene imine, H 3 CCH(═NH)
NO2ACANID is nitroacetanilide (NO 2 C 6 H 4 NH(C═O)CH 3
EDDN is ethylene diamine dinitrate
EOADN is ethanolamine dinitrate
PVNO 3 is polyvinyl nitrate
HP 70% is an aqueous solution containing 70% hydrogen peroxide
HP 90% is 90% hydrogen peroxide
As described above, the performance of th liquid monopropellants described in Table I was evaluated relative to a baseline nitrogen tetroxide and monomethylhydrazine (NTO/MMH) bipropellant and a baseline anhydrous hydrazine monopropellant. The theoretical boost velocities of the monopropellant compositions A, B, E, F, and G were computed relative to a baseline bipropellant composed of 62% NTO and 38% MMH, at baseline mass fractions of 0.1, 0.5 and 0.9 mass fraction. Also, the relative boost velocities of monopropellant. Compositions A, B, C, D, E, F and G were compared to that of the baseline monopropellant anhydrous hydrazine at 0.1, 0.5, and 0.9 mass fraction.
Hazards testing was conducted on Compositions A, B, C and D. In particular impact, friction and electrostatic data were evaluated and found to be acceptable. Detonation tests with a Number 8 cap were run on a variety of formulations. The Composition C formulation was nondetonable. This composition was also Class 1.3 in the NOL card gap test.
In accordance with the present invention Table 2 shows the theoretical performance values of Ivac (P c =125 psia & ε=180) and V REL (boost velocity relative to N 2 O 4 /MMH @(m f ) N204/MMH =0.1, 0.5, and 0.9) were calculated for mixtures of either 70% HP or 90% HP and aminoguanidine nitrate (AGN), triaminoguanidine nitrate (TAGNO3, whose water solubility is only slight), TAG azide (TAGN3, whose water solubility is unknown), cyanoguanidine (GCN), aziridine (ethylene imine, ETNH), nitroacetanilide (NO 2 C 6 H 4 NH (C=O)CH 3 , NO2ACANID), ethylene diamine dinitrate (EDDN), ethanolamine dinitrate (EOADN), and polyvinyl nitrate (PVNO3). Results are attached. They are all either maxima in terms of V REL , and usually in terms of Ivac, or are simply 50/50 mixtures (which are estimated to be practical).
The best fuel was PVNO3. It and EOADN were the only fuels that were superior to the baseline with 70% HP as the oxidizer.
INDUSTRIAL APPLICABILITY
The liquid monopropellants of the present invention will find their primary applicability as safe, nontoxic smokeless impulse propellants and gas generators in applications such as thrust vector control motors.
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Nondetonable, or low detonation sensitivity, substantially nontoxic liquid monopropellants are provided. The liquid propellants are formed from aqueous solutions of solid oxidizers in liquid oxidizers and water soluble liquid fuels and formulated to have a freezing point less than −10° C. Liquid oxidizers may be inorganic or organic aqueous solutions, with hydrogen peroxide being preferred. Preferred solid oxidizers are water soluble nitrates including ammonium dinitramide, aminoguanidine dinitrate, ammonium nitrate, hydroxylamine nitrate, hydrazine nitrate, guanidine nitrate and aminoguanidine nitrate. Preferred liquid fuels are water soluble alcohols, amines and amine nitrates, hydroxyethyl hydrazine, hydroxyethylhydrazine nitrate, cyanoguanidine, guanidines, aminoguanidines, triaminoguanidines, and their nitrate salts, ethanolamine dinitrate, ethylenediamine dinitrate, polyvinyl nitrate, and aziridine.
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FIELD OF INVENTION
[0001] The present invention relates to microporous carbon and methods for preparing same. In particular, this invention relates to the preparation of carbonaceous electrode material for electric double layer capacitors having a large capacitance per volume, a low resistivity and moderately high bulk density. The carbonaceous material is preferably produced by thermo-chemical carbonizing and subsequently chemical treating of a carbon precursor of mineral carbide origin.
BACKGROUND OF THE INVENTION
[0002] During extensive development of electric double layer capacitors (EDLC), also called ultra-capacitors or supercapacitors, and its components it has been found that the key to a good supercapacitor is a pair of polarizable electrodes, more precisely a carbonaceous electrode material possessing high sorption behavior of electrolyte ions. A general question is how to increase the electrochemically active surface while maintaining the high bulk density of carbonaceous material.
[0003] The widespread, so-called activated, carbon materials for EDLC are made by carbonizing organic substrates: resins, tars etc., and subsequently oxidizing the formed carbonaceous material. The yield and structural properties such as porosity and density of electrochemically active carbon materials significantly depend on the nature and properties of carbonaceous raw material. Furthermore, it is recognized that the electric double layer capacity depends strongly on the adsorption interaction of the ions in the pores, and hence the relationship between the pore size and the effective ion size determines the specific EDL capacitance of the carbonaceous electrodes [Salitra et al. J. Electrochem. Soc. 147 (2000), 2486]. U.S. Pat. Nos. 6,043,183 and 6,060,424 describe the manufacturing of high power density and high energy density carbons, respectively, for use in double layer energy storage devices. In prior art the high power density of carbon is related to maximizing the fraction of mesopores ranging between 2.0 to 50.0 nm, whereas the high energy density is related to maximizing the fraction of micropores with a pore size less than 2.0 nm. Another U.S. Pat. No. 5,965,483 describes a process for increasing the fraction of micropores in the range of 0.8 to 2.0 nm in already activated carbon by blending the activated carbon with potassium hydroxide solution subsequently heated at high temperature.
[0004] The recommended classification of pores according to IUPAC is that pores, which diameters range between 2 and 50 nm, should be considered as mesopores, and pores with a diameter of below 2.0 nm as micropores.
[0005] When the carbon material is characterized by uniform microporous structure and narrow pore size distribution, the respective polarizable electrode most frequently is able to adsorb different amount of positively and negatively charged ions from electrolyte solution. In most commercial organic electrolytes the cations (ammonium, phosphonium, imidazolium etc.) are of a bigger size than the anions (BF 4 , PF 6 etc), therefore the negatively charged electrodes are usually limiting the performance of electrical double-layer capacitors. The application of active carbon with different pore size for negatively and positively charged electrodes in EDLC is considered in U.S. patent application No. 2002/0097549.
[0006] It is thus an object of this invention to provide a method for improving the carbon micropore size distribution to increase the specific ion capacity of microporous carbon, and hence to increase the energy density of EDLC comprising one or both electrodes from this carbon.
[0007] The post-treatment (called activation, oxidation, pore-modification, etc.) of carbonaceous material to create and/or enhance the porosity in carbonaceous substrate is conventionally executed by heating the carbonaceous material impregnated with liquid chemical activation agents such as alkali metal hydroxides, carbonates, derivatives of sulfuric and phosphoric acids, and combinations thereof. Drawback of these methods is the difficulty to wash out from carbon the reaction by-products. More convenient is to tailor carbon pore sizes by oxidation with gaseous oxidizing agents. Traditional oxidizing medium comprises water vapor, carbon dioxide or the mixture of those with a carrier gas such as nitrogen, argon or helium. The oxidation creates pores and increases surface area of the carbonaceous material. There exists an optimum reaction/activation that provides a maximum electrochemical performance for the carbon in the electrolyte solution. A drawback of such activated carbon materials, however, is a substantial loss of substrate, which usually exceeds 30-50 wt. %. An undesirably big amount of lost carbon material is caused by the restricted diffusion of molecules of the oxidizing agent into the inner parts of the carbon particles. At the oxidizing reaction temperature the gaseous oxidants more likely interact with the carbon atoms at surface layers of carbon particles, without penetrating to the core of the particles.
[0008] It is a further object of this invention to provide a more productive method for improving the pore size distribution of microporous carbon by specifically oxidizing the carbon in micropores of less than 1.0 nm in size, while minimizing the loss of mass.
[0009] It is yet another object of this invention to provide an improved carbon with a narrow pore size distribution.
SUMMARY OF THE INVENTION
[0010] The above objectives of the invention are achieved by a method of enlarging micropores having a size less than a predetermined size in a microporous carbon material comprising the steps of;
[0011] selecting a liquid reagent acting as an oxidant at elevated temperature for which the molecules thereof are absorbed in the micropores to be enlarged; impregnating the carbon material with said liquid reagent; and
[0012] thereafter heating the carbon material to a temperature exceeding the oxidizing temperature for said reagent.
[0013] In a preferred embodiment the porous carbon material used has a bulk density of at least 0.6 g/cm 3 , a microporosity of at least 0.45 cm 3 /g as measured by benzene absorption and with a pore size distribution in which at least 20%, preferably at least 30%, more preferably at least 40% of the micropores are of a size less than 1 nm, and a specific surface larger than 800 m 2 /g, preferably larger than 1000 m 2 /g; the reagent being water. The microporous carbon material is preferably a carbon powder material having micropores produced by halogenation of a metal or metalloid carbide. Advantageously, the impregnating of the porous carbon material is made by saturating the material at the boiling temperature of the liquid phase, of the reagent and heating the impregnated carbon material at 800-1200° C., preferably at 900° C., in inert gas atmosphere.
[0014] The invention also relates to a microporous carbon material having a bulk density of at least 0.6 g/cm 3 , a specific surface area of 1000-2200 m 2 /g and a relative specific surface area by pore size showing a maximum peak within the pore size range 0.75-2.1 nm according to the Density Functional Theory, at least 85% of the total surface area resulting from pores with a size less than two times of the peak pore size and less than 10% of the total surface area resulting from pores with a size less than 0.65 nm.
[0015] In a preferred embodiment, less than 1% of the total surface area results from pores with a size less than 0.6 nm.
DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a plot of the characteristic XRD spectrum of inventive carbon powders.
[0017] FIG. 2 is a graph showing an effect of different oxidative treatments on the pore size distribution of the high-surface area microporous carbon (example 1) according to the Density Functional Theory.
[0018] FIG. 3 is a graph showing the pore size distribution of the high-surface area microporous carbon materials of TiC origin according to the Density Functional Theory.
[0019] FIG. 4 is a graph showing a dependence of micro-porosity and specific gravimetric and volumetric EIS capacitance of microporous carbon electrodes of TiC origin in 1M TEMA/acetonitrile electrolyte.
[0020] FIG. 5 is a Ragone Plot of “1000F” unpacked supercapacitors showing the advantage of inventive carbon materials (cation-active electrode from the carbon of example 2).
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] The novelty of method is that microporous carbon is used as molecular sieve for the liquid oxidizing agent, which therefore interacts with a carbon in micropores rather than in meso- and macropores. The liquid oxidant gives at elevated temperatures gaseous reaction products that are removed from the carbon by a flow of inert gas.
[0022] Oxidizing heat-treatment of the microporous carbon pre-impregnated with oxidizing agent produces carbon material with improved pore characteristics, which makes these carbon materials more suitable for use in EDLCs than previously known activated carbon materials.
[0023] These improved characteristics include:
[0024] 1) an increase of the specific capacitance of the carbon
[0025] 2) an increase of the deliverable energy density of the carbon
[0026] 3) a decrease of the electrical resistance of the carbon
[0027] The present invention provides a method for making a highly microporous carbon with dominating pore size of approximately 1 nm. More precisely a carbon with a maximum pore size peak in the small micropore interval end 0.6-0.9 nm for silicon and titanium carbide, a carbon with a peak pore size in the large micropore interval 1.9-2.2 nm with carbides like Mo2C or B4C and a number of tailored carbons within the wider interval 0.75-2.1 by using non-stochiometric metal carbides like TiCl-x where 0.5<x<1.0 for example. A corresponding chemical reaction is expressed by the general equation:
M y C+ yz/ 2X 2 →C+ y MX z
where subscripts are stoichiometrical constants, X 2 corresponds to a halogen, preferably chlorine, and M denotes the metal or metalloid such as Ti, Si, B or Al. The reaction temperature to yield microporous amorphous carbon depends on the precursor carbide and ranges between 400 and 1100° C. Typical X-ray diffraction spectrum of microporous carbon from above-listed carbides is presented in FIG. 1 . The absence of a strong graphite 002 diffraction peak around 2Theta 44 degrees confirms that there is no significant amount of long-range structures in the carbon.
[0028] The dominating size of micropores in carbon is particularly determined by the precursor carbide i.e. the position and the distance from each other of carbon atoms in the carbide crystal lattice. Conductivity of carbon particularly depends on the size and shape of the graphene sheets in carbon particles. The ratio of graphitic and disordered amorphous carbon can particularly be controlled by the halogenation conditions: temperature and catalytic ingredients. More precisely, the micrographitic domains in amorphous carbon are created at slightly elevated reaction temperature compared to that needed to form amorphous carbon or by using catalysts, e.g. metals of the iron subgroup in reaction medium. Typical armorphous microporous carbon formed by chlorinating of relevant metal or metalloid carbides have the pore size maximum peak in the interval 0.75-2.1 nm. The pore size distribution tail to larger pore sizes, as meso pores (larger than 2 nm) is surprisingly low. At least 85% of the pores, based on the total surface area, have been observed to have a size less than two times the pore size maximum peak of the specifically reacted metal or metalloid carbide, see for example FIG. 2 . The pore distribution tail for pores that are much smaller than the peak size contributes to a considerable extent to the measured specific surface area, but these pores deny access for the commercially used electrolyte ions used in batteries or capacitors. Thus, these small pores do not contribute to the battery or capacitor performance. To optimize the performance of such carbon electrodes the tail representing the smallest sized pores must be reduced. According to the invention an increase of the fraction of electrochemically active micropores in carbon is achieved by filling the micropores with the oxidizing reagent in liquid phase at a temperature below that needed to start the oxidation reaction. When water was used as oxidizing agent the liquid phase treatment of carbon powder was executed in boiling water until the carbon particles precipitated. Other gaseous products giving oxidizing liquids such as e g nitric acid, ammonium nitrate and hydrogen peroxide may be used. Other saturation methods such as vacuum or pressurized filling may be used. After that a wet carbon slurry consisting of approximately 100-200% (wt.) of oxidizing liquid per dry carbon is heated to oxidizing temperature in inert gas atmosphere to obtain a carbon material with moderately widened micropores throughout the whole particle. Different oxidation procedures were systematically studied and the following conclusions are drawn.
[0029] Oxidation of microporous precursor carbon by water considerably reduces the fraction of smallest micropores with a diameter less than 0.7 nm. This effect is observed for the carbon pre-saturated in liquid oxidant with subsequent oxidation in argon flow as well as for the carbon subjected to the prolonged oxidation in the flow of gaseous oxidant (cf. FIGS. 2 and 3 ). Significant difference in pore-size distribution of those materials is observed at pore sizes above 0.8 nm. When the heating of water saturated carbon material is executed at oxidizing temperature in argon atmosphere, the fraction of micropores of approximately 1.0 nm is more than 10-20% higher than in the carbon oxidized in the flow of water vapor. The flow method needs more time to influence internal micropores. The price to do this is that the surface of particles became overoxidized with unnecessary loss of mass as a result.
[0030] Comparison of pore volume data and specific surface areas, presented in Table 1, reveals that in the case of carbon materials derived from TiC (samples 1a-c and 3a-c) the inventive oxidizing treatment, more precisely the heating of the water-impregnated carbon at 900° C., results in marginal increase of respective figures compared to the precursor carbon. The comparative oxidation in flow of water vapors oppositely leads to substantial increase in pore volume. These results are well supported by the relative amounts of oxidized carbon material lost as indicated in Table 1. The advantage of the inventive oxidation method is well seen in specific physical and electrochemical data presented in Table 2. From several test series applying different precursor carbon it is obvious that the inventive oxidizing treatment using pre-impregnation of a liquid reagent influences the porosity and consequently the bulk density of the respective electrodes noticeably less than the comparative treatment in a flow of a gaseous oxidant. Furthermore, while the impregnation method does not change the porosity of precursor carbon, it is obvious that the improved specific capacitance at negative potential values (EIS capacitance at −1.4V is presented in Table 2) is achieved mainly by improving the pore sizes to give better adsorption of cations from the electrolyte solution.
[0031] In a carbon having pores being modified in accordance with the method described above less than 10% of the total specific surface area by pore size according to the Density Functional Theory results from pores with a size less than 0.65 nm and less than 1% results from pores with a size less than 0.6 nm.
[0032] The surprising effect of liquid-phase impregnation prior to oxidation can be explained by the microporous carbon, comprising pores of less than 0.7-0.8 nm, behaving as “molecular sieve” for the water molecules. Classical water-sieves used to eliminate moisture from organic solvents and to dry gases usually comprise pores of 0.3-1.0 nm. Although molecular sieves consisting of pores of 0.3 to 0.5 nm absorb water molecules more specifically, the sieves comprising pores of 0.5 to 1.0 nm are sometimes preferred in practical applications because these sieves are more easily regenerated, i.e. dried at elevated temperatures. Water that is adsorbed during impregnation in larger micropores is more likely to evaporate during heat-up of the wet carbon slurry, and hence predominantly such molecules that are absorbed in small micropores participate in the oxidation reaction. The molecular sieve effect of small micropores was particularly confirmed by comparative tests: 1) impregnation of carbon in boiling water for 1 h prior to heat-treatment at 900° C. in Argon flow; 2) repeated impregnation and heat treatment using the same routine; and 3) prolonged impregnation (5-6 h) of carbon prior to heat-treatment. When the effect on the pore size distribution and electrochemical properties of carbon were observed after carbon treatment using the first mentioned step 1, there was no further changes after treatment according steps 2 and 3. However, there is opportunity to use the carbon, which is oxidized by absorbed water molecules as described above, to gain a further sieving effect for another, liquid reagent that has somewhat bigger size polar molecules, which can be absorbed by the enlarged micropores in such a carbon. It is thus possible to gain a further tailoring of micropore size by impregnating the carbon having micropores enlarged by the method described above with the use of water, with a second liquid reagent that has a boiling point below decomposition temperature and decomposes to volatile products comprising at least one component that oxidizes carbon.
TABLE 1 Specific surface (S BET ) according to BET, pore volume according to benzene (W S ) and nitrogen (V tot ) sorption of different carbon materials (1-5). In sample numbers, “a” defines the precursor carbon, “b” - treatment by the inventive method and “c” - the comparative gas-flow oxidation The last column refers to the percentage of carbon lost during oxidative treatment. Carbon. W S S BET V tot Lost Carbon No. [cm 3 g −1 ] [m 2 g −1 ] [cm 3 g −1 ] [%] 1a 0.67 1402 0.72 — 1b 0.68 1555 0.78 4 1c 0.97 1987 1.09 30 2a 0.45 1083 0.54 — 2b 0.56 1320 0.76 17 2c 0.91 1791 0.96 47 3a 0.59 1390 0.71 — 3b 0.67 1503 0.71 15 3c 0.91 1929 0.96 39 4a 0.47 1070 0.49 — 4b 0.56 1200 0.63 54 4c 0.64 1397 0.75 65 5a 0.42 938 0.46 — 5b 0.53 1188 0.59 27 6a 0.44 1031 0.50 — 6b 0.49 1115 0.64 12
[0033]
TABLE 2
Bulk density, thickness and specific capacitance of electrodes from
different precursors, inventive and comparative carbon materials measured
in 1 M TEMA/AN electrolyte. In sample numbers, “a” defines the
precursor carbon, “b” - the treatment by the inventive method
and “c” - the comparative gas-flow oxidation.
Carbon
d
EIS [F/g]
EIS [F/cm 3 ]
Porosity*
No.
[g/cm 3 ]
−1.4 V
+1.4 V
−1.4 V
+1.4 V
[%]
1a
0.66
86
129
57
85
44
1b
0.65
102
132
66
87
44
1c
0.53
116
128
61
68
51
2a
0.77
59
117
45
90
35
2b
0.63
92
134
58
84
35
2c
0.53
105
130
55
69
48
3a
0.73
65
116
47
84
43
3b
0.67
101
138
67
94
45
3c
0.56
107
123
59
69
51
4a
0.74
53
123
39
91
35
4b
0.62
90
128
56
80
35
4c
0.63
102
136
64
85
40
5a
0.85
50
101
42
86
36
5b
0.75
79
107
59
81
40
6a
0.83
43
89
36
74
37
6b
0.68
63
101
43
69
33
*Porosity (cm 3 /cm 3 ) = W s · d · 100%, where W s is pore volume according to Benzene sorption and d is bulk density of the electrode.
[0034] One advantage of the method provided by this invention is that presaturation of microporous carbon material with the oxidizing agent prior to starting the oxidizing reaction yields carbon with very narrow pore size distribution tailored to possess superior sorption behavior of the electrolyte ions. Another advantage of the method is that no external flow of oxidizing gas or vapor is applied. Therefore is avoided the undesirable bulk oxidation of surface layers of carbon particles and the yield of electrode carbon material is much higher compared to that obtained by the conventional carbon activation processes of oxidizing in gas/vapor atmosphere at high temperature. An important advantage is also that the bulk density of conductive and highly microporous carbon material is only slightly reduced during the oxidation process. The high density of electrodes is in fact a key to the high volumetric electrochemical characteristics of supercapacitors.
[0035] Supercapacitors of approximately 1000F were assembled so that the positively charged electrodes of all devices were composed from the precursor carbon 1a made from TiC. Negatively charged electrodes of SC 348, SC 432 and SC 420 were composed from precursor carbon (1a), inventive carbon (1b) and comparative carbon (1c), respectively. It is seen from Table 3 and from the Ragone plot ( FIG. 5 ) that a capacitor including negatively charged electrodes from inventive carbon has considerable advantage in practical applications. For instance, the “10-second” and “5-second” application parameters shown in FIG. 5 are of practical use in automotive applications.
TABLE 3 Examples of electrochemical performance* of prototype electric double layer capacitors according to the present invention. Electrode Specific Specific Energy pair Volume Capacitance Resistance Stored SC # +/− [cm 3 ] [F cm −3 ] [Ω cm 3 ] [Wh L −1 ] 348 1a/1a 84.2 11.67 0.040 10.1 432 1a/1b 97.2 11.93 0.030 10.4 420 1a/1c 97.2 10.70 0.026 9.3 *Data for unpacked cells
EXAMPLE 1
Typical procedure for preparation of microporous precursor carbon material from fine powder of Titanium Carbide
[0036] Titanium carbide (H. C. Starck, grade C.A., 300 g) with an average particle size of 1.3-3 microns was loaded into a quartz rotary kiln reactor and let to react with a flow of chlorine gas (99.999% assay) for 4 h at 950° C. Flow rate of chlorine gas was 1.6/min and rotation speed of reactor tube ˜2.5 rpm. The by-product, TiCl 4 , was led away by the stream of the excess chlorine and passed through a water-cooled condenser into a collector. After that the reactor was flushed with Argon (0.5 l/min) at 1000° C. for 1 h to remove the excess of chlorine and residues of gaseous by-products from carbon. During heating and cooling, the reactor was flushed with a slow stream (0.5 l/min) of argon. Resulting carbon powder (47.6 g) was moved into quartz stationary bed reactor and treated with hydrogen gas at 800° C. for 2.5 h to dechlorinate deeply the carbon material. During heating and cooling, the reactor was flushed with a slow stream of Argon (0.3 l/min). Final yield of the carbon material 1a was 45.6 g (75.9% of theoretical).
EXAMPLE 2
Inventive carbon material by modification of micropores of the carbon of Example 1
[0037] A carbon powder of Example 1 (39 g) was boiled for 2 h in 250 ml water in a round-bottom flask equipped with reflux cooler. After that the carbon was filtered and the paste, containing approximately 2 g water per 1 g carbon was placed in a quartz reaction vessel and loaded into a horizontal quartz reactor heated by a tube furnace. The argon flow was then passed with a flow rate of 0.6 l/min through the reactor and the furnace was heated up to 900° C. using a heat-up gradient of 15°/min. The heating of a carbon at 900° C. was continued in argon flow for 2 h. After that the reactor was slowly cooled to room temperature. The yield of thus modified carbon 1b was 37.5 g (96%).
EXAMPLE 3
Comparative carbon material by gas-phase oxidation of the carbon of Example 1
[0038] A carbon powder of Example 1 (40 g) was placed in a quartz reaction vessel and loaded into horizontal quartz reactor heated by a tube furnace. Thereupon the reactor was flushed with argon to remove air and the furnace was heated up to 900° C. using a heat-up gradient of 15°/min. The argon flow was then passed with a flow rate of 0.8 l/min through distilled water heated up to 75-80° C. and the resultant argon/water vapor mixture with approximate ratio of 10/9 by volume was let to interact with a carbon at 900° C. for 2.5 h. After that the reactor was flushed with argon for one more hour at 900° C. to complete the activation of a carbon surface and then slowly cooled to room temperature. The yield of thus modified carbon 1c was 28 g (70%).
EXAMPLE 4
Typical synthesis of microporous precursor carbon material from Silicon Carbide
[0039] Silicon carbide (H. C. Starck, lot. 3481, 60.2 g) with an average particle size of 1 micron was loaded into a quartz rotary kiln reactor and let to react with a flow of chlorine gas (99.999% assay) for 3.5 h at 1100° C. Flow rate of chlorine gas was 1 l/min and rotation speed of reactor tube ˜2.5 rpm. The by-product, SiCl 4 , was led away by the stream of the excess chlorine and passed through a water-cooled condenser into a collector. After that the reactor was flushed with Argon (0.5 l/min) at 1100° C. for 1 h to remove the excess of chlorine and residues of gaseous by-products from carbon. During heating and cooling, the reactor was flushed with a slow stream (0.5 l/min) of Argon. The yield of the carbon material 2a was 18 g (99.4% of theoretical).
EXAMPLE 5
[0040] A carbon powder of Example 4 (6 g) was treated as described in Example 2. The yield of thus modified carbon 2b was 5 g (83%).
EXAMPLE 6
[0041] A carbon powder of Example 4 (15 g) was treated as described in Example 3. The yield of thus modified carbon 2c was 7.9 g (52.7%).
EXAMPLE 7
Typical preparation of microporous precursor carbon material from Titanium Carbide in fluidized bed
[0042] Titanium carbide (Pacific Particulate Materials, lot 10310564, 1000 g) with an average particle size of 70 microns was loaded into a fluidized bed reactor and let to react with a flow of chlorine gas (99.999% assay) for 4 h at 950° C. Flow rate of chlorine gas was 10 l/min. The by-product, TiCl 4 , was led away by the stream of excess chlorine and passed through a water-cooled condenser into a collector. After that the reactor was flushed with Argon (5 l/min) at 1000° C. for 0.5 h to remove the excess of chlorine and residues of gaseous by-products from carbon. During heating and cooling, the reactor was flushed with a stream (5 l/min) of argon. Resulting carbon powder (190 g) was moved into quartz stationary bed reactor and treated with hydrogen gas at 800° C. for 2.5 h to dechlorinate deeply the carbon material. During heating and cooling, the reactor was flushed with a slow stream of Argon (0.3 l/min). Final yield of the carbon material 3a was 180 g (90% of theoretical). The carbon powder was milled prior electrode manufacturing.
EXAMPLE 8
[0043] A carbon powder of Example 7 (30.3 g) was treated as described in Example 2. The yield of thus modified carbon 3b was 25.7 g (85%).
EXAMPLE 9
[0044] A carbon powder of Example 7 (5.2 g) was milled and treated as described in Example 3, with exception that the oxidation was prolonged by 1 h. The yield of thus modified carbon 3c was 3.2 g (61%).
EXAMPLE 10
Preparation of microporous precursor carbon material from Titanium Carbide using catalyst assisted chlorination
[0045] Titanium carbide (H. C. Starck, grade C.A., 250 g) with an average particle size of 1.3-3 microns was thoroughly mixed with cobalt(II) and nickel(II) chlorides solution in ethanol at room temperature, with the final content of 16 mg of each chloride per gram of carbide. Upon that the ethanol was evaporated. The dry reaction mixture was loaded into a quartz rotary kiln reactor and let to react with a flow of chlorine gas (99.999% assay) for 4.5 h at 500° C. Flow rate of chlorine gas was 1.6 l/min and rotation speed of reactor tube ˜2.5 rpm. The by-products were led away by the stream of excess chlorine and passed through a water-cooled condenser into a collector. After that the reactor was flushed with Argon (0.5 l/min) at 1050° C. for 1 h to remove the excess of chlorine and residues of gaseous by-products from carbon. During heating and cooling, the reactor was flushed with a slow stream (0.5 l/min) of argon. Resulting carbon powder (49 g) was moved into quartz stationary bed reactor and treated with hydrogen gas at 800° C. for 3 h to dechlorinate deeply the carbon material. During heating and cooling, the reactor was flushed with a slow stream of Argon (0.3 l/min). Final yield of the carbon material 4a was 46 g (91% of theoretical).
EXAMPLE 11
[0046] A carbon powder of Example 10 (10.1 g) was treated as described in Example 2. The yield of thus modified carbon 4b was 4.7 g (46%).
EXAMPLE 12
[0047] A carbon powder of Example 10 (10 g) was treated as described in Example 3, with exception that the oxidation was prolonged by 1 h. The yield of thus modified carbon 4c was 3.5 g (35%).
EXAMPLE 13
[0048] Activated carbon cloth (Chemviron FM-1/250) was milled to fine powder (sample No. 5a) prior to further treatments and electrode manufacturing.
EXAMPLE 14
[0049] A carbon powder of Example 13 (3.3 g) was treated as described in Example 2. The yield of thus modified carbon 5b was 2.4 g (73%).
EXAMPLE 15
[0050] Activated carbon pellets (Chemviron WS45) were milled to fine powder (sample No. 6a) prior to further treatments and electrode manufacturing.
EXAMPLE 16
[0051] The carbon powder of Example 15 (5.8 g) was treated as described in Example 2. The yield of thus modified carbon 6b was 5.1 g (88%).
[0000] Characterization of Carbon Materials According to this Invention
[0052] Low temperature nitrogen sorption experiments were performed using Gemini Sorptometer 2375 (Micromeritics). The specific surface area of carbon materials was calculated according BET theory up to the nitrogen relative pressure (P/P 0 ) of 0.2. The total volume of pores was calculated from nitrogen adsorption at relative pressure (P/P 0 ) of 0.95, and the pore size distributions from adsorption characteristics according to the Density Functional theory.
[0053] Adsorption dynamics of benzene vapours was studied at room temperature using computer controlled weighing of the carbon samples in benzene vapours at normal pressure and room temperature in time. The volume of pores that adsorbed benzene under the above-described conditions, was calculated according to the equation
W s =( m 2 −m 1 )/ m 1 ·d C 6 H 6 [cm 3 g −1 ]
where m 1 and m 2 are the initial and final weights of the test-sample, respectively, and d C 6 H 6 is the density of benzene at room temperature.
Method for Preparation of Electrodes
[0054] Carbon powder (10 g) was stirred in ethanol and kept at ˜0° C. for 5 minutes. After that 6% wt. of PTFE (as a 60% suspension in water) was added to the slurry, thoroughly mixed and gently pressed until a wet cake was formed. Thereupon the ethanol was evaporated. The cake was then impregnated with heptane, shaped to a cylinder and extruded by rolling the body in the axial direction of the cylinder. This procedure was repeated until elastic properties appeared. Finally the heptane was removed at ˜75°, the extruded cake rolled stepwise down to the desired thickness, preferably 100-115 microns, dried in vacuum at 170° C. and plated from one side with an aluminum layer of 4±1 microns using Plasma Activated Physical Vapor Deposition.
[0000] Electrochemical Evaluation of Carbon Materials
[0055] The electrochemical tests were performed in a 3-electrode electrochemical cell, using the Solartron potentiostat 1287 with FRA analyzer. Electrochemical experiments were done in an electrolyte comprising 1.0M Triethylmethylammonium tetrafluoroborate (TEMA) in Acetonitrile (AN). During experiments the electrolyte was degassed with Argon. Experiments using constant voltage (CV), constant current (CC), and impedance (EIS) technique were carried out. The region of the ideal polarizabilty was observed between −1.5 to +1.5V (vs. SCE). Discharge capacitance for the negatively and positively charged electrode materials was calculated from the CV and CC plots. The EIS measurements were carried out at AC 5 mV and DC potentials: −1.4V and +1.4V. The EIS capacitance was calculated at frequency of 10 mHz.
[0000] Assembling and Preconditioning of Capacitors
[0056] The electrodes were attached to Al foil of 10 microns thickness (current collector) and interleaved with a separator. An ion-permeable separator paper from Codashi Nippon was used in the present examples. The electrode pairs from positively and negatively charged polarizable electrodes were connected in parallel. The electrode pack thus prepared was placed in a sealed box, kept at 100° C. under vacuum for three days to remove all gases absorbed and then impregnated with electrolyte comprising a solution of a mixture of 0.75M triethylmethylammonium tetrafluoroborate and 0.75M tetraethylammonium tetrafluoroborate in acetonitrile. The electric double layer capacitor (EDLC) cells thus fabricated were cycled within the voltage range of 1.2-2.5 V under constant current conditions.
[0000] Evaluation of Supercapacitors
[0057] The constant current (CC) and constant voltage (CV) tests were carried out using the potentiostat Solartron 1287. The nominal voltage of capacitors was estimated from the CV plots. The capacitance of the supercapacitors using discharge from 2.5V to 0V was calculated from CC plots according to the formula: C=Idt/dE. Electrochemical impedance spectroscopy (EIS) was used to determine the series resistance of the capacitor at frequency 10 Hz (DC=2.5V; AC=5 mV).
[0058] The power, energy performance and respective Ragone plots were calculated using constant resistance test mode and charge/discharge cycling between 2.5V and 1.25V.
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A method to selectively increase in high-density porous carbon materials the pore size of such pores that are too small to be accessible for certain molecules. The method applies to porous carbon materials with a density of at least 0.6 g/cm 3 , with a microporosity of at least 0.45 cm 3 /g as measured by benzene absorption and with pore size distribution where at least 20% of the micropores are of size below 10 A. Specific surface of the precursor carbon material is typically >800 m 2 /g. The method further employs the use of such liquid oxidants for which the precursor material will function as a molecular sieve, water being a preferred such oxidant.
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BACKGROUND OF THE INVENTION
The present invention relates to writing instruments and memorandum paper dispensers. It finds particular application in conjunction with a combined caricature memorandum pen and roll paper dispenser and will be described with particular reference thereto. However, it is to be appreciated, that the invention will also find application in conjunction with felt tip markers, mechanical pencils, and other writing instruments, writing instruments with different caricatures, caricature writing instruments without paper dispensers, writing instruments with other types of paper dispensers, novelty toys, and the like.
Heretofore, pencils, fountain pens, ballpoint pens, and the like have been designed which incorporate a paper holder in the body thereof. Many of the prior art paper holders included ratchet and other complex mechanical feed mechanisms for controlling the feed of the contained memorandum paper. Such mechanisms were relatively expensive to manufacture, subject to early failure, subject to jamming, and the like.
Some prior art paper dispensers incorporated in writing instruments included paper cutting structures. More complex paper cutting structures which utilized moving parts were again mechanically complex, expensive, subject to jamming, and the like. Paper cutters which incorporated a sharp edge were apt to cut the user and can be particularly dangerous to children.
The prior art writing instruments with built-in paper dispensers tended to be relatively bulky and clumsy. The exterior design was relatively dull and unattractive.
Typically, the paper dispensing portion of the prior art writing mechanisms was mounted in the region that a pocket clip would be found on a writing instrument without a paper dispenser. The paper dispensing mechanism in many instances rendered a pocket clip unavailable or inconvenient.
The present invention contemplates a new and improved memorandum writing instrument which overcomes the above-referenced problems and others.
SUMMARY OF THE INVENTION
In accordance with one aspect of the present invention, a combined writing instrument and memorandum paper dispenser has an integrally molded caricature.
In accordance with another aspect of the present invention, a writing instrument with built-in paper dispenser is provided in which the paper dispenser is free of gears and complex parts.
In accordance with one more limited aspect of the present invention, the paper is perforated to facilitate neat clipping of the paper without sharp and dangerous cutting edges.
In accordance with another more limited aspect of the present invention, a friction pad, such as a foam ball, is mounted in frictional contact with a roll of paper to be dispensed to control paper rotation.
In accordance with another aspect of the present invention, a caricature writing instrument is provided in combination with accessories such as a removable pocket clip, glasses, hats, and other humorous accessories.
In accordance with a more limited aspect, the accessories utilize multi-point attachments or contact surfaces.
One advantage of the present invention resides in its simplicity.
Another advantage of the present invention is its eye-catching appearance.
Another advantage of the present invention is that it is child safe.
Still further advantages of the present invention will be apparent to those of ordinary skill in the art upon reading and understanding the following detailed description of the preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may take form in various parts and arrangements of parts, and in various steps and arrangements of steps. The drawings are only for purposes of illustrating a preferred embodiment and are not to be construed as limiting the invention.
FIG. 1 is a front view of a writing instrument in accordance with the present invention;
FIG. 2 is a side exploded view illustrating the parts of FIG. 1;
FIG. 3 is a top view of the shirt clip of FIG. 1 with the top cap removed;
FIGS. 4A and 4B are top and front views of an alternate embodiment of a pocket clip;
FIG. 5 illustrates a foam brake arrangement for braking rotation of the paper roll;
FIG. 6 is a top view with top removed and the face deleted for simplicity of illustration; and
FIG. 7 is a top view with the top removed in which the paper is wound on a core.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIGS. 1 and 2, a pen body has a forward portion or half 10 and a rearward portion or half 12 which are fastened together. A caricature or face 14 is molded into the forward pen half. In the illustrated embodiment, the rear pen half includes no details of the caricature to facilitate its use with a plurality of different caricatures with the same rear half. The rear half 12 of the pen is specially contoured 16 to conform to the user's hand and facilitate holding of the pen. A plurality of alignment or "scrunch" pins are provided between the halves to assure accurate mating during assembly. The halves are preferably fastened together by ultrasonic welding, a non-contact, non-fusion welding technique in which plastics are joined by coalescence or atomic movement stimulated by high frequency vibrations. The rear half 12 defines a cut out region 18 which defines a paper exit slot.
The front pen half and the rear pen half define mating divider wall portions 20, 22 which divide the pen into a nib cavity 24 and a paper cavity 26. A small aperture 28 is defined in the divider walls 20, 22 such that the nib cavity is vented to the atmosphere. This aperture provides for pressure equalization which releases any vacuum which might be created and allows ink to flow from an ink reservoir to a writing ball of a pen nib 30. Alternately, when a felt tip marking pen or nib is utilized, the aperture is eliminated or sealed to insure that solvent based inks do not evaporate from the nib cavity. The nib 30 may be installed prior to the ultrasonic welding process. Alternately, the nib may be pressure fit after the ultrasonic welding process.
The paper cavity 26 extends above the divider wall portions 20, 22 at the lower edge of the slot 18. The paper cavity is generally cylindrical to accommodate a roll 32 of paper. Preferably, the paper is specially perforated 34 to facilitate the neat severance of a piece of note paper. A domed top 36 closes the upper end of the paper cavity. In the preferred embodiment, the top 36 has a tight interference fit with the interior of the front and rear pen halves at the top of the paper cavity. The cap includes grooves extending radially from a top center thereof to assist the user in rotating or manipulating the top to gain access to the paper cavity.
The caricature or face 14 includes integrally molded nose, eyebrows, lips, teeth, split chin, and comical smile. Recesses are defined for receiving eye assemblies 38 with moveable pupils. As the user writes with the pen, the face and particularly the eyes are jostled causing the pupils to move. The eye assemblies have an oval, white, opaque backing over which an oval, transparent eye lens is sealed. The eye lens is spaced from the opaque backing such that a smaller black colored pupil is movably received therebetween. The eyes are fixed with hot melt glue in the preferred embodiment. However, other adhesives or welding techniques may be utilized to permanently fasten the eyes securely into the eye sockets. Once the ink reservoir is depleted, the pen assembly can continue to be used as a novelty item.
A pen cap 40 is a tapered, removable cylinder with only the large end completely open. The small end of the cap is sealed except for a small diameter safety hole. That is, if the cap were inadvertently swallowed by a child and became lodged in the child's throat, the safety hole is of a sufficient diameter to allow the child to breathe until the cap can be safely dislodged. The cap is of sufficient dimension to conceal the pen nib to prevent accidental marking of shirts and protect the point from damage when the pen is dropped. The cap has a plurality of ridges that blend smoothly into the more rounded middle of the cap which aid the user in grasping and removing the cap. The cap fits onto a lower portion of the pen body with the open top fitting below the caricature's chin. Both the lower pen body and the pen cap are tapered to insure a tight, friction fit.
With continuing reference to FIG. 1 and further reference to FIG. 3, a shirt or pocket clip 50 retains the pen in a user's shirt pocket. The pen clip 50 includes a retaining ring 52 from which support bracket means 54 extend. The ring 52 is a plurality of tapered, vertical ribs 56 which engage a lower portion of the cap in tight frictional engagement when the clip is frictionally positioned on the cap. A pair of hands 58 extend downward from the support brackets 54 for engaging a forward surface of the user's shirt pocket. A tie 60 extends downward and forward for engaging the front surface of the user's pocket. The tie may be mounted to the ring 52 or a single support bracket may extend in front of the ring and mount the tie and both hands. The pocket clip with the hands, tie, and pen body utilizes multi-point attachments or contact surfaces. Optionally, as illustrated in FIGS. 4A and 4B, the pocket clip may be connected to the pen body with a C-shaped snap ring 62.
With reference to FIG. 5, a foam ball 70 is optionally inserted under the top 36 and pressed into frictional engagement with the paper roll 32 as the top is inserted. The foam ball provides a friction brake which limits free rotation of the paper roll.
When the optional foam brake 70 is provided, the foam acts as a friction brake to insure that the paper roll does not free wheel and unintentionally unravel paper from the pen. The foam, which is held by compression and friction within the cap, expands and contracts to accommodate rolls of paper of different widths.
With reference to FIG. 6, a specially manufactured paper roll of perforated paper 32 is received in the paper cavity. The user simply withdraws one or more sections of paper, as may be desired, and detaches the paper sheets along the perforation 34. No additional components or cutters are required. When used up, the roll is easily replaced by removing the top 36 and inserting in a new roll of paper. Alternately, the cavity may be used to store small items such as paper clips, stamp roll, rubber bands, push pins, coins, and the like.
As yet another alternative, the top has outward projections 72 which are engaged under an inward peripheral ring 74 at the top of the paper cavity such that the top is frictionally retained to the top of the pen, but free to rotate through a full 360°. Paper is dispensed or retracted by turning the top. The foam ball 70 transmits the rotational force to the paper roll 32. For a more reliable transfer of the rotational force, a paper core 76 may be affixed, such as with glue, in the center of the roll, as illustrated in FIG. 7.
In yet another alternate embodiment, one or both ends of the paper roll are coated with an adhesive material. The adhesive may be applied with a spray, brush, or dip operation. The hardened adhesive would secure the paper edges together preventing the paper from unintentionally unwinding. Yet, the width and the strength of the adhesive is sufficiently small that the paper can be unwound by the operator. Analogously, a permanently tacky adhesive could be applied adjacent to one edge of the paper roll such that as each sheet of paper is ripped off, it can be selectively adhered to a selected object.
Optionally, the paper may also be printed or watermarked with a background design or impression. The background design or impression can be utilized to customize the pen for group purchases, such as club insignia, advertising messages, or the like.
In operation, the replaceable roll of perforated paper is inserted in the paper cavity 26 with a small portion of the leading edge extending through the paper slot 18. The top 36 and, where used, the foam ball 70 are inserted. The operator grasps the exposed, leading edge and withdraws a sheet, thus unwinding the roll. When a perforation 34 and about a half inch of the next sheet are exposed, the user grasps the sheet between the thumb and index finger of one hand and holds the leading edge of the adjoining sheet and pen with the other. The sheet to be removed is then torn from the roll at the perforation. Once the paper sheet is removed, the user makes appropriate notes on the paper with the pen. The sheets can be utilized for writing addresses, telephone numbers, secret messages, notations, reminders, making calculations, drawings, scribblings, and the like. No sharp or jagged edges are required around the paper slot. The sheets are detached with clean borders without the safety hazard to small children.
The pen includes a number of other child or user safety features. Both the top 36 and the pen cap 40 have a small diameter safety hole, such as a 3/16 inch hole. If either the top or the cap becomes lodged in a child's throat, the safety hole serves as an air passage so that the child can continue breathing, albeit in a restricted manner, until the cap or top can be removed. Sharp or jagged edges have been minimized and eliminated. The perforated paper roll eliminates the need for sharp cutting edges. Molded plastic construction also provides for smoother surfaces to prevent cutting and abrasions. The pen is constructed of a non-toxic plastic material, preferably styrene. The eyes are set in eye socket recesses which are surrounded by a circumferential lip. The lip guards the edges of the eyes such that a child cannot pry the eyes from the pen. Optionally, the eyes may be integrally molded with a barbed stem which is ultrasonically welded into apertures in the front half. The tight interference fit between the nib and the pen body insures that the nib cannot be removed by small children. To tighten the fit, small vertical ribs are located on the inside portion of the nose cone aperture of the pen where the pen nib nose frictionally engages the pen body.
In the illustrated embodiment, the hands and necktie are spaced in appropriate distance to retain the clip on the user's shirt pocket. Preferably, the members are sufficiently flexible that at least the hands can be flexed further forward to accommodate clipping the pen to thicker objects, such as a soft cover of a notebook, a baseball cap, a car visor, a jacket lapel, or the like. Alternately, the hands and tie can be placed further forward to accommodate such thicker structures.
With reference again to FIG. 2, one portion of a hook and loop, self-gripping fastener so is connected to the rear pen portion. Another hook and loop self-gripping fastener portion 82 with an adhesive back is provided. A peel off surface 84 of the adhesive back is removed to expose the adhesive and the second portion attached to a wall or bulletin board, adjacent to a telephone, an automobile visor, or other location in which the pen will regularly be stored. The hook and loop self-gripping fastener portions are selectively mated to mount the pen and separated when the pen is to be used. The rear half 12 has a specially contoured surface portion 86 to facilitate attachment of the hook and loop material.
Various other caricatures may also be utilized. These caricatures may include famous people, cartoon characters, popular musicians, performing animals, holiday designs, and the like. Moreover, the caricatures may be of the products of corporations using the pen for advertising and promotional purposes, such as beverage bottles, food or tobacco boxes or containers, and the like.
With reference again to FIG. 1, optionally small holes or bores 90 are provided at selected locations on the caricature for receiving accessories. For example, one or more of the small bores 90 may be provided adjacent the eyes such that a projecting pin 92 from a pair of appropriately sized glasses 94 can be snap fit into an appropriate position on the caricature. Analogously, small bores can be provided for receiving snap pins attached to different sunglasses, ears, noses, lips, teeth, mustaches, wigs, beards, and the like. Bores can also be provided to receive other accessories which customize the caricature to the personality of the user, such as a guitar, football, golf club, cigar, sports equipment, tools, beverage bottle, beach equipment, computer, and the like.
As yet another alternative, the top 36 can have a shape of an accessory such as a cowboy hat, baseball hat, derby, hard hat, football helmet, and the like. Alternately, the cap top may be covered with a fuzzy or furry material to simulate hair.
Various themes can be used on the pocket clip 50, such as baseball glove, hand holding a baseball, and a baseball shirt; a hand holding a football, an empty hand, and a football jersey; a guitar, a microphone, and a pair of hands; an apron and hands; and the like.
The invention has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to those of ordinary skill in the art upon reading and understanding the preceding detailed description. It is intended that the invention be construed as including all such alterations and modifications insofar as they come within the scope of the appended claims or the equivalents thereof.
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A rear pen portion (12) has a notch (18) defined longitudinally therein from a dividing wall (22) to an upper end. A front pen portion (10) has a caricature of a face (14) molded therein and is permanently secured to the rear pen portion. The notch defines a paper access slot longitudinally above the dividing wall. A roll (32) of perforated paper is received in a paper cavity (26) above the dividing wall. A top (36) closes the paper cavity. A cap (40) protects a nib (30) or other writing point from damage and drying out. A pocket clip (50) which is slidably received on the cap has at least a pair of hands (58) which reach over and grasp a user's pocket or other mounting surface.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of German Patent Application No. DE10256144.3, filed Nov. 29, 2002. The disclosure of the above application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The invention relates to a fastening device for an elongated object, in particular a cable tree, having a holder intended for attachment of the elongated object and having an adjacency surface for the elongated object, and having a fastening element connectable to the holder for fastening the holder to a part.
BACKGROUND OF THE INVENTION
[0003] Fastening devices of the kind specified are employed principally for fastening cable trees in motor vehicles. What is meant by a cable tree is a bundle of electrical lines extending in like direction and connected to form a structural unit by winding them with a tape. For fastening to a part, the cable tree is connected to the holder of the fastening device with a tape and then fastened to the part by means of the fastening element attached to the holder. To compensate for manufacturing dimensional deviations, the holder may be made displaceable in a lengthwise direction of the cable tree relative to the fastening element.
[0004] A fastening device of this kind is disclosed in DE 295 10 148 U1. The plate-like holder here comprises an oblong hole. In the oblong hole, a holding pin is inserted, whose fastening end projects from the holder and which has a recess to be engaged by segments of the edges of the oblong hole. For connecting holder and holding pin, the holding pin, fastening end foremost, is pressed into the oblong hole far enough so that the edges of the oblong hole snap into the recess in the holding pin. Only when the two parts have been connected with each other can the holder be connected to the cable tree. No possibility of re-separating the holder and the fastening element from each other is provided.
[0005] Further, U.S. Pat. No. 5,112,013 discloses a device for fastening cable trees in motor vehicles, comprising a tape encircling the cable tree and a fastening element for fastening the tape to a part. On the tape, a cross-piece is provided, extending in a lengthwise direction of the cable tree and insertable in a guide groove of the fastening element, in which groove it is displaceable lengthwise of the cable strand to compensate for dimensional tolerances. Here, the fastening element and tape are connected to each other before installation, and then can no longer be separated from each other.
SUMMARY OF THE INVENTION
[0006] The object of the invention is to create a fastening device of the kind initially mentioned, distinguished by especially simple assembly, and rendering different modes of installation available. This object is accomplished by the invention as specified in the claims.
[0007] In the fastening device according to the invention, for connection of the holder to the fastening element, a plug-in assemblable snap coupling is provided, closable by means of a force directed towards the adjacency surface of the holder. In this way, various advantages are gained in assembly. If the holder is connected to the fastening element before attachment of the cable tree, then the holder can be brought into coupling position in relation to the fastening element, and then the coupling can be snapped in by gentle pressure on the adjacency surface of the holder. Another simple possibility of assembly consists in that the fastening element is placed on the holder from above as it rests on a substrate and then pressed home. Both modes of assembly are readily performed either manually or automatically.
[0008] The conformation according to the invention, however, also permits the holder to be connected to the cable tree separately from the fastening element, the fastening element and the holder being only then plugged together. This may be advantageous since the fastening element projecting from the holder will not interfere when the holder and cable tree are then assembled. The conformation according to the invention is of advantage further if separate installation of the fastening element and the cable tree in the vehicle is desired. Thus, in some applications, it may be advantageous to install a number of fastening elements in the vehicle manually or with a robot using suitable setting devices, and then connecting the cable tree, already provided with holders, to the set fastening elements by plugging the snap couplings together. Since the closing of the snap couplings requires less expenditure of effort than the setting of the fastening elements, the installation of the cable tree can be simplified by such a procedure.
[0009] Another advantage of the fastening device according to the invention lies in the possibility of combining different sizes or types of holder with the fastening element in the manner of a modular principle. Thus, for example, fastening elements for different hole sizes in the part may be produced and finished with the same holder design. Likewise, different conformations of the holder may be fastened to the same construction of fastening elements. In this way, numerous requirements of applications can be met with low tool costs.
[0010] According to another aspect of the invention, the snap coupling is so configured that it can be released again by means of a tool after locking. In this way, the cable tree can be simply pulled for repairs without destroying or damaging the fastening device.
[0011] In yet another aspect of the invention, the snap coupling forms a connection displaceable in a lengthwise direction of the cable tree between the holder and the fastening element. By this displaceable connection, dimensional deviations between the position of two neighboring holders and the position of the fastening locations on the part can be compensated.
[0012] Preferably, the one part of the snap coupling comprises an undercut recess and the other part comprises at least one spring pin insertable in the recess, having a lateral projection snapping into the undercut of the recess. The recess, in the manner of an oblong hole, may have a greater extent in a lengthwise direction of the holder than the spring pin insertable in the holder, in order thereby to make possible a displacement of the holder relative to the fastening element.
[0013] A preferred embodiment provides that the holder, on its under side away from the adjacency surface, comprises two fingers projecting downward with catches projecting laterally. Each finger may be arranged on an elastically deformable web of the holder, formed by two parallel slits. This conformation makes possible a simple forming mold for making the holder, and ensures a suitable flexibility of the fingers.
[0014] In the position connected to the fastening element, the holder may be secured against twisting relative to the fastening element by means for positively interlocking geometrically. In this way, the snap coupling is relieved and maintenance of a defined holder position is assured. Preferably, for security against rotation, the fastening element comprises two ribs embracing the holder on its long sides.
[0015] To facilitate assembly, the holder displaceable relative to the fastening element may be retainable in an intermediate location, whence a displacement in opposed directions with defined exertion of force is possible. For this purpose, the holder or the fastening element may have projections on which in each instance, the other part is supported and which are surmountable by an elevated force of displacement.
[0016] The fastening element, according to the invention, comprises a holding pin on the side away from the holder, anchorable in a hole of a part, preferably with the aid of a spring catch element. For support on the part, the fastening element may comprise a flange encircling the fastening end of the holding pin joined to the fastening element. The peripheral edge of the flange may be provided further with a sealing lip, preferably of softer material. The coupling part of the fastening element preferably comprises a rectangular frame having a rectangular aperture, the longer sides of the frame being connected to the flange by struts extending transverse to the plane of the frame. The struts create a clearance between the frame and the flange, accessible on the short sides of the frame and thus permitting release of the coupling parts snapped into the frame with the aid of a tool.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The invention will be illustrated below in more detail in terms of an embodiment represented by way of example in the drawings, in which:
[0018] [0018]FIG. 1 is a perspective view of a holder for a fastening device for an elongated object according to a preferred embodiment of the present invention;
[0019] [0019]FIG. 2 is a perspective view of a fastening element of the present invention;
[0020] [0020]FIG. 3 is a perspective side view of the interconnected parts of the fastening device of the present invention; and
[0021] [0021]FIG. 4 is an oblique perspective plan view of the interconnected parts of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] [0022]FIG. 1 shows the holder 1 of the fastening device. The holder 1 consists of an essentially rectangular plate, articulated into a middle segment 2 and two end segments 3 forming the narrow ends. The end segments 3 are each attached to the middle segment 2 by a blunt-edged elevated step 4 on top of the holder 1 . Consequently, the top of the middle segment 2 , viewed from above, lies deeper than the adjacency surfaces 5 , formed by the tops of the end segments 3 , for the cable tree to be fastened to the holder 1 . The steps 4 facing each other on top of the holder 1 correspond to back-to-back steps 6 on its under side. Opposed to the steps 6 , there are projections 7 configured at the outer corners of the end segments 3 . The steps 6 and the projections 7 serve to secure the lateral position of tapes slung or wound about the cable tree and around the end segments in order to fasten the former. For better adaptation of the holder 1 to the peripheral contour of a cable tree, the end segments 3 and the middle segment 2 are provided with a curvature concave upwards, whose axis of curvature lies on the longitudinal centerline of the holder 1 .
[0023] For fastening the holder 1 , the middle segment 2 on its under side comprises two spring fingers 8 projecting downward. The fingers 8 are arranged symmetrical to a longitudinal median plane dividing the holder 1 , and at their opposed sides, they each have a catch 9 with a locking surface 10 facing the middle segment 2 and a ramp surface 11 turned away from the middle segment 2 . The fingers 8 together form a first coupling part 12 of a two-part snap coupling.
[0024] The fingers 8 are elastically deformably connected to the middle segment 2 of the holder 1 . As may be seen in FIG. 3, the middle segment 2 comprises four parallel slits 13 piercing it completely. The slits 13 form two outer webs 14 and a middle web 15 . A finger 8 is attached to each of the outer webs 14 . The webs 14 form elastically deformable elements that yield springingly when a force bringing them closer to each other is applied to the free ends of the fingers 8 . This makes possible a springing compression of the fingers 8 for plugging the snap coupling together.
[0025] [0025]FIG. 2 shows a fastening element 16 intended for connecting the holder 1 to a part, in particular of sheet metal, not shown in detail. The fastening element 16 has a holding pin 17 insertable in an opening of a part and there retainable by means of a catch element 18 . On the holding pin 17 , a plate-like flange 19 is arranged. The flange 19 serves to support the fastening element 16 in the part. It may in addition be provided with an annular sealing lip 20 of softer material, in order to be able to tightly close the opening in the part that receives the holding pin.
[0026] On the side away from the holding pin 17 , a rectangular frame 22 is fastened to the flange 19 by means of two struts 21 , said frame extending essentially in a plane parallel to the flange 19 . The frame 22 forms the second coupling part of the two-part snap coupling 23 . The struts 21 are arranged on the longer sides of the frame 22 . The frame 22 comprises a rectangular framed opening 24 . The width of the framed opening 24 is smaller than the distance between the struts 21 . In this way, on the under side of the longer sides 25 of the frame 22 , towards the flange 19 , an adjacency surface 26 is formed, receding in the manner of an undercut relative to the framed opening 24 and intended for adjacency of the locking surfaces 10 with the catch projections 9 of the fingers 8 .
[0027] The width of the framed opening 24 corresponds substantially to the distance between the sides, turned away from each other, of the fingers 8 of the holder 1 . In the framed opening 24 , symmetrical with respect to the center of the opening, projections 27 are attached to the sides 25 , their distance being somewhat greater than the width of the fingers 8 measured in a lengthwise direction of the holder 1 . On their outer sides turned away from each other, the legs 25 bear parallel ledges 28 , whose spacing corresponds essentially to the width of the middle segment 2 of the holder 1 . The ledges 28 are intended to secure the holder 1 against rotation.
[0028] For assembly with the fastening element 16 , the holder 1 is placed on the frame 22 with longitudinal axis oriented parallel to the latter, and pressed against the fastening element 16 by fingers 8 turned towards the framed opening 24 . The fingers 8 thus slide over the sides 25 by the ramp surfaces 11 of the catches 9 , and are thereby pressed together. As soon as the holder 1 reaches the position shown in FIG. 4 and rests on the frame 22 , the sides 25 release the catches 9 , whereby the latter snap into the locking position shown in FIG. 4, in which their locking surfaces 10 rest against the adjacency surfaces 26 and fix the holder 1 to the fastening element 16 . The ledges 28 thus laterally embrace the middle segment 2 and thereby secure the holder 1 against rotation.
[0029] The holder 1 may be connected to the fastening element 16 either centrally or, insofar as the length of the framed opening 24 permits, eccentrically. If the holder, as shown in FIGS. 3 and 4, is mounted centrally, then it is secured in that position by bearing of the fingers 8 on the projections 27 . By a force acting on the holder 1 in lengthwise direction, however, the supporting resistance of the projections 27 can be overcome, and the holder 1 shifted relative to the fastening element 16 . In this way, deviations of location between the position of the holder 1 on a cable tree and the opening in the part accommodating the fastening element 16 can be compensated.
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The invention relates to a fastening device for an elongated object, in particular a cable tree, having a holder ( 1 ) intended for attachment of the elongated object and an adjacency surface ( 5 ) for the elongated object, and having a fastening element ( 16 ) connectable to the holder ( 1 ) for fastening the holder ( 1 ) to a part. For connection of the holder ( 1 ) to the fastening element ( 16 ), a plug-in assemblable snap coupling is provided, closable by a force directed against the adjacency surface ( 5 ) of the holder ( 1 ).
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present disclosed technology relates generally to a system for steering and operating forklift trucks, and more specifically to steering and operating a narrow-aisle, articulated forklift truck using a hydraulic actuator.
2. Description of the Related Art
A typical narrow-aisle articulated forklift truck (or “forklift”) comprises front and rear chassis sections each having a pair of wheels on a respective common axis. The rear wheels provide drive-motion to the forklift truck, while the front wheels are non-driven and steer the truck. The chassis sections are pivoted together about a vertical axis so that the front chassis section, including a mast, can be turned at an angle of approximately 90° each way (preferably 180°-205° total range of movement) relative to the rear chassis section to the allow the truck to insert loads into, and remove loads from, the faces of the aisle.
Without limitation on the generality of useful applications of the present invention, an exemplary use consists of loading and unloading palletized inventory in narrow-aisle facilities, such as warehouses. Steering with the front wheels is generally preferred for such applications because rear-wheel steering forklifts generally have relatively large turning radii and are thus ill-suited for loading and unloading storage bins in narrow aisles, such as those found in many warehouses and other storage facilities. Narrow-aisle, articulated forklift trucks, on the other hand, allow the mast-portion of the forklift to turn independently from the body of the truck, which allows the operator to load or unload material positioned perpendicular to the aisle along which the truck is traveling. Typical narrow-aisle trucks are capable of rotating the front chassis mast section at least 90° each way relative to a direction of travel along a warehouse shelf aisle.
A problem condition associated with many previous articulated forklift trucks is the articulating joint between the front and rear chassis sections. An electric or hydraulic motor is typically used to steer the forklift truck by rotating the front chassis section relative to the rear section. Because the front chassis includes the mast, which is subjected to heavy loads, the rotation motor and connection are high-wear components which can be expensive to replace. What is needed is an articulated forklift truck capable of maneuvering in narrow aisles and handling heavy loads while minimizing the wear on the articulating component of the truck.
Heretofore there has not been a forklift truck embodying the capabilities of the invention presented herein.
SUMMARY OF THE INVENTION
Disclosed herein in an exemplary embodiment is a narrow-aisle articulated forklift truck including front- and rear-chassis portions. A hydraulic actuator capable of allowing rotation through approximately 180°-205° joins the two portions and is capable of absorbing the high-wear forces of loads applied to the front-chassis portion.
The hydraulic actuator provides a connection between the front and rear chassis portions, allows the front-chassis portion to rotate about the actuator, and provides a means for hydraulic power to pass through the actuator to the forklift truck mast, allowing the mast to tilt and the fork to raise and lower while protecting the hydraulic hoses.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings constitute a part of this specification and include exemplary embodiments of the disclosed subject matter illustrating various objects and features thereof, wherein like references are generally numbered alike in the several views.
FIG. 1 is an isometric view of an articulated forklift with a hydraulic steering actuator comprising a preferred embodiment of the present invention.
FIG. 2 is a side elevational view of the preferred embodiment of the present invention.
FIG. 3 is a top-down plan view of the preferred embodiment of the present invention demonstrating the rotational capabilities of the front-chassis portion.
FIG. 4A is an isometric view of the hydraulic steering actuator.
FIG. 4B is another isometric view of the hydraulic steering actuator.
FIG. 5A is an exploded isometric view of the hydraulic steering actuator and a mounting bracket used for connecting the actuator to the front-chassis portion of the forklift.
FIG. 5B is another isometric view of the hydraulic actuator and the mounting bracket shown in FIG. 5A .
FIG. 6 is a sectional view of the hydraulic actuator taken generally a long line 6 - 6 in FIG. 5B .
FIG. 7 is an elevational view showing the connection of the mounting bracket and the hydraulic actuator in the direction of arrow 7 in FIG. 6 .
FIG. 8A is an exploded isometric view of the hydraulic actuator and the mounting block used for connecting the actuator to the rear-chassis portion of the forklift.
FIG. 8B is an isometric view of the hydraulic actuator and mounting block of FIG. 8A .
FIG. 9 is a side elevational view of the connection of the mounting block and the hydraulic actuator.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
I. Introduction and Environment
As required, detailed aspects of the disclosed subject matter are disclosed herein; however, it is to be understood that the disclosed aspects are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art how to variously employ the present invention in virtually any appropriately detailed structure.
Certain terminology will be used in the following description for convenience in reference only and will not be limiting. For example, up, down, front, back, right and left refer to the invention as oriented in the view being referred to. The words “inwardly” and “outwardly” refer to directions toward and away from, respectively, the geometric center of the embodiment being described and designated parts thereof. Forwardly and rearwardly are generally in reference to the direction of travel, if appropriate. Said terminology will include the words specifically mentioned, derivatives thereof and words of similar meaning.
A preferred embodiment of the present invention is an articulating forklift truck 2 comprised of a front-chassis portion 5 and a rear-chassis portion 3 . The forklift truck 2 is designed to operate along narrow aisles by loading inventory or items located perpendicular to the forklift truck's path. The front-chassis portion 5 and the rear-chassis portion 3 are joined at a pivot point formed by a hydraulic actuator 8 bolted to a mounting block 78 and a mounting bracket 10 . An example of a suitable hydraulic actuator 8 includes the T20 Series Hydraulic Actuator manufactured by Helac Corporation of Enumclaw, Wash. Such a hydraulic actuator 8 operates as a complete steering and bearing system in a single, rugged component. The actuator 8 is adapted for handling the high-wear loads placed upon it when inventory is lifted by the forklift truck 2 .
II. Articulating Forklift Truck 2
Referring to the drawings in more detail, the reference numeral 2 generally refers to the articulating forklift truck used for loading and unloading inventory along narrow aisles. Articulating forklift trucks are used in such circumstances because the front-chassis portion 5 of the forklift truck 2 is capable of rotating 90° or more to the right or the left of the path traveled by the forklift truck. The forklift mast 6 and the fork blades 4 are mounted to the front-chassis portion 5 and, when rotated, can lift or unload inventory without adjusting the travel path of the forklift truck 2 .
FIGS. 1-3 generally show an articulating forklift truck 2 in a preferred embodiment, including the front-chassis portion 5 and the rear-chassis portion 3 . The rear-chassis portion 3 is further comprised of an operator's seat 20 , a roll cage 22 , steering controls (steering wheel) 24 and mast and fork controls 26 . A mounting block 78 with upper and lower mounting flanges 80 , 81 is located below the operator's seat 20 and the steering controls 24 . A steering and control subsystem 12 , a hydraulic subsystem 13 , and a computer processor 14 are mounted within the rear-chassis 3 for coordinating control signals from the operator to the forklift truck 2 . For example, the hydraulic steering and control subsystem 12 can differentially drive the rear wheels 15 for effectively operating the forklift 2 in a zero turning radius (“ZTR”) mode of operation. Thus, the forklift front portion 5 can be advanced towards a line of shelves even when the front wheels 17 are turned at 90° right angles to the longitudinal axis. The control subsystem 12 can automatically meter hydraulic fluid to the steering actuator 8 and otherwise control the drive train of the forklift 2 in various operating modes, such as straight-line driving, turning and store-and-retrieve warehouse shelving procedures.
The front-chassis portion 5 is further comprised of a mast 6 and forks 4 vertically adjustably mounted thereon. A fork cable assembly 30 is mounted atop the mast 6 and connected to the forks 4 . The cable assembly 30 is controlled via the fork controls 26 and is capable of raising and lowering the fork 4 along the mast 6 . A mounting bracket 10 is connected to the rear of the mast 6 . Two mast tilt hydraulic cylinders 28 are mounted on either side of the mounting bracket 10 and connected to the mast 6 . The tilt cylinders 28 allow the mast 6 to be tilted forward or backwards, allowing positioning of the forks 4 .
A central portion 7 joins the front-chassis portion 5 to the rear-chassis portion 3 . The central portion 7 is comprised primarily of a hydraulic actuator 8 bolted to the mounting block 78 and the mounting bracket 10 . A sensor system 31 is attached to the mounting block 78 and the hydraulic actuator 8 and includes a rotation sensor 16 for determining the rotation degree of the front-chassis portion 5 relative to the rear-chassis portion 3 , and a hydraulic sensor 18 for determining the tilt of the mast, along with the other hydraulic functions of the forklift truck 2 .
As shown in FIG. 3 , the front-chassis portion 5 is rotatable about the hydraulic actuator 8 . The rotation radius R indicates the rotational path of the front-chassis portion 5 as it rotates about the hydraulic actuator 8 . The rotation path allows for at least a 90° rotation of the front-chassis portion 5 to either side of the forklift truck 2 longitudinal axis.
FIGS. 4A and 4B show the hydraulic actuator 8 in more detail. The actuator 8 is comprised of an actuator body 36 , an actuator upper flange 40 , a lower flange 41 , and a rotator shaft 38 . Each actuator flange 40 , 41 includes a hydraulic inlet/outlet port 34 and a plurality of bolt holes 32 . The bolt holes 32 allow the actuator 8 to be physically bolted to the mounting block 78 via a plurality of mounting bolts 54 .
The upper actuator flange 40 includes a first port 42 , and the lower actuator flange 41 includes a second port 43 . The first and second ports 42 , 43 include plugs which can be loosened and tightened to adjust the rotation angle of the actuator. When constructing the forklift truck 2 , the plugs located in the first and second ports 42 , 43 are loosened. The actuator 8 is rotated 90° so that it is perpendicular to the mounting bracket 10 . The plugs located in the first and second ports 42 , 43 are then re-tightened. This allows the forklift front chassis portion 5 to rotate through 180° or more for sideloading capability.
FIGS. 5A-7 show the connection of the hydraulic actuator 8 to the mounting bracket 10 . As shown in FIG. 5A , the mounting plate 10 is further comprised of a bracket plate 44 including a lower mounting projection 60 with a lower mounting projection opening 66 , a bracket base protrusion 64 with a bracket base protrusion opening 70 , four tilt-hydraulic connection flanges 50 each including a hinge receiver 52 , two recesses 46 each including two hydraulic access receivers 48 , and four bolt-holes 58 . An upper mounting projection 62 includes an upper mounting projection opening 68 which receives the upper stem of the hydraulic actuator rotator shaft 38 . An upper locking assembly 72 secures the upper mounting projection 62 to the hydraulic actuator 8 .
The upper mounting projection 62 bolts to the bracket plate 44 via four mounting bolts 54 and associated washers 56 . The lower stem of the rotator shaft 38 is secured within the lower mounting projection opening 66 with a lower locking assembly 74 . As shown in FIG. 5B , with the hydraulic actuator 8 mounted to the mounting bracket 10 , the hydraulic inlet/outlet ports 34 are accessible facing out from the bracket 10 . A tilt hydraulic cylinder 28 is connected to each pair of connector flanges 50 via a hinge connection 76 .
FIGS. 8A-9 demonstrate the connection of the hydraulic actuator 8 to the mounting block 78 . As shown in FIG. 8A , the mounting block 78 includes an upper mounting flange 80 and a lower mounting flange 81 , each including a plurality of bolt holes 82 and a hydraulic port access 84 . Mounting bolts 54 connect the hydraulic actuator 8 to the mounting block 78 through the flange bolt holes 82 and the actuator bolt holes 32 . A sensor system 31 comprising a sensor body 86 and a sensor arm 88 is mounted to the top face of the mounting block 78 . The arm 88 interacts with the hydraulic actuator 8 to determine the rotation angle of the actuator 8 .
As shown in FIGS. 8B and 9 , hydraulic hoses 90 are fed through the hydraulic port accesses 84 and connected to the hydraulic actuator's hydraulic inlet/outlet ports 34 . The hydraulic hoses 90 connect to the hydraulic subsystem 13 located in the rear-chassis portion, and travel through the actuator 8 to the various hydraulically powered components located in the front-chassis portion 5 .
III. Operation of the Hydraulic Steering Actuator 8 and the Forklift Truck 2
In an embodiment of the present invention, an operator positioned in the operator's seat 20 in the rear-chassis portion 3 controls the motion of the forklift truck 2 by powering the rear wheels 15 . Using the steering controls 24 , the operator turns the front-chassis portion 5 by rotating the hydraulic actuator 8 , turning the front wheels 17 and directing the forklift truck 2 in the process.
The operator also controls the tilt of the mast 6 and the lift of the fork 4 using the fork controls 26 . The tilt of the mast 6 is controlled through the hydraulic system. The hydraulic hoses 90 connect to the hydraulic actuator 8 , from which the hydraulic tilt cylinders 28 are fed. These hydraulic cylinders 28 allow the entire mast 6 and the fork 4 to tilt away from or towards the rear-chassis portion 3 of the forklift truck 2 . If the operator requires the fork 4 to be maneuvered beneath a piece of inventory, the operator can tilt the mast and the fork 4 forward, guide the truck toward the object, and then tilt the mast 6 and the fork 4 backwards, resulting in the inventory object being lifted from the ground and onto the fork 4 .
The rotator shaft 38 of the hydraulic actuator 8 is drivingly connected to and causes the front-chassis portion 5 to rotate according to the steering wheel movements by the operator. The upper and lower locking assemblies 72 , 74 create a rigid connection between the rotator shaft 38 and the upper 62 and lower 60 mounting projections of the mounting bracket 10 . An example of the locking assemblies 72 , 74 is the Ringfeder Locking Assembly RfN 7013 manufactured by Ringfeder GMBH of Germany. The forklift front wheels may optionally turn in the same direction as the actuator rotator shaft 38 to assist in turning the forklift truck 2 .
It will be appreciated that the articulated forklift truck can be used for various applications not described herein. Moreover, the articulated forklift truck can be compiled of additional elements or alternative elements to those mentioned herein, while providing similar results.
It is to be understood that while certain aspects of the disclosed subject matter have been shown and described, the disclosed subject matter is not limited thereto and encompasses various other embodiments and aspects.
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A hydraulic steering actuator system for a forklift with front and rear sections includes a hydraulic steering motor. The forklift front section includes a mast mounting a pair of fork blades and a pair of wheels. The forklift rear section mounts a pair of drive wheels. The forklift front and rear sections are connected by an articulated connection with a vertical rotational axis. The steering actuator motor driveshaft extends generally along the vertical rotational axis. First and second actuator mounting brackets are connected to the forklift front and rear sections respectively. One of the mounting brackets includes upper and lower locking assemblies locking the hydraulic steering motor driveshaft whereby torque applied to the steering motor is transmitted to the articulated connection for turning the forklift front section relative to the forklift rear section. The range of motion is preferably 180°-205° for accommodating side-loading operations from relatively high storage shelves, e.g. in narrow-aisle warehouses.
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INTRODUCTION
This invention relates generally to communications systems and, more particularly, to communications system receivers for use in receiving signals which have been transmitted through a dispersive transmission medium, such as a fading multipath medium.
BACKGROUND OF THE INVENTION
In fading multipath transmission systems, such as those characterized by troposcatter communication links, for example, the transmitted signal is conveyed through the multipath medium along a plurality of decorrelated paths so that a plurality of signals, each representing the transmitted signal but having varying energy contents, are received. Fading effects in such communication systems are reduced when each of the several diversity channels conveying a given signal have decorrelated fading characteristics. Accordingly, a plurality of diversity receivers are used and one or more of the diversity receiver channel signals having the greatest signal strengths are selected as most probably carrying a reliably detectable message signal. In another diversity approach, a composite signal is generated from a combination of all of the received diversity channel signals. In the latter case the diversity channel signals may be appropriately weighted before they are combined. A suitable signal processing technique which has heretofore been utilized in providing appropriate signal weights has been based on a mean-square error criterion, particularly with the transmission of digital data, the weighting factors being utilized to equalize the multipath distortion in each diversity channel to substantially remove any intersymbol interference and to provide proper diversity combining.
DISCUSSION OF THE PRIOR ART
Diversity channel receiver systems using such approach have been described in the prior art. One such system, for example, has been described in U.S. Pat. No. 3,879,664, issued on Apr. 22, 1975 to Peter Monsen. As disclosed therein, a high speed digital communications receiver is used in a diversity receiver system in which a predetection combiner of the receiver utilizes a forward adaptive transversal filter equalizer, having a plurality of weighting sections, in each of the diversity channels for processing each of the received bandpass diversity signals prior to demodulation. The combined weighted output from the predetection combiner is then demodulated and the data therein appropriately reconstructed and an error signal generated. The error signal is modulated and limited for use in adaptive control circuitry which provides appropriate adaptive weighting signals for use in the processing of the received diversity signals at each of the forward filter equalizers. The unmodulated error signal is used in a backward adaptation control circuit for providing appropriate adaptive weighting signals for use in a single backward filter equalizer which suitably processes the reconstructed data to form a cancellation signal which is used to eliminate intersymbol interference and source correlation effects in the demodulated combined weighted output signal. A suitable timing system permits the receiver clock to follow transmitter clock variations and a novel automatic gain control system at the input IF receiver amplifiers is used to reduce the dynamic range requirements of the forward filter weight components.
Such a system provides an effective implementation of an adaptive forward transversal filter equalization system useful with or without a backward filter equalizer and which provides advantages over the systems used or suggested prior thereto, as discussed in the Monsen patent. However, in many applications it may be desirable to further improve the structure and operation thereof so as to reduce the costs thereof and to improve the ease with which such a system can be manufactured.
A disadvantage of the system described in the above-referenced Monsen patent is that the tapped delay lines required in each diversity channel must operate at intermediate frequencies (IF) so that they are normally implemented by utilizing surface wave tapped delay line devices. Such devices are relatively high loss devices at the intermediate frequencies of the radio equipment and, since they are not readily available commercially, they must often be specially made for the application in which they are to be used. For such reason and further because a number of such tapped delay line devices are required, one for each diversity channel, the overall cost thereof becomes relatively high.
Moreover, in the system shown in the above-referenced Monsen patent a relatively large number of large gain-bandwidth product RF amplifiers are required, pairs of such amplifiers, for example, each having a gain of about 30dB, normally being utilized at each delay line tap in each channel. A similar pair thereof is also needed prior to demodulation of the combined signals. Such requirements further increase the costs of manufacture and maintenance of the system and tend to reduce the reliability of the operation thereof in the field.
SUMMARY OF THE INVENTION
In order to overcome the above disadvantages, the system of the invention is arranged to perform the required time delay operation at baseband frequency, rather than at IF frequency, while the complex multiplication and correlations needed for weighting purposes can still be performed at IF frequencies utilizing simple PIN diode multipliers. Such an arrangement in accordance with the invention reduces the total number of tapped delay lines which are required. Further, the delay line operation performed at baseband signal frequency results in much less loss than that incurred at IF frequencies. Accordingly, the number of large gain-bandwidth RF amplifiers required for the overall system operation is considerably reduced over that previously required in the specific implementations of the system described in the above-referred-to Monsen patent.
DESCRIPTION OF THE INVENTION
The system of the invention can be described in more detail with the assistance of the accompanying drawings wherein
FIG. 1 shows a broad block diagram of a high speed digital communications receiver utilizing a forward filter equalizer and diversity combiner;
FIG. 2 shows a more specific block diagram of a portion of a forward filter equalizer and diversity combiner of the prior art which is useful in the system of FIG. 1;
FIG. 3 shows a more specific block diagram of a portion of a forward filter equalizer and diversity combiner in accordance with the invention, which is also useful in the system of FIG. 1; and
FIG. 4 shows a more specific block diagram of another portion of the forward filter equalizer and diversity combiner in accordance with the invention.
An overall system utilizing a forward transversal and filter equalizer is shown in broad block diagram form in FIG. 1. The system shown therein, for example, could be specifically implemented in accordance with a system of the type described in the aforesaid U.S. Pat. No. 3,897,664 issued to Peter Monsen. Thus, a plurality of diversity channels, identified as "Channel 1" through "Channel D" supply a plurality of input signals to intermediate frequency (IF) amplifiers 10 at each channel. As discussed in the aforesaid Monsen patent, a suitable automatic gain control (AGC) system essentially fixes all the IF amplifier gains according to the strongest of the receiver signals. The signals from IF amplifiers 10 are supplied to a forward transversal filter equalizer, diversity combiner and demodulator 11. The output thereof, at baseband frequency, is then supplied to a data detector, error generator and backward transversal filter equalizer 12 for producing an output data signal. The error generator provides an error signal which is appropriately modulated and fed back to the forward filter equalizer for use in generating the desired weighting signals for use therein. An unmodulated error signal can be used for providing appropriate weighting signals for use in the backward filter equalizer.
While a specific implementation of the portions 11 and 12 of the system shown in FIG. 1 is described in detail in the above-mentioned Monsen patent, the forward filter equalizer and diversity combiner portion of such system is effectively reproduced in simplified block diagram form in FIG. 2 here, two channels of which are representatively depicted.
As can be seen therein, the input signal from the IF amplifier of each channel is supplied to a tapped delay line 15 shown as having time delays 15 1 through 15 N each identified as equal in a preferred embodiment to a time delay of τ/2, where τ/2 is one-half the data symbol interval as discussed in the Monsen patent. The signals at each tap are appropriately amplified by amplifiers 16 which may, in an appropriate system, be relatively large gain-bandwidth RF amplifiers having gains of approximately 30dB and bandwidths much larger than the signal in order to insure phase stability with temperature. The amplifiers are identified by the representations A ij and B ij respectively, where "i" designates the channel and "j" designates the delay line tap. Such amplifiers are required because of the relatively high losses incurred in the time delay device at the intermediate frequency involved. For example, such tapped delay lines may be in the form of tapped surface wave delay line devices which, at such frequencies, are known to produce relatively high losses along the delay line. Accordingly, the gains of amplifiers 16 are suitably arranged to provide a sufficient signal level at complex multipliers 17.
The tapped signals are appropriately weighted by weighting signals (identified as W ij ). Such weights are suitably controlled as described in the patent via weight control circuitry responsive to the error signal fed back from the error generator circuitry and to the time delayed received input signal which provides for suitable time alignment of the error signal and the received signal. The weighted signals at the outputs of multipliers 17 are appropriately combined at summing devices 18, the outputs of all of the channels being suitably combined at combiner 19. The latter combined signal is amplified by a pair of large gain-bandwidth RF amplifiers 20 and 21, the amplified signal thereupon being demodulated by demodulator 22 to supply the required signal at baseband frequency to the data detector and error generator of the system as shown in FIG. 1. The data detector, error generator and backward filter equalizer are all disclosed in detail in the aforesaid Monsen patent.
As seen in FIG. 2, a separate tapped delay line is required for each of the input channels and, because of the high losses incurred therein, sufficient signal amplification is required at each of the taps prior to the weighting of the tapped signals. Further, appropriate amplification is required prior to demodulation which converts the signal from IF to baseband frequency. For a four-channel system (D=4) and using a delay line having three taps (N=3), four delay line devices and twenty-six large gain-bandwidth IF amplifiers are required. As discussed in the Monsen patent, the signals present in FIG. 2 are complex in nature, i.e., such signals have real and imaginary components, although for simplicity only a single signal line is depicted in the drawings.
A significant reduction in complexity and cost compared to the system shown in FIG. 2 can be achieved when using a system in accordance with the invention, a preferred embodiment of which is shown in block diagram form in FIG. 3 for the portion of the overall system of FIG. 1 which corresponds to that depicted in FIG. 2. As seen in FIG. 3, the signal from the IF amplifier of each channel is supplied to a signal splitter 25 which supplies N such signals to each of a plurality of N complex weighting multipliers 26. Thus, the input signal from channel 1 is supplied to N multipliers 26 1 , through 26 1N , the signal from channel 2 to multipliers 26 21 through 26 2N (not shown), and so on, to the signal from channel D which is supplied to multipliers 26 D1 through 26 DN . The input signal to each channel is also supplied through a time delay device 27 to a further signal splitter 28 which supplies such time delay signal to each of a plurality of N weight control complex correlators 29, in a similar manner. The latter signals are correlated with complex modulated error signals supplied from the error generator as discussed above with reference to FIGS. 1 and 2 to produce weight control signals for supply to the complex weighting multipliers 26 as desired. The generation of such complex error signals is described below with reference to FIG. 4. Time delays 27, as discussed above, are used in order to provide alignment of the received signal with such error signals. In an exemplary embodiment, as shown here and as discussed in the Monsen patent, for example, such latter time delay may correspond to the data symbol interval, τ.
The weighted signals from the complex multipliers 26 are then selectively combined, as shown, at each of a plurality of N combiners 30 1 through 30 N . Thus, the signals from multipliers 26 11 through 26 D1 are combined, at combiner 30, the signals from multipliers 26 12 through 26 D2 are combined at combiner 30 2 (not shown), and so on, to the signals from multipliers 26 1N through 26 DN at combiner 30 N . The outputs of combiners 30 1 through 30 N are each suitably amplified by a pair of large gain-bandwidth product IF amplifiers 31 1 through 31 N and 32 1 through 32 N as shown, the amplified outputs of which are each appropriately demodulated by demodulators 33 1 through 33 N , as shown. The output of demodulator 33 1 is supplied to a first delay element 34 1 of a plurality of delay elements 34 each having a delay equal to τ/2 as discussed above with respect to the delay lines of FIG. 2. The outputs of the demodulators 33 2 through 33 N are combined with successive outputs of each of the successive delay elements 34 1 through 34 N-1 , as shown at combiners 35 1 through 35 N-1 , the successively combined signals being in each case supplied to the next successive delay element. The final combined signal at combiner 35 N-1 is supplied to the data detector and error generator of the overall system of FIG. 1, at the baseband frequency, as required.
In the system of the invention the specific error signals E ij depicted in FIG. 3 are obtained from the error signal, as shown in FIG. 4, which is fed back from the error generator of FIG. 1. As shown in FIG. 4, the latter error signal, for example, can be suitably digitized, in a manner discussed in the above-referenced Monsen patent, and supplied to a complex digital shift register 40 to supply a plurality of N time-shifted complex error signals which are each then supplied to frequency converters 41 1 through 41 N which shift the frequency upward by the frequency of local oscillator 42. The error signals are amplified and supplied to signal splitters 43 1 through 43 N for correlation with the time delayed received signals at complex correlators 29, as depicted in FIG. 3.
Since the data detection and error generation (and the backward filter equalization operation, if used) in the overall system of the invention shown in FIG. 1 can be implemented in substantially the same manner as already disclosed in the above-referenced Monsen patent, such operations and the structures utilized therefor need not be described in more detail here. Similarly, the timing system disclosed in the aforesaid patent can be utilized here or, alternatively, a timing system such as that disclosed in Megabit Digital Troposcatter Subsystem (MDTS), Preliminary Design and Visualization Plan, Apr. 19, 1974, U.S. Army Contract No. DAAB07-74-C-0040 could also be used. Accordingly, the timing system need not be described in more detail here.
In the invention as disclosed with reference to FIG. 3 the error signals, weighting signals and combined weighted signals, as well as the demodulated signals and the signals at the outputs of each of the taps of the baseband delay line device, are all complex signals, i.e., such signals each have a real and an imaginary part in the same manner as discussed with respect to the signals in the above-referenced Monsen patent. For clarity, the complex signals are not specifically shown as such in the figures, although it is clear to those in the art that both the real and imaginary parts thereof must be operated upon in substantially the manner as shown in the operation of the system described in the aforesaid Monsen patent.
As can be seen in FIG. 3, the delay elements thereof effectively correspond to a single delay line at baseband frequency, as opposed to the plurality of complex tapped delay lines (the number thereof being equal to the number of diversity channels D) required in the previous system shown in FIG. 2. Moreover, while the number of demodulators in FIG. 3 is increased over that needed in the previous system and becomes equal to the number of tapped delay elements, their implementation is considerably easier and less expensive than the implementation of the multiple IF delay lines required in FIG. 2. Moreover, in addition to such advantages, the number of large gain-bandwidth amplifiers required to be implemented in the system of FIG. 3 is reduced to the need for amplifiers 31 and 32 for each of the combined signals. Thus, in a system having "D" diversity channels and having delay lines utilizing "N" taps, the number of large gain-bandwidth IF amplifiers in the system of FIG. 3 is equal to 2N, while in the system of FIG. 3 the number of such amplifiers is equal to 2DN+2. For example, for a system having four diversity channels (D=4) and three taps (N=3), the system of FIG. 3 requires six amplifiers while the system of FIG. 2 requires twenty-six such amplifiers. The use of fewer large gain-bandwidth amplifiers provides a significant advantage in reduced costs and complexity and increased reliability.
While the particular embodiment of the invention described above may be preferred in many applications, modifications thereto will occur to those in the art within the spirit and scope of the invention. For example, in some applications the specific time delays of each of the delay elements 34 1 through 34 N-1 need not necessarily be selected as equal to τ/2 and, further, the time delays thereof need not necessarily be uniform but may differ from each other. Hence, the invention is not to be construed as limited to the specific embodiment disclosed above except defined by the appended claims.
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An improved high speed digital communications diversity receiver using a forward adaptive transversal filter equalizer, having a plurality of weighting sections in each diversity channel to provide a combined weighting signal, wherein the required complex multiplications and correlations needed for weighting purposes are performed at IF frequencies, while the time-delayed combining operations for providing the desired combined weighted output signal are performed at baseband frequencies. Such an arrangement reduces the number of tapped delay lines normally needed for such transversal filter equalizer operation and further reduces the signal losses incurred in operating delay line devices at intermediate frequencies so that fewer large gain-bandwidth product amplifiers are required in the system than the number required in previously available systems using such forward transversal filter equalizers.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to one-way drive mechanisms and more particularly to an improved one-way pawl and ratchet-type clutch mechanism of high torque transmitting capability and which is of simplified construction and economical to manufacture.
2. Description of the Prior Art
One-way drive mechanisms, hereinafter generally referred to as clutches, are well known and used in a wide variety of applications ranging from low speed high torque ratchet mechanisms such as those employed in hand tools or wrenches to high speed transmission devices employed in complex drive systems for automobiles, aircraft, or the like.
The known one-way clutches, particularly those employed for relatively high torque transmission at low to moderate speeds, have frequently taken the form of a pawl and ratchet drive mechanism. These known mechanisms typically have employed relatively rotatable drive and driven clutch members having opposed surfaces provided with recesses defining shoulders or ratchet teeth for engaging one or more of a plurality of separate pawl members each biased to a position to engage a shoulder or ratchet tooth on both of the relatively rotating members to interlock the two for movement together upon rotation of the drive member in one direction, with the separate resilient means being deformable to permit disengagement between the pawl and the shoulders or ratchet teeth on at least one of the opposed surfaces to permit freewheeling, or relative rotation of the driving member in the opposite direction.
Examples of known pawl and ratchet drive mechanisms may be found, for example, in U.S. Pat. No. 5,449,057, No. 5,070,978, No. 4,711,311, and No. 2,226,247. In U.S. Pat. No. 2,226,247, a camming action provided by a camming surface on one of the clutch members is relied upon to pivot the pawls for engagement and/or disengagement rather than to use a separate resilient spring element urging the pawl to the engaged position. U.S. Pat. Nos., 3,623,582 and 2,631,446 disclose drive mechanisms in which a separate resilient element is disposed between opposing radial faces on the drive and driven coaxial rotary members, and employ leaf spring segments which project into recesses or openings in the opposed surfaces to interlock the members for rotation in one direction while permitting overrunning in the opposite direction. These devices are employed for relatively lightweight operations such as a self-winding watch or a manually operated cigarette lighter flint wheel actuator.
The close tolerances and high strength required for the component parts, and the number and size of those component parts, of known one-way clutches employed for high speed, high torque operations such as those shown in U.S. Pat. Nos. 5,449,057 and 5,070,978, above, have made these devices very expensive to manufacture. Also, the number and size of the component parts has made the automated assembly of the completed devices difficult.
It is, accordingly, a primary object of the present invention to provide an improved one-way drive mechanism which has a minimum number of component parts and which is particularly well suited for drives employed in low to intermediate speed mechanisms.
Another object is to provide an improved one-way drive mechanism which is capable of transmitting high torque loads and which is highly reliable in operation.
It is another object of the present invention to provide such a one-way drive mechanism which is very economical to manufacture and which is substantially maintenance free.
It is another object of the present invention to provide such a one-way drive mechanism in which the pawls and resilient pawl supporting means is rigidly mounted on or integrally formed with one of the drive or driven clutch elements for rotation therewith and for engagement with ratchet teeth carried by the other of the drive or driven clutch elements.
SUMMARY OF THE INVENTION
The foregoing and other objects and advantages are achieved in a one-way drive mechanism according to a preferred embodiment of the present invention which includes an annular drive member and an annular driven member, each having a substantially planar, annular clutch plate section having inner surfaces disposed in closely spaced parallel relation to one another for rotation about a common axis. One of the clutch plate sections has an annular row of spaced ratchet teeth formed on its inner surface and the other clutch plate section has at least one aperture defining an opening for an elongated rigid pawl supported on an elongated resilient arm. A contoured slot preferably extends along the sides of the support arm and a part of the pawl, and a surface of the aperture defines an abutment surface engaging one end of the pawl for transmitting driving torque.
The elongated slot (or slots) may be formed by a stamping, die cutting, laser cutting or other operation to integrally form the elongated rigid pawl and its support arm as a part of the planar clutch plate section, with the support arm being deformed, or twisted, slightly out of the plane of the clutch plate section to normally urge the other end of the pawl into engagement with the ratchet teeth. The support arm is sufficiently resilient to permit the ratchet teeth to cam the pawls back substantially into the plane of its supporting clutch plate section to permit overrunning.
One of the clutch plate members preferably has an axially extending annular rim on its outer periphery, with connecting means such as gear teeth, splines, a key slot or the like for connecting the rim to a rotary drive or rotary driven element. The other of the annular drive member or annular driven member preferably has an axially extending hub on its inner periphery with connecting means on the hub for transferring torque to or from a second rotary element. Retaining means on one of the drive or driven members is provided for engaging the other of the drive or driven members to retain the drive and driven clutch members in assembled relation with the inner surfaces in spaced parallel relation. Preferably the annular drive member and the annular driven member are each integrally formed from a single substantially homogeneous mass of metal material such as a suitable steel sheet material by a drawing and/or die forming. A suitable pawl stop may be formed adjacent each aperture by staking a small tab from the flat clutch plate section and forming the tab into overlying relation with the portion of the elongated slot forming the abutment surface to prevent the end of the pawl from being deflected through the aperture under load.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other features and advantages of the invention will be apparent from the detailed description contained hereinbelow, taken in conjunction with the drawings, in which:
FIG. 1 is a diagrammatic illustration, in section, of a one-way drive mechanism according to the present invention;
FIG. 2 is a top plan view of the bottom clutch element shown in FIG. 1;
FIG. 3 is an enlarged fragmentary sectional view of a portion of the structure shown in FIG. 1;
FIG. 4 is an enlarged fragmentary sectional view of another portion of the structure shown in FIG. 1;
FIG. 5 is a further enlarged fragmentary sectional view taken on line 5--5 of FIG. 1;
FIG. 6 is an enlarged top plan view of a pawl and pawl support arm shown in FIG. 2; and
FIG. 7 is an elevation view of the structure shown in FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings in detail, a one-way drive mechanism, or clutch, is designated generally by the reference numeral 10 in FIG. 1. The clutch 10 includes a drive member 12 and a driven member 14 assembled together and supported for coaxial rotation. It will be understood that the terms "drive member" and "driven member" are arbitrary as either member may be driven from a suitable power source to transfer torque through the other member to drive a separate mechanism such as a shaft, gear, chain, belt or other element.
As seen in FIGS. 1 and 2, drive member 12 includes a substantially planar, annular clutch plate section 16 having an integrally formed, axially extending transition section 18 on its inner periphery. Transition section 18, in turn, terminates in a substantially flat, radially extending web portion 20 terminating at its radially inner end in an axially extending hub 22 having an inturned annular short flange 24 on its free distal end. Clutch plate section 16 also has an integrally formed axially extending annular rim 26 around its outer periphery, with suitable drive means such as gear teeth 28 carried on the outer cylindrical surface of the rim. Rim 26 is preferably initially formed with a short axially extending lip 30 (shown in broken lines in FIG. 1) which, upon assembly of the clutch mechanism, is formed inwardly into a short radial flange 32.
As most clearly seen in FIG. 1, driven member 14 also includes a substantially flat planar clutch plate portion 34 terminating at its inner end in an axially extending cylindrical transition element 36 which terminates in a radially extending, substantially planar web portion 38 having integrally formed on its inner periphery an axially extending hub 40. Hub 40 has an outer cylindrical surface telescopingly received in the hub 22 for relative rotation therein, with hub 40 having its free end terminating in abutting relation with the flange 24 on member 12. Suitable drive means such as gear teeth 42 are formed on the inner periphery of hub 40 for transmitting torque to a shaft or other element, not shown.
Annular clutch plate section 34 also terminates at its outer periphery in an axially extending rim portion 44 having a cylindrical outer surface telescopingly received within the inner cylindrical surface of hub 26 for relative rotation therein. The free end of hub 44, when drive and driven members 14 and 16, respectively, are assembled together, abuts against the inturned inner surface of flange 32 so that flanges 32 and 24 fix the drive and driven members against axial movement relative to one another to maintain the inner opposing surfaces of clutch plates sections 16 and 34 in fixed parallel closely spaced relation to one another.
Drive and driven members 12 and 14, respectively, are preferably formed by a drawing operation from a single sheet of high strength steel material. During the drawing operation, a plurality of spaced ratchet teeth, or depressions 46 are formed in an annular ring on the inner surface 48 of plate section 34. Each depression 46 is formed with an inclined surface or ramp portion 50 and an abutment surface or shoulder 52 for receiving and engaging one of the pawls 54 carried by the clutch plate section 16.
The pawls 54 are preferably formed as an integral part of the clutch plate section 16 of the drive member 12, and preferably a plurality of such pawls are formed at spaced intervals at a location to engage the ratchet teeth 46 when the clutch is assembled and members 12 and 14 are rotated relative to one another. In this preferred embodiment, each pawl 54 is integrally formed on the free end of an elongated support arm 56. As best seen in FIG. 2, pawls 54 and arms 56 are defined by a first elongated, contoured slot segment 58 extending along one side of each arm 56 and continuing along the inner radial edge of pawl 54, then along one end and along the full radial outer edge of pawl 54. A second elongated slot, or slot segments 60, extend along the other side edge of arm 56 and along a portion of the radial inner edge of pawl 54. The pawl 54 is severed, as in a shearing operation, along a straight line 62 so that each of the pawls 54 are supported by its associated arm 56 in a contoured cutout or opening 63 in the clutch plate section 16. The pawls and supporting arms are joined at a location closer to one end of the pawl, namely, the trailing end 64 adjacent shear line 62.
As best seen in FIGS. 6 and 7, the support arms 56 are twisted slightly from the plane of plate section 16 so as to project the forward or drive end surface 66 of the pawls 54 toward the clutch plate section 34, with the trailing end 64 of each pawl remaining within the cutout opening in abutting relation with the clutch plate 16 along line 66. In order to prevent the pawl 54 from being deflected outward through the cutout opening in plate 16 under load, a tab portion 68 is severed, as in a die cutting or stamping operation, along three sides. The tab 68 is then deformed out of the plane of plate section 16 and formed around to overlie a portion of the trailing edge of the pawl cutout 63 and to underlie the trailing end 64 of the pawls 54.
The elongated arms 56 are sufficiently resilient so that the inwardly directed substantially planar surface 70 of each pawl will be deflected by contact with the inner surface 48 substantially into the plane of clutch plate section 16 to permit overrunning of the clutch as by relative movement of clutch plate section 34 to the right as seen in FIG. 5. If necessary, the support arms 56 may be ground to provide a reduced cross section, or lightening holes or grooves may be provided along the length of the respective arms to obtain the desired torsion bar or spring effect tending to urge the leading edge 66 toward inner surface 48 with the desired force whereby, when a depression 46 moves past a pawl 54 in the overrunning operation mode, the resilient arm 56 will project the pawl 54 to the position shown in FIG. 5, with the top surface 70 engaging the inclined ramp portion 50 of the respective ratchet teeth or depressions 46. Continued relative movement in the overrunning direction will cause the ramp portion 54 to cam the pawl back into the opening 63 in the clutch plate section 16 to permit free overrunning.
When the drive member is moved in the torque transmitting direction, or to the right in FIG. 5 relative to the driven member, the resilient arm 56 will project one or more of the pawls 54 into a depression 46 until the edge surface 66 comes into abutting relation with shoulder 52. The relatively close spacing of clutch plate sections 16 and 34 permits the pawls 54 to make a very small angle relative to the planes of the clutch plate sections so that only a relatively small component of axial force is transmitted through the pawl tending to separate or increase the spacing 72 between the inner surfaces 48 and 74 as seen in FIG. 5. Thus, the mechanism may be made from relatively lightweight material and still be capable of transmitting very high torque loads. At the same time, the mechanism is of very simple construction and has a minimum of parts whereby assembly is facilitated and maintenance is substantially eliminated.
The overrunning drive mechanism according to the present invention may be used in a wide variety of applications, but is particularly well adapted for use in low to moderate speed drives such as might be employed in boat winches, bicycle drives or the like.
It should be understood that various modifications might be made to the structure as described hereinabove without departing from the spirit of the invention. For example, the pawls and support arms could be separately manufactured and joined to the clutch plate section of the drive member, in a generally hammer-shaped cutout or opening, by suitable means such as welding. Also, it is believed apparent that the support arms and pawls, as well as the ratchet teeth or depressions, may be formed in various ways. For example, a laser cutting operation may be employed to shape the pawls and support arms. Also, it is believed apparent that various drive arrangements might be employed on the outer periphery of rim 26 and the inner periphery of hub 40. For example, while the gear teeth illustrated at 28 and 40 might be formed, as by a simple rolling operation, other means such as key-ways or splines may be integrally formed on the rim and hub, or a separate drive mechanism such as a sprocket may be separately formed and attached to the outer periphery of the rim 26.
While I have disclosed and described a preferred embodiment of the invention, I wish it understood that I do not intend to be restricted solely thereto, but rather that I intend to include all embodiments which would be apparent to one skilled in the art and which come within the spirit and scope of the invention.
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An overrunning clutch comprising annular drive and driven members having generally planar clutch plate sections supported in fixed parallel relation for rotation about a common axis. One clutch plate section has an annular row of ratchet teeth formed in the inner surface and the other clutch plate section has at least one aperture extending therethrough, with an elongated rigid pawl supported on one end of a resilient arm located in the aperture. The aperture provides an abutment surface for one end of the pawl and the resilient arm is biased to urge the other end of the pawl from the aperture to engage the ratchet teeth. The rigid pawl, the resilient arm and the other clutch plate section may be integrally formed, and the clutch assembly may consist of two pieces only.
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FIELD OF THE INVENTION
This invention relates to laboratory fume hood controllers and more specifically to methods and apparatus for varying a fume hood's face velocity in response to variations in one or more hood containment affecting conditions.
BACKGROUND OF THE INVENTION
A laboratory fume hood is a ventilated enclosure where harmful materials can be handled safely. The hood captures contaminants and prevents them from escaping into the laboratory by using an exhaust blower to draw air and contaminants in and around the hood's work area away from the operator so that inhalation of and contact with the contaminants are minimized. Access to the interior of the hood is through an opening which is closed with a sash which typically slides up and down to vary the opening into the hood.
The velocity of the air flow through the hood opening is called the face velocity. The more hazardous the material being handled, the higher the recommended face velocity, and guidelines have been established relating face velocity to toxicity. Typical face velocities for laboratory fume hoods are 60 to 150 feet per minute (fpm), depending upon the application.
When an operator is working in the hood, the sash is opened to allow free access to the materials inside. The sash may be opened partially or fully, depending on the operations to be performed in the hood. While fume hood and sash sizes vary, the opening provided by a fully opened sash is on the order of ten square feet. Thus the maximum air flow which the blower must provide is typically on the order of 600 to 1500 cubic feet per minute (cfm).
The sash is closed when the hood is not being used by an operator. It is common to store hazardous materials inside the hood when the hood is not in use, and a positive airflow must therefore be maintained to exhaust contaminants from such materials even when the hood is not in use and the sash is closed. As the hazard level of the materials being handled and the resulting minimum face velocity increases, maintaining a safe face velocity becomes more difficult.
An important consideration in the design of a fume hood system is the cost of running the system. There are three major areas of costs: the capital expenditure of installing the hood, the cost of power to operate the hood exhaust blower, and the cost of heating, cooling, and delivering the "make-up air," which replaces the air exhausted from the room by the fume hood. For a hood operating continuously with an opening of 10 square feet and a face velocity of 100 fpm, the cost of heating and cooling the make up air could, for example, run as high as fifteen hundred dollars per year in the northeastern U.S. Where chemical work is done, large numbers of fume hoods may be required. For example, the Massachusetts Institute of Technology has approximately 650 fume hoods, most of which are in operation 24 hours a day.
Capital or investment costs is an important factor in the design of fume hood systems. This relates to the capital cost of the supply and exhaust fans, duct work, boiler and chillers, and other equipment related to the movement and conditioning of the outside air brought into and exhausted from the building through the fume hoods. The size, capacity and cost of this equipment is integrally related to the peak capacity of air volume to be exhausted from the hoods. This total volume is in turn directly related to the face velocities of those hoods. For example, a 20% reduction in the face velocity for which the building hoods are designed, from 100 FPM to 80 FPM allows for a 20% reduction in the required capacity of the system air handling equipment.
Consequently, there are strong economic reasons for using the lowest face velocity which still produces acceptable fume hood capture and containment. Much research has been performed recently on the factors affecting this minimum acceptable face velocity. For example, with a fume hood having no equipment in the first 6" back from the sash, uniform face velocity distribution across the face of the hood, and no high cross drafts, the face velocity can be set to 60 FPM and excellent containment will occur. However, spillage will occur at 60 FPM if people walk past the hood, someone waves their arms near the opening or supply air diffusers blow air past the corners in front of the hood. All these disturbances create cross drafts and challenges to the fume hood containment which can pull fumes out of the hood. Increasing the face velocity to 100 or 125 FPM significantly reduces the spillage caused by these factors. Above 150 FPM, the air flow into the hood can become turbulent creating eddy currents and local low pressure areas which can also create spillage.
Because of the above factors, many laboratories operate their hoods at 100 to 125 FPM. Others allow the face velocities to drop to 70 to 80 FPM when the laboratories are unoccupied and operators are not near the hood where they might create crossdrafts from their motions. A very few companies operate their hoods at 60 FPM, but only with strict operating guidelines in order to prevent disturbance of the fume hood's containment.
In order to save energy and reduce the peak air capacity in laboratories, fume hood control systems are presently used that maintain a constant face velocity independent of the sash opening. Early versions of these systems operated by changing volume in a two or three step operation based on the sash height or the amount of sash opening. Much better and more recent systems provide continuous control of the air volume based on sash position and are referred to as variable air volume systems. An example of one of these systems is described in U.S. Pat. Nos. 4,528,898 and 4,706,553. These systems work well, but are dependent on the operator lowering the sash. When the operator does lower the sash, the exhaust, and typically also the room supply air volume, are reduced proportionately which generates the energy savings. If many hoods are used in a building with these controls, both the average and typical peak total air volumes will be reduced due to the diversity in the hood's operation. In other words, it is unlikely that all the hoods will be fully open at any one time. A problem for the building designer, however, is in estimating how much diversity will actually occur in the building. Consequently, many designers take a worst case view and don't size the buildings capacity below or much below the 100% capacity assumption of all the hoods full open at the same time. This is done because the designer is concerned that the users will not lower the sash when leaving the hood area. This is unfortunate because studies have shown that operators spend only a small fraction of their time in front of the hood.
In an attempt to bypass the operator problem of not closing sashes some fume hood manufacturers have introduced devices such as shown in U.S. Pat. No. 4,774,878 that detect the presence of the operator in front of the hood and raise the sash to some preset position. When the operator moves away from the hood, the sash is automatically closed. Typically, a two state or variable air volume control system is also used to vary the air volumes to maintain a constant face velocity at the two different sash positions.
These sash operator systems have not as of yet received widespread acceptance among researchers for several reasons. Firstly, the rapid movement of the sash up and down can occur even when a person just walks past the hood, producing a disturbing false reaction of the hood. Also, many researchers like to operate the sash at various heights, and this is made more difficult by the two position operators. Further, many hoods have wires, tubes and small hoses going into the hood near the bottom of the sash opening. Uncontrolled movement of the sash might hit these wires and hoses and potentially tip over delicate glassware to which the tubes and hoses are connected. This in turn could create a serious and potentially dangerous accident. Lastly, many hoods have horizontally moving sashes which make it difficult to implement a system to move the sashes in order to increase or decrease the amount of hood opening.
For all of the above reasons, a better approach is needed for reducing both energy usage and peak estimated replacement volume while not creating a potential hazard and not adversely affecting the researcher's work.
SUMMARY OF THE INVENTION
An object of this invention is to provide an improved method and apparatus for controlling a fume hood, which controller (a) substantially reduces the replacement air utilized by the system, regardless of sash position, (b) permits fume hood systems to be designed for lower peak volume flow without permitting or creating any danger of a breakdown in toxic fume containment or any danger of damage to ongoing experiments or equipment, and (c) permits researchers complete flexibility in selecting sash positions.
In accordance with the above, this invention provides a controller for use with a fume hood having a face velocity control. The face velocity control may control face velocity directly or may control it indirectly by controlling flow volume or some other conditions affecting face velocity. The controller has a detector for detecting at least one containment affecting condition, which condition may be (a) the presence or proximity of a person within a predetermined area of the fume hood, (b) movement within a predetermined area of the fume hood, either by a person or as a result of air drafts or other conditions, and/or (c) the presence of equipment or material within a predetermined distance from the front of the hood. Appropriate detectors are provided for each condition to be detected. In response to the detector detecting a selected change in containment affecting conditions, the face velocity control makes a corresponding change in the face velocity of the fume hood to a preselected velocity which is appropriate for the changed containment condition. The change may be an increase in the face velocity of the fume hood to a level sufficient to assure containment of fumes in the hood with the containment affecting condition present, or the change may be a reduction in the face velocity of the fume hood to a selected decreased level in response to the detection of a selected reduction in containment affecting condition. The incrementing preferably occurs substantially instantaneously on the detection of a containment affecting condition, while a reduction in face velocity is delayed for a selected time period when a selected reduction in containment affecting condition is detected. Containment affecting conditions may include a person being within a selected area of the face of the hood, the detection of movement within a selected area of the face of the hood, which movement may be of a person or may be air motion or turbulance either inside or outside the hood, may be a tracer fluid ejected in the hood, with the escape of such tracer fluid being measured, or may be the detection of apparatus within a predetermined distance from the front of the hood.
The face velocity control may control volume through the fume hood with a change being a change in flow volume. The system may include a means for establishing a maximum flow volume and/or a means for establishing a minimum flow volume with the maximum flow volume and/or the minimum flow volume being changed in response to a change in containment affecting condition. An offset in the controlled flow volume may also be effected in response to a change in containment affecting condition. Where the fume hood has an opening which may be covered to varying extents by at least one moveable sash, a selected volume is normally maintained relative to the sash position. The selected volume maintained may be changed in response to the detection of a change in containment affecting condition. For some embodiments, the selected volume maintained is a constant volume regardless of sash position.
For some embodiments, a first face velocity is caused in response to a detection of a containment affecting condition, and a second lower face velocity is caused in response to the absence of a detection. Where there may be varying degrees of containment, and the detection detects the degree of containment affecting condition, the change in face velocity may be to a face velocity appropriate for the detected degree of containment affecting condition. The changes in face velocity may be discrete or may be substantially continuous based on the degree of detected containment affecting condition.
The face velocity control may include a speed control for a blower exhausting the fume hood, or may directly change the flow from the fume hood.
The foregoing other objects, features, and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention as illustrated in the accompanying drawings.
IN THE DRAWINGS
FIG. 1 is a side-view representation of a prior art fume hood system.
FIG. 2 is a semi block diagram of a fume hood system in accordance with a first embodiment of the invention.
FIG. 3 and FIG. 4 are block diagrams of a passive and of an active motion detection system, respectively, which may be utilized in practicing the teachings of this invention.
FIG. 5 is a block diagram of an alternative embodiment of the invention illustrating another sensing concept.
FIG. 6A illustrates a typical detection zone for a proximity or motion detector and also illustrates the detection of another detection containment condition.
FIG. 6B is a front perspective view of a fume hood illustrating additional containment affecting condition detection elements.
FIG. 7 is a block diagram of a sash position sensing circuit which may be utilized in conjunction with various embodiments of this invention.
FIGS. 8, 9, 10 and 11 are diagrams illustrating the relationship between air flow and sash position for various embodiments of the invention.
FIG. 12 is a schematic diagram of a circuit for controlling minimum and maximum air flows.
FIG. 13 is a semi-block schematic diagram of a flow controller which may be utilized in conjunction with various embodiments of the invention to control minimum and maximum air flows.
FIG. 14 is a semi-block diagram of still another embodiment of the invention.
DETAILED DESCRIPTION
FIG. 1 shows a prior art system used primarily to maintain a constant face velocity. Air flow sensor 27 is placed in an opening in the fume hood so that it can directly sense the velocity of air entering the hood. Sensor 27 could be placed in the sash opening or in a separate opening in the side of hood enclosure 10, as shown by opening 26 in FIG. 1. In this system, the sensor may be used to control either the speed of blower 14 or to control a damper in the exhaust ducting 15 to control the air flow. U.S. Pat. No. 4,741,257 describes a similar device that measures the pressure drop between the inside and outside of the hood as a method of sensing a quantity related in some way to face velocity.
Systems of the type shown in FIG. 1 have several problems relating to the maintenance of a constant face velocity such as speed of response, stability, susceptibility to contamination of the air flow sensor, etc. One potential problem which relates to the present invention is that the face velocity of a hood controlled by these devices is affected by the user standing close to the front of the hood. However, unlike the present invention, these systems reduce the face velocity when the user stands near the opening of the hood, which is directly opposite of the desired result. The present invention increases the average face velocity to generate better fume hood capture and containment.
Prior art devices also work slowly, so that even if they could produce the intended result, it would be too late to protect the user. Due both to the time delay and the wrong control action of these systems, the disturbance of a person walking past the hood could create a significantly worse reaction than a hood with no such control system. The present invention uses different sensing and control equipment to immediately detect the disturbance and respond rapidly in the correct manner to provide better fume hood operation.
The present invention also differs from prior art systems that detect the presence of a user and raise the sash while trying to maintain a constant face velocity for two different sash positions. The goal of such prior art systems is to maintain a constant face velocity, or if no volume controller is used, then the volume may actually be fixed. The present invention also tries to sense the user, but unlike the prior art, it changes face velocity to change the hood volume and save energy; it does not disturb or move the hood sash or sashes.
Consequently, the present invention is universally applicable to all hoods even those that do not have a movable sash or such hoods as canopy hoods. Also, this system, when used in combination with a constant face velocity control system such as that described in U.S. Pat. Nos. 4,528,898 and 4,706,553, can achieve greater energy savings then when such systems are used alone due to the decrease in average face velocity that the present invention achieves.
Referring to FIG. 2, a first embodiment of the present invention is shown as it would be applied to a conventional fume hood with a damper 30 or similar air throttling or resistance type flow control element. This damper controls the flow out of fume hood 10 and is actuated by actuator 31. Flow controller 32 controls actuator 31 and may consist of a constant volume controller to maintain a given volume flow independent of sash position, a two state (or multi-state) volume controller that changes the volume of the hood based on the sash height or open area of the sash, or a variable volume control system which maintains a constant face velocity based on sash position. U.S. Pat. Nos. 4,741,257; 4,528,898; and 4,706,553 describe various types of variable volume control systems which could be used for flow controller block 32. All of these flow controllers work to maintain a given setpoint value of face velocity. In the constant volume systems, this can be interpreted directly as a setpoint of volume, whereas in the variable volume systems the fume hood volume will vary for a given face velocity setpoint. In many cases, with the variable volume systems, there will also be a minimum and maximum exhaust volume limit placed on the fume hood control.
Transducer 35 and person/motion detector circuit 34 work together to detect the presence and movement of the user/researcher in front of the hood. The transducer may also detect significant air motion or turbulence in front of or near the hood. When air motion or user proximity/movement is detected, it activates face velocity setpoint change circuit 33. This circuit acts on flow controller 32 in one of many possible ways, but generally acts to increase its face velocity and/or volume flow setpoint. Alternatively, it may act to modify the minimum and maximum exhaust volume limits of the flow controller through the volume clamps circuit 39.
Transducer 35 and detector circuit 34 may be implemented with a variety of technologies such as is used in security or intrusion alarm systems. For example, transducer 35 could be implemented by using a passive far-infrared (typically 8-14 um) motion sensor, an active ultrasonic motion sensor, an active microwave motion sensor, an active near infrared (typically 880-940 nm) or visible light proximity sensor, or a combination thereof. Based on the type of transducer used, a compatible detector circuit 34 would be employed.
FIG. 3 illustrates an implementation using a passive pyro-electric infrared motion sensor and detector circuit. The pyro electric detector 41 detects changes in heat patterns caused by the movement of a person relative to their background radiation, in a detection zone. The optical system 40, for example a mirror or fresnel lens, focuses the infrared energy, in for example the 8-14 um spectrum, onto the detector. After a variable gain stage 42 which controls the sensitivity of detection, the amplified signal is filtered in signal processing circuit 43 with a band pass filter which attenuates unwanted frequency of interest which is generally in the 0.3--3 Hz range. When the signal is of a desired amplitude, comparator 44 triggers a timer 45. The timer changes the state of relay (46), and thus of its output, for some preset time period. The output from relay 46 is applied to control change circuit 33 (FIG. 2).
The timer will restart its timing period if the comparator triggers a second time within the preset time period. This preset time period, or turn off delay time, is used to keep the detector on even if the researcher is still for a few minutes while he is working in front of the hood, and also to prevent the nuisance and potential danger of the system increasing and decreasing the face velocity based on how still the researcher is while the researcher is still in front of the hood. Alternatively, a smaller turn off delay could be used if the passive system were combined with some sort of active proximity or presence detector
With the use of variable voltage control 47 the circuit could detect different zones. For example the variable voltage output would indicate the detection of the researcher in the lab relative to a detection zone in front of the fume hood. The variable voltage would tell the face velocity setpoint change block 33 of FIG. 2 to increase the face velocity a little when the researcher is present in the room and to increase the face velocity even more if the researcher is in front of the hood.
A complete active system that includes a Doppler motion detection is shown in FIG. 4. These systems can be combined with a passive detector and are typically based on one of three technologies: infrared 800-900 nm, microwaves or ultrasonics. The active system detects the presence and or movement of a person. Movement, which indicates where the researcher is and how fast he is moving, is detected by the Doppler effect for microwave and ultrasonics. Presence, which indicates if the researcher is present at a particular location, is detected by an infrared beam.
For the circuit of FIG. 4, transmitter 48 sends a pulse of appropriate frequency into the detection zone. Depending on the presence of personnel in the detection zone, the pulse is either returned to the receiver 49 within a selected clock interval or not. If the receiver receives the signal, preamplifier 51 boosts the signal so that, assuming the signal is received within the interval of clock 50, sample and hold amplifier 52 can sample the pulses, with the signals of interest on them. The pulses are sampled in sync with the transmitted pulses of clock 50. Doppler/presence detector 53 detects the motion or presence from the sampled signal, the presence detector detecting presence of a signal and the Doppler detector detecting frequency shift. The signal is filtered and processed in signal processing circuit 54 so that unwanted signals are attenuated, thus increasing the S/N ratio for the frequency of interest.
The block diagram of FIG. 4 illustrates two potential outputs, one indicating if the researcher is in the detection zone and the other detecting where in the zone the researcher is. In the first case, detecting if the researcher is in the detection zone, the output of relay 57 tells the face velocity setpoint change block 33 of FIG. 2 to increase the face velocity by a present amount. The later case would change the face velocity by a certain percent relative to the distance of the researcher from the hood.
The presence of the researcher in the detection zone is indicated by the signal amplitude out of block 54 increasing until it rises above the threshold of the comparator 55. The comparator starts a timer 56. The timer switches the state of the relay 57 for some preset time. As for the circuit of FIG. 3, the timer will reset back to zero if the comparator triggers a second time within the timer set period. The relay tells the face velocity setpoint change block 33 (FIG. 2) to change the face velocity.
To indicate the position of the researcher relative to the fume hood, the signal coming out of block 54 would be converted to a variable voltage by circuit 58, the voltage output telling the face velocity setpoint change block 33 (FIG. 2) the distance of the researcher from the fume hood. The face velocity may then be increased as the researcher moves closer to the fume hood and decreased as the researcher moves further from the fume hood.
The use of both a presence detector and a motion detector may prove useful to prevent the system from being adversely affected by people walking past the hood. If someone walks past the hood, the system must quickly activate the active mode. However, if the person does not stop in front of the hood, but continues walking, it would be wasteful to leave the hood in the active mode for more than perhaps 10 seconds. This prevents a person from walking around the room and activating all the hoods simultaneously. The presence detector is desirable for use in conjunction with the motion detector so that the active mode is only left on for greater than 10 seconds if a researcher remains standing in front of the hood.
FIG. 5 illustrates another sensing concept to detect a person walking up to and standing in front of the hood. This involves a floor mat type switch 36 which is activated by standing on a special mat placed in front of the hood. These devices are of the general type used to open doors, although generally modified in appearance and construction to fit in better for a laboratory application. For example a capacitive plate sensor or inductive plate sensor which would operate by stepping on a sheet of metal either on top of or embedded into the floor would provide a neater installation for this application which would be less affected by spilled chemicals. There are also many similar sensors such as piezoelectric or FSR (Force Sensing Resistor) which are very flat and can for example be laminated into corrosion resistant plastic. Detectors of this type typically work on pressure or on the capacitive or conductive affects of the human body. Except for the change in detector, the system of FIG. 5 has the same components and operates in the same way as the system of FIG. 2.
When passive or active detectors such as those shown in FIGS. 3 or 4 are used, the optics cf the system will need to be adjusted to sense the proper area in front of the hood. Some field adjustability is desirable based on the different sizes of hoods and different lab casework layouts in which the hoods are applied. FIG. 6A shows a typical detector zone 50 for a detector 35 that is mounted on a hood 10 as shown in FIG. 6B. In some cases, two or more detectors may need to be used or special optics may be required that can specifically shape the detection field of a single detector. For example, it may prove useful to observe the hood area from a height of 3' or 4' on up to ignore chairs, tables, equipment and other fixed or movable objects. When, for instance, infrared detectors are used, special fresnel type lenses or specially shaped mirrors may be used. The size of the zone 50 would vary with application. For example, the zone might extend 1' to 4' from the front of the hood and beyond each side of the hood by from 0 to 3'.
Other means to implement sensor 35 and detector circuit 34 would be through creating a light curtain or projecting a light beam around the desired detection zone, 50 of FIG. 6A. When an operator crosses and momentarily breaks the light beam, the detector circuit signals the presence of the operator. The circuit of FIG. 4 could be used to implement this type of detector circuit.
In addition to sensing the presence or motion of a user near the hood, there are, as was mentioned earlier, potentially other factors which might dictate the need for a higher face velocity, for example, the presence of an air velocity greater than 30 to 50 FPM such as from a nearby supply air diffuser. Additionally, the presence of apparatus in the first 6" or so of the hood back from the front of the sash can also decrease hood containment, necessitating the need for a higher face velocity.
There are many kinds and types of air velocity sensors that could be used to detect air motion, either in front of or at the corners or sides of the fume hood. Unfortunately, many of these tend to be point sensors such as hot wire or thermistor-type thermal anemometers. A better system would sense the presence of low air velocity over a wider area. One such approach would use long streamers, 51 (FIG. 6B) the length of each such streamer being roughly equal to the height of the sash openings. The streamers 51 would be placed at the front corners or edges of the hood where the hood is most affected by air currents. These streamers would be made of some light material easily moved by wind or other air currents striking the streamer. The motion of the streamers could then be detected by the motion detectors that were described earlier. Alternatively, the motion could be detected directly by a suitable motion detector 52 to which each streamer 51 is attached As each streamer moves, its motion is transmitted to the corresponding detector 52, which senses the motion by for example moving the contact point on a variable resistor or by sensing the variation in pressure, weight or twisting force applied to a sensitive force measuring device such as piezoelectric or strain gauge transducer.
An even simpler approach is to use the pyro-electric or heat sensor mentioned earlier. These devices can be made sensitive to the motion of air that is at a different temperature than the background. For example, the conditioned supply air coming out of a diffuser near a hood is typically 55° F. versus the background room temperature of 70° F. Depending on the turbulence of the airflow near the hood, this air motion would be detected by the pyro electric sensor
As mentioned earlier, one other factor affecting hood capture is the presence of apparatus in the first 6" of the hood work surface. This region 55 is shown in FIG. 6A. To sense this condition, a simple active or proximity sensor could be used to send a light or other type of beam from one side to the other side of the inside of the hood. Anything placed in the zone traversed by the beam would signal the system to increase the face velocity. One implementation shown in FIG. 6A has an active transmitter and receiver unit 56. This unit bounces a light, ultrasonic, microwave or other appropriate wavelength beam 58 off reflector 57 and back to the transmitter/receiver unit 56. The circuit of FIG. 4 could again be used to implement the sensor and detector circuits. Pressure sensitive "floor mat" type switches, or equivalent pressure sensing material strips, could also be used to detect the presence of apparatus in "buffer" zone 55.
Another method to determine if there are influences that are disturbing hood containment is to actually measure the containment of the hood in some way such as by releasing a harmless fluid, such as a tracer gas or vapor in the hood and measuring outside the hood to see if any is escaping. This measurement of the hood's containment could be used to help vary the face velocity to the optimum point or to provide a two step operation.
As mentioned earlier, one approach to detect air motion in, around or near the hood is to use an air velocity sensor that measures the air velocity near the hood to directly look for high velocities that could affect containment. Alternatively, an air velocity sensor either in the sidewall or someplace in front of the hood could be used to detect disturbances caused by a user standing in front of the hood or by air turbulence near the hood. The former could be sensed, for example, by observing an increase in the air velocity through the sensor when in fact no change in the actual face velocity (which would also be detected or probably computed by using exhaust volume and sash area measurements) occurred. In order to sense air turbulence, the variations or "noise" in the air velocity signal could be observed. A very noisy signal that was changing a lot would indicate the presence of air turbulence near the hood. In order not to be confused with changes in velocity caused by movement of the sash, the sash position or the effective area of the sash could be monitored if it was desired to separate out any air velocity changes caused by the movement of a sash.
Alternatively the actual exhaust volume of the hood could be measured or metered by appropriate means and this value could be divided by the sash position to generate a calculated face velocity. Variations between this term and the sidewall face velocity could be then compared, particularly on a transient basis, in order to detect disturbance causing conditions around or inside the hood.
The last sensor that might be utilized to vary or change face velocity is a sash movement sensor. Movement of the sash or sashes creates turbulence; therefore, an increase in face velocity during and after the movement of the sash might help to increase the hood's containment of fumes during such an operation. The movement of the sash can be easily sensed by the use of a sash sensor such as those described in U.S. Pat. Nos. 4,528,898 and 4,706,553 where a spring wound, multiturn pot assembly is used to measure sash height. A differentiator circuit such as that shown in FIG. 7 could be used to detect even a small movement of the sash. In this figure, sash sensor 62 produces a variable voltage signal that is differentiated by op amp circuit 60. Comparator 61 compares the differentiated signal to a reference to generate a two state output that could be used to switch a relay when the sash moves.
As mentioned earlier, the system utilized could involve many of the different sensors described above in combination. Also, the outputs of the different sensors might be utilized as variable outputs or as two state or relay outputs in order to detect the magnitude of the disturbance or closeness of a person to the hood. This variable output might be used to create a variable face velocity with a magnitude dependent on the magnitude of the disturbance.
Block 33 of FIG. 2 is the circuit which accepts the relay closure or signal from the disturbance detector or detectors 34 in order to modify the face velocity or volume command of the flow controller 32.
There are several ways in which the face velocity or volume could be changed in order to increase containment when a disturbance occurs. FIG. 8 is a diagram indicating one way that volume could be changed. In this example, the hood is operated with a standby face velocity of 70 FPM which is shown by lines 131 and 105 which intersect at the point 149 of minimum flow, which point in this example occurs at 20% of open area. When a disturbance occurs, the face velocity is increased producing a flow to sash-position curve outlined in FIG. 8 by lines 130 and 104. Under some situations, it may be desirable to maintain the same minimum flow for both standby and active (disturbance) modes. This is shown in FIG. 8 by the curve including lines 130, 134 and 105. In this example the minimum flow occurs at 28.6% of the full open sash at point 135. For operations along lines 130, 131 and 134, face velocity will increase as sash opening decreases to maintain the desired constant flow volume.
Similarly, it sometimes is advantageous to have a maximum limit for both standby and active modes. FIG. 9 shows this with an example where the standby mode uses 70 FPM within both minimum and maximum limits. The standby mode is indicated by lines 132, 107 and 120. Points 110 and 111 indicate the minimum and maximum limit intercepts, respectively. The active mode at 100 FPM is indicated by lines 132, 106, and 120. The intercept points are 108 and 109 for minimum and maximum limits, respectively. Different maximum limits may also be employed as shown for the 100 FPM curve 132, 106, 137 and 136 where point 112 is the maximum intercept point. Again, for operation along lines 120 or 136, face velocity will decrease as sash opening is increased to maintain constant volume flow.
Another way of operating the system is to have the face velocity constant at some value such as 100 FPM, but a maximum clamp is engaged when a disturbance is detected. FIG. 10 illustrates this where lines 133, 113 and 121 would indicate a standby mode with a maximum clamp level of, for example, 50%. Under the active mode, the clamp is raised to 70% as shown by lines 133, 113, 114 and 123. Alternatively the maximum clamp may be eliminated altogether in the active mode as illustrated by extending line 114 to point 117 where 100% open occurs at 100% flow.
In other cases, it may be useful to add or subtract an offset to the hood's flow versus changes in the face velocity. FIG. 11 shows an example of this where lines 148 and 140 indicate a standby mode and lines 148 and 141 indicate the active mode, offset 147 being the difference. A maximum clamp may also be added in the active mode as shown by line 124 with an intercept point of 145.
It is also possible to operate a fume hood system at a substantially constant volume through most positions of the sashes, with a trip switch or other element being utilized to reduce the volume for sash openings below a selected threshold. This results in a stepped, varying face velocity curve with changes in sash position, the step occurring at the threshold position. This stepped face velocity curve may have an offset superimposed thereon in accordance with the teachings of this invention based on detected containment affecting conditions.
Another variation would be to have multiple face velocity levels or a variable face velocity based on conditions near the hood. Alternatively, a single face velocity could be used with multiple maximum clamps or again a variable maximum clamp based on hood conditions or disturbances. FIG. 10 shows a situation where three different maximum clamps are used. These might correspond, for example, to a standby mode where nc one is near the hood, an active mode where someone is standing quietly near the hood, and a turbulent mode where rapid motion is detected near the hood. The maximum clamps indicated by lines 121, 123, and 122 would correspond, respectively, to these conditions.
A typical schematic block diagram which could implement block 33 of FIG. 2 for a single or multiple relay contact closure is shown in FIG. 12. In this figure, the active or highest face velocity or flow volume setpoint is provided and adjusted by a trimpot 70 which is buffered by op amp 71 and is then attenuated by the fixed and/or variable resistor string 72, 73, 74, and 77. Relays 75 and 76 are the output relay or relays of the disturbance detector circuitry of block 34. If only two states of operation are desired, then only relay 75 and fixed or variable resistor 73 is used. For three states of operation, relay 76 and resistor 74 can be added as shown. The output of this attenuation circuit can then be buffered as shown in op amp 78. Additional relays and resistors could be added for even more states if desired.
If a true variable control is desired, then the output of op amp 71 could be multiplied by using an analog or digital signal multiplier circuit with a variable output signal from the disturbance detector block 34. The resultant output signal from this multiplier or the output from op amp 78 of FIG. 12 is then used as the face velocity setpoint or volume setpoint value for flow controller 32 of FIG. 2.
As was mentioned earlier, many different volume or face velocity controllers may be used for block 32. Additionally, depending on the control approach desired, an additional circuit block may be needed to provide maximum and/or minimum volume clamps. This block is shown in FIG. 2 as block 39. This block may be implemented with fixed volume clamps or variable clamps that are controlled by the disturbance detector. The circuit of FIG. 12 can be used to implement these variable maximum or minimum clamp setpoint circuits. If both clamps are desired to be variable, then two of these circuits would be needed.
FIG. 13 shows how these clamps could be implemented in conjunction with block 32. The minimum and maximum volume clamp signals 86 and 87 respectively from block 39 of FIG. 2, being either fixed or variable signals, are then used as input signals to the actual volume clamp circuits in block 32. The actual minimum clamp circuit is implemented with op amp 82, its associated diode and resistor 84. The actual maximum clamp circuit is implemented with op amp 83, its associated diode and resistor 85. These clamps work on a linear volume command output on line 88 from velocity or volume control block 80. The linear clamped signal is thus used to drive block 81 which in turn controls the volume moving through a damper, or air flow control valve.
If a variable speed drive or inverter is used to control flow instead of a damper, FIG. 14 shows how the system can be implemented. Operation is the same as for FIG. 2, except damper 30 and actuator 31 are replaced by block 14 which consists of a blower and blower speed controller. For the blower system, block 81 (FIG. 13) would be used to control the blower speed.
In both FIGS. 2 and 14, optional sash sensor, velocity sensors or volume sensors can be used in conjunction with the flow controller block 32 to provide proper control of face velocity or flow. U.S. Pat. Nos. 4,528,898 and 4,706,553 illustrate some typical applications and implementations of block 32 using these sensors.
While the invention has been shown and described above with reference to various embodiments, and specific implementations have been shown and suggested for various elements of the system, it is apparent that the various sensor and control circuits shown are merely illustrative and that other devices and techniques might be utilized in particular applications. Thus, while the invention has been particularly shown and described above for the preferred embodiments, the foregoing other changes in form or detail may be made therein by one skilled in the art without departing from the spirit and scope of the invention.
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This invention relates to a fume hood controlling method and apparatus which reduces the amount of replacement air required to operate a fume hood by permitting the fume hood to operate at a relatively low face velocity in the absence of a containment affecting condition, but which is capable of detecting the occurrence of a containment affecting condition, such as the presence or movement of a user within a selected area of the face of the fume hood, and of increasing face velocity to a selected level in response to such detection. When the detected condition no longer exists, the control automatically returns the fume hood to the lower face velocity, preferably with a time delay. Maximum replacement air volume and minimum replacement air volume may also be controlled in response to such detection.
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FIELD OF THE INVENTION
The present invention is directed to a novel waterproofing laminate which does not require the need for a separate, disposable, release sheet. Particularly, the present invention relates to improved bituminous waterproofing laminates. The present invention is also directed to novel methods of making and using the abovementioned waterproofing laminates.
BACKGROUND OF THE INVENTION
It is known that concrete surfaces and the like can be sealed in a waterproof manner by forming or applying thereon a membrane of a bituminous composition, such as asphalt, tar or pitch, which is substantially impermeable to moisture and water vapor. Preformed sheet-like materials useful for this purpose are well known. Examples of these materials are disclosed in U.S. Pat. Nos. 3,741,856, 3,853,682 and 3,900,102. These waterproofing materials have a laminate structure of a support sheet adjacent to a membrane of bituminous composition which has adhesive properties which renders it adherent to the support material and to the substructure, such as a concrete slab, to which it is applied. Laminate structures presently commercially available are supplied in the form of rolls which further comprise a flexible release sheet adjacent to the exposed surface of the bituminous membrane. This release sheet is a required component in the present mode of manufacture and serves, in the end product, to prevent the adhesive membrane from adhering to the sheet immediately adjacent thereto when in roll form. The release sheet does not form a part of the finally applied sheet-like structure which renders a substructure waterproof and, therefore, creates problems of removal and disposal at the job site.
Preformed flexible, sheet-like waterproofing material require the utilization of a release sheet, such as in the form of a siliconized paper, as an integral component in the presently known methods of formation. A release sheet capable of withstanding high temperatures is used as a forming surface upon which a hot semi-fluid bituminous composition, generally having a temperature of about 250° F., or greater, is applied. The composition must be cooled prior to superimposing a polymeric support on its free surface in order to minimize deterioration of the support. The resultant laminate structure, including the release sheet, is then formed into rolls for shipment. Alternately, when support sheets having a non-adherent free surface are used, the formed support/membrane laminate is formed into rolls for storage and shipment by removing the laminate from the release sheet at the end of the manufacturing process.
Recently, waterproofing laminates have been developed which eliminate the need for a separate release sheet. U.S. Pat. No. 4,215,160 to Rosenberg and Gaidis describes a waterproofing laminate comprising a bituminous asphalt layer and a carrier sheet which eliminates the need for a release sheet by applying a release agent, specifically a poly(dimethylsiloxane) base release coating, to the backside of the carrier sheet prior to producing the product roll of laminate. Thus, a release agent-carrier-bituminous asphalt "jelly roll" is formed.
When laminates are applied, adjacent layers are typically overlapped. Unfortunately, when the laminate of the '160 patent is utilized the uppermost laminate's bituminous adhesive layer must be laid down over the release agent coated carrier layer of the already adhered sheet, onto which it cannot stick. Thus, the release agent at the overlapping seam must be scrubbed off with a suitable organic solvent. This practice is undesirable from health, safety and environmental viewpoints. As a result, this type of "paperless" waterproofing laminate has not met with success in the marketplace.
SUMMARY OF THE INVENTION
The present invention provides a novel preformed sheet-like waterproofing laminate structure of a flexible sheet-like membrane and an adhesive bituminous composition which does not require a separate disposable release sheet and, furthermore, incorporates a release agent which is readily removed by wet abrasion; thus, eliminating the shortcomings of prior laminates.
The present waterproofing laminates comprise a flexible sheet-like polymeric support having a first major side thereof coated with a release coating which is substantially non-adherent to bituminous compositions and having a second major side thereof coated with a flexible membrane layer of an adhesive bituminous composition, wherein said release coating can be removed with wet abrasion.
The present invention also relates to a novel method of manufacturing the abovementioned waterproofing laminates. The method comprises applying a flexible polymeric support, one major side of which is coated with a release coating which is non-adherent with respect to bituminous compositions and which can be removed by wet abrasion. The polymeric support is applied with its non-adherent major side in a face-to-face relationship with the forming surface. A hot bituminous composition having a temperature above the melting point of the polymeric support member is applied to the other major side of the polymeric support while simultaneously cooling for a time sufficient to cause the bituminous composition to become handleable. The present method does not require the utilization of heat resistance release sheet during the formation or packaging of the laminate structure.
The present invention also relates to a novel method of forming tight overlap seams between the adjacent layers of the present laminates. The method involves removing the first applied layer with a wet abrasion, drying the surface and then applying an upper overlapping laminate.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows, in cross section, the present laminate (1, 2 and 3) installed in overlapping fashion over a concrete surface 4. The first sheet 1 is applied, the release coating over the overlap region 5 is wiped clean by wet abrasion and the next sheet 2 is applied. These steps are repeated for subsequent sheets.
FIG. 2 shows a roll of the present laminate being applied. The product laminate 5 being applied, is similar to the product of FIG. 4 below. 14' is a thin strip of double-sided release paper along the overlap region 5. This long-edge mounted release strip is removed from the first applied laminate 2 before the next applied laminate 3 is positioned. Thus, only the end laps need to be water washed before overlap.
FIG. 3 is a diagram of the preferred mixing scheme for preparing the present release coating, where 6 is the silicone emulsion tank or container, 7 is the aqueous thickener solution tank or container, 8 is the water inlet line, 9 is the silicone catalyst emulsion tank or container, 10 is the mixing tank (preferably of minimum size) and 11 is the coating pan of minimized size and with no recycle, unless air knife coating equipment is used wherein a blow-off return line 16 is required.
FIG. 4 is a cross-sectional representation of the preferred waterproofing laminate product, where 12 is a rubberized asphalt layer 36 inch wide, 13 is PET carrier film 351/2 inch wide, 14' and 14" are 6 inch double-sided release strips along the edge and 15 is the wet abrasion removable silicone release coating. (NOTE: The edge mounted release strips are utilized because it is believed that it will be easier for the applicator to only have to wash the "end" laps. Furthermore, a single release stop product, as in FIG. 2 above, is most preferred.)
DETAILED DESCRIPTION OF THE INVENTION
The waterproofing laminate of the present invention comprises a support sheet having superimposed on one major surface thereof a membrane of an adhesive bituminous composition. The opposite major surface of the support sheet is treated to be non-adherent to the bituminous membrane. The treatment must also be removable by wet abrasion.
The present method permits the utilization of a wide variety of sheet-like polymeric supports to form waterproofing laminate structures. Generally the support should be substantially impermeable to water and, based on the laminate structure's end use, capable of stretching with movement of the concrete or other material of the substrate to which it is ultimately applied.
The polymeric supports can be formed of natural rubber or of a synthetic organic polymer such as polyethylene, polypropylene or other polyolefin, a polyamide, a polyester, e.g., polyethlene terephthalate, a polyurethane, a polyvinyl halide, such as a polyvinyl chloride and copolymers thereof, such as a polyvinyl chloride and vinylidene chloride, a synthetic rubber, such as polychloroprene or butyl rubber, regenerated cellulose, cellulose, cellulose ethers or cellulose esters.
The supports can be films in the form of solid sheets, cellular films or woven and non-woven fabrics which are sufficiently non-porous to restrict the flow of the hot bituminous composition therethrough when applied.
Preferred support sheets are of poly(ethylene terephthalate) (PET) sheets, e.g. MYLAR and MELINEX brand sheets manufactured by E. I. Dupont denemours, Wilmington, Del, and ICI, London, England, respectively, and REVVAL brand MR-32058 sheet, manufactured by E. I. DuPont de Nemours, Co., Wilmington, Del. The preferred support typically at-e from about 0.5 to about 10 nails in thickness. Valeronl® brand oriented cross-laminated polyolefin film may also be used, however, due to its wetability, this film will require a wash coat as described below:
The support sheet may be treated with a wash coat to improve the wetability of the release coating. The wash should be applied to the outward face and may be applied to both faces of the support sheet. Suitable wash coats have the following desirable characteristics: good adhesion to polyethylene film; and, low surfactant content.
A preferred wash coat is DARAN 820 polyvinylidene chloride emulsion manufactured by W. R. Grace & Co.-Conn., Lexington, Mass. Support sheets which are precoated with a wash coat may also be used, e.g., Revval P86, manufactured by E. I. DuPont de Nemours, which has an acrylic wash coat on both sides.
The outside, i.e. non-bituminous, face of the support must be treated with a release coating. The release coating should be capable of making the surface substantially non-adherent to the bituminous material being used. The coating can be formed in any known manner at any time prior to application of the support to a forming surface as described hereinbelow. For example, the release coating can be formed on one of the major surfaces of the support by the deposition of an emulsion silicon composition which is cured by the aid of a catalyst and/or heat. The support can then be formed into rolls for storage and delivery to the site of formation of the waterproofing laminate structure. The support sheet can have any additional conventional features incorporated into its structure.
The release coating of the present invention must be non-adherent with respect to the bituminous compositions and must be readily removed by wet abrasion. As used herein the term "non-adherent" means that it prevents adhesion between two surfaces. Samples are deemed to be non-adherent if they yield a Keil release of less than 100 gm/in as determined by the method outlined herein below:
Keil Release Test for Rubberized Asphalt Laminate
Purpose:
This test procedure shall be the standard method for determining the release characteristic of rubberized asphalt laminate. It is an indication of the amount of force necessary to pull the silicone release paper from the mastic in the composite rubberized asphalt laminate.
Standard Test Method:
A. Equipment
1. Keil tester, with 0-500 gram scale, by Dow Corning (Model No. 2), or OHaus Model 8012.
2. Sample of rubberized asphalt laminate, 3" by 6" which has been conditioned for approximately 30 minutes in the lab.
Procedures:
1. Take a 3" by 6" sample of rubberized asphalt laminate to be tested and draw a line down the sample one inch from the center of the 3" side, on each side of the center (i.e., the lines should be 1/2" from the sides of the sample), or use a 2" wide templet.
2. Run a razor along each line or edge of the templet so that the silicone release paper is cut through to the mastic.
3. Using scotch tape, tape the sides of the rubberized asphalt laminate sample so that none of the mastic is visible (this it to prevent the mastic from adhering to the Keil Tester).
4. Peel back about I inch of the 2 inch wide portion of the release paper and fold the paper over on itself. Tape the exposed rubberized asphalt laminate with scotch tape.
5. Place the rubberized asphalt laminate sample in the Keil Tester, making sure that the 3" side containing the folded release paper and taped over rubberized asphalt laminate is at the bottom.
6. Fasten the silicone coated paper to the scale. Fasten the taped over rubberized asphalt laminate to the fixed clamp at the base of the Keil Tester.
7. Start the Keil tester and record the reading on the scale at one inch intervals as the paper releases from the mastic. Record only the force at 2, 3, 4 and 5 inches.
According to the present invention, the release coating must be a coating which is removable by wet abrasion. As used herein the term "wet abrasion" means that the release coating can be rubbed off by hand with a water wet/damp cloth, rag, plastic pot scrubber, brush or towel. Preferably this type of release coating is a water-based silicone emulsion, most preferably these emulsions are fast curing. Silicone emulsions suitable for use in the present invention are described in U.S. Pat. No. 4,190,688 to Traver et al. incorporated herein by reference. Suitable commercially available emulsion coatings include the SYL-OFF® System IV family of reactive silicone emulsions, the SYL-OFF® System VII family of emulsions containing reactive organofunctional silixone (both manufactured by Dow Corning Corp, Midland, Mich.) and water dilutable emulsions of reactive silicone polymers like SM 2145/SM 2146c Silicone Paper Release (manufactured by General Electric company, Waterford, N.Y.). A preferred embodiment of the present invention has the following formula:
______________________________________Deionized water: 54.84% (wt.)1.5% Sodium Alginate Solution: 28.92%(Kelgin-MV -medium high viscosity,mfg. by Kelco Algin, Chicago, IL)Polyalkylene oxide modified dimethyl 0.12%polysiloxane surfactant:(Silwet L-7607, mfg. byUnion Carbide Corp., Danbury, CT)Silicone catalyst emulsion X-27741: 8.05%(Mfg. by Dow Corning, Midland, MI)Silicone polymer emulsion X-27740: 8.05%(Mfg. by Dow Corning, Midland, MI)Antifoam Emulsion (Dow Corning 1430 Antifoam) 0.02%(Mfg. by Dow Corning, Midland, MI) Σ100.00%______________________________________
The above formula, at from 1% to 101. solids, is applied by either a rod coater or an air knife coater. An air knife coater is used to apply anywhere from 1.4 to 60 grams per square meter (wet) or per square meter to 4 grams per square meter after drying. (Preferably 0.4 grams per square meter to 1.6 grams per square meter after drying). Dry coating weight can be measured by X-Ray flourescence or other suitable methods. Other coating methods can be used. When using Meyer rods, suitable coatings can be achieved from a 3-7% silicone solids bath containing 1-2% carboxy methyl cellulose or 0.25-.5% sodium alginate. A #16 or #18 Meyer rod is typically used. When using the Direct Gravure method, suitable coatings can be achieved from a 7-15% silicone solids bath with and without thickener or extender, depending on the base sheet. Good results can be obtained using 80-150 line/inch gravure cylinder. When using the Offset Gravure methods, suitable coatings can be achieved from a 20-40% silicone solids bath without thickener. When using a size press, suitable coatings can be achieved from a 10-20% silicone solids bath without thickener or extender. Horizontal and inclined configurations are suitable, but vertical application is not recommended. Reverse roll coating method can also be used.
The bituminous compositions of the present invention can be any tar, asphalt, pitch or the like which is adhesive to and will render waterproof the contemplated substructure on which the final laminate product is to be used without the aid of heat or additional bonding agents at the site of application.
Thus, for application to surfaces of concrete, which are comparatively rough and dusty, the layer of adhesive composition must be at least about 0.010 to 0.2 inch (0.063 to 0.5 cm), the thicker the layer of adhesive composition the better the waterproofing effect, but in general, a layer of about 0.03 to 0.10 inch (0.08 to 0.25 cm) which is suitable.
Bituminous adhesive compositions are generally formed of natural or synthetic rubber, virgin or reclaimed, blended into bitumen to provide a smooth mix. The ratio by weight of bitumen to rubber is usually greater than about 75:25 with ratios of from about 80:20 to 95:5 being preferred. The compositions should be a non-solvent type which, preferably, is semi-fluid at temperatures of from about 125° C., and capable of application onto the support sheet as a coating. The resultant product is a flexible, pressure sensitive membrane having cold flow properties.
The resulting waterproofing laminate is preferably manufactured according to the method described in U.S. Pat. Nos. 4,992,334; 5,028,487 and 4,442,148, all incorporated herein by reference; however, a support sheet with a preapplied release coat is utilized and release paper is eliminated. The formed sheet-like waterproofing laminate structure is taken up as a roll with the non-adherent side of the support film in facing relationship with the free surface of the bituminous composition. Rolls of desired lengths of material are cut away from the remainder of the laminate structure to yield a free surface of the continuous belt, ready for additional formation of laminate structure. For vertical applications, the product can be rolled with the adhesive face on the inside. For horizontal applications, the product can be rolled with the adhesive face on the outside; thus, a small sheet of release paper is wrapped around the exposed adhesive to facilitate handling.
As noted above, the novel waterproofing laminates provide a waterproof barrier over a surface, particularly a concrete surface, by unrolling a desired length of material, applying the exposed bituminous layer to said surface, removing the silicone coating over edges to be overlapped and forming overlap seals as needed in order to form a continuous membrane over the whole surface.
The following example is given for illustrative purposes only and is not meant to limit the invention except as set forth by the claims hereinbelow. All parts and percentages are by weight except where otherwise indicated.
EXAMPLE I
Method of Preparing Release Coating
A) A sodium alginate solution is prepared by adding 1576 pounds of deionized water to a large Cowles mixer. The Cowles mixer is then turned on to the slowest speed setting. 24 pounds of sodium alginate (Kelgin MV) is slowly sifted into the vortex of the water. The Cowles blade speed is increased as thickening occurs to keep the liquid surface moving rapidly. The solutions is mixed 45 minutes or longer until the solution is smooth and free from lumps. The solutions is transferred to clean drums for storage. The solution is allowed to stand overnight before using. The Brookfield viscosity should be 400 to 1500 centipose using a #3 spindle at 60 RPM at 72° F. to 76° F. The sample must be at least 12 hours old before testing the viscosity.
B) The coating is prepared in mixing equipment similar to the diagram in FIG. 3. To the mix tank, 250 pounds of deionized water is added. 110 pounds of sodium alginate solution prepared according to step (A) above is then added. The mixture is mixed together without generating foam. 269 grams of silwet L-7607 wetting agent is added to a 5 gallon plastic pail containing 10 pounds deionized water. The mixture is thoroughly mixed together with a small hand held mixer then this mixture is added to the large mixing tank containing the previously added ingredients. 40.9 pounds of Dow corning X-27741 emulsion is added to the large mix tank. Mixing is continued without generating foam. 40.9 pounds Dow Corning X-27740 emulsion is added to the large mix tank. The solution is mixed without generating foam. 58 grams of Dow Corning DC-31 antifoam emulsion is added to a plastic pail containing 10 pounds deionized water. They are thoroughly mixed together with a small hand held mixer then this mixture is added to the large mixing tank containing the previously added ingredients. The final addition to the large mix tank is 38.2 pounds deionized water to bring the total tank contents to 500 pounds net weight. The final coating formula is 7.0% solids and has a Brookfield viscosity of 30 to 150 centipose.
C) The above coating is gravity fed to the coating equipment coating pan as required to keep the coating pan full.
D) The coating is applied to the support film using an air knife coater as shown in FIG. 3. The amount of wet coating applied to the support film is such that the final dry release coating weight is 0.1 grams per square meter to 4 grams per square meter and preferably 0.4 grams per square meter to 1.6 grams per square meter. The amount of wet coating applied to the support film is controlled by 1) the viscosity of the coating solution, 2) the speed and direction of the applicator roll, 3) the speed of the web through the coating equipment, 4) the air knife air pressure, 5) the angle of the air knife air jet to the support film, 6) the width of the air knife slot, and 7) the distance the air knife is from the support film.
E) After the support film is coated the web passes through a hot air oven to dry the coating and to cure the silicone release coating without causing the support film to distort from reaching too high a temperature. For this process, the oven had five separate heating zones. The first to zones were set at 300° F. and the last three zones were set at 325° F. The total time in the oven is 20 seconds.
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The present waterproofing laminates comprise a flexible sheet-like polymeric support having a first major side thereof coated with a release coating which is substantially non-adherent to bituminous compositions and having a second major side thereof coated with a flexible membrane layer of an adhesive bituminous composition, wherein said release coating can be removed with wet abrasion. These laminates can be formed into rolls for shipment without the need for a large release paper layer over the bituminous adhesive layer. The present invention also relates to a novel method of forming tight overlap seams between the adjacent layers of the present laminates. The method involves washing the first applied layer with a wet abrasion before applying an upper overlapping laminate.
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CROSS-REFERENCE
This application claims the benefit of the priority of presently pending Provisional U.S. Application No. 61/551,435, filed Oct. 26, 2011 entitled Mountable Earth-Embedding Anchor With Removable Underground Conduit Panels And Installation Apparatus, and is incorporated by reference herein in its entirety as if made a part of the present specification.
FIELD OF THE INVENTION
The present disclosure is directed toward the rapid and precise removable installation of a substrate-penetrating device that preferably facilitates the underground delivery of various utilities from devices mounted thereon.
BACKGROUND
Methods and apparatuses that facilitate the installation and removal of various utilities from devices mounted thereon would be very beneficial. Such utilities include, but are not limited to, electricity, water, oil, gases, sewage, other fluids, etc. Currently, in order to install something as simple as an electric lamp post, users must dig a hole, run the underground wire conduit through the hole, and pour concrete into the hole to make a permanent base for the lamp post. This process is tedious, time-consuming and costly in terms of both time and resources. In addition, in the event it is desired to move the utility fixture (e.g. lamp post, etc.) the concrete mooring, being permanent, is not easily removable from the site, and in any event is not reusable. If such mooring must be removed, such removal adds to the overall cost of utility fixture installation (and removal). There have been no useful and accepted advances in this field despite the fact that the presently accepted anchoring methods for utility fixtures are expensive, wasteful and not ecologically sound, as the concrete plug or mooring is most often left behind if a utility fixture is moved to another location, or otherwise no longer in use.
SUMMARY OF THE INVENTION
The present disclosure is directed to a substrate-penetrating device, such as a mountable earth-embedding anchor, with removable underground conduit panels and installation apparatus. The apparatuses and methods of the present disclosure save time, labor, materials, etc., and significantly reduce cost. According to the present disclosure, the methods and apparatuses disclosed herein significantly facilitate changes in location for various fixtures and components that heretofore were deemed permanent. Variations of the present invention described herein allow for the simplified installation, removal and relocation of fixtures such as, for example, lamp posts, signage, and virtually any object that must be firmly implanted into the ground. As stated above, at the present time, according to accepted custom, such objects are placed substantially permanently into the ground, requiring materials, such as, for example concrete, to be used as the permanent mooring. Once implanted into such a mooring, such objects are not easily removed, for example, for reuse in a different location. Indeed, upon removal from their permanent mooring or anchoring such objects are necessarily damaged and cannot be reused. For the purpose of this specification, the terms “substrate-penetrating” and “earth-embedding” may be used interchangeably or in combination.
According to one variation, devices mounted on the presently disclosed mountable earth-embedding anchor with removable underground conduit panels can be connected underground to each other, as well as to similar or different devices, etc. The base plate and removable underground conduit panels of the disclosed mountable earth-embedding anchor with removable underground conduit panels can also accommodate a greater diversity of devices and a larger number of devices substantially simultaneously. Furthermore, the devices presently disclosed require only one individual to operate the devices, and the installation apparatus can be reused for installation of other mountable earth-embedding anchors.
According to one variation, the present invention is directed to a substrate-penetrating device preferably having at least a portion of the device submerged in a substrate comprising at least one removable underground conduit panel that allows passage of materials from underground conduits into the substrate-penetrating or earth-embedding device.
According to a further variation, the present invention relates to a substrate-penetrating, or earth-embedding device comprising an anchor. The anchor preferably comprises a drilling component, and at least one chamber bounded by a housing, with the housing comprising at least one removable panel. According to a variation, the substrate-penetrating earth-embedding device is mountable and comprises an installation head. According to a further variation, the device further comprises an installation apparatus for engaging the installation head, or any part of the device, with the installation apparatus preferably comprising a means for translating and delivering a force, such as a rotational, liner manual or automated mechanical or other direct or indirect force, and combinations thereof, to the anchor. In one variation, the installation head preferably comprises a spirit level. Preferably, the rotational force supplied to the device is a manually-delivered force, and, most preferably, the anchor device is removable and preferably secures a utility fixture in a substrate without a supplemental stabilizer, such as, for example, cement, concrete, etc. The anchor device is manufactured as a single piece, or the anchor may comprise separate pieces that are assembled.
In a further variation, the present disclosure relates to a method for installing and securing a utility fixture that allows passage of materials between mounted devices and underground conduits comprising the steps of providing an anchor device having a first length, with the anchor device comprising a drilling component, at least one chamber with the chamber bounded by a housing and comprising at least one removable panel, and a installation head. The anchor device is oriented to an initial installation position on a substrate surface. Preferably, an installation apparatus is provided and engages the installation apparatus via an anchor device installation head. A force, such as, for example, a rotational force, is provided to the installation apparatus, delivering the anchor device from the initial installation position on a substrate surface to a final installation position whereby a substantial and desired and pre-determined length of the anchor device is directed beneath the substrate surface. A utility fixture to be secured is then provided and secured to the installation head.
BRIEF DESCRIPTION OF THE DRAWINGS
Having thus described variations of the disclosure in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
FIG. 1 is a detailed view of the installation apparatus for one variation of the present invention, along with a detailed perspective view of the spirit level;
FIG. 2 is a perspective view and detailed plan view of a variation of the mountable earth-embedding anchor with removable underground conduit panels;
FIG. 3 is a perspective view of a variation of the present invention shown in place in the ground substrate, and showing an underground conduit attached to each side;
FIG. 4 is a perspective view of a variation of the present invention showing the mountable substrate-penetrating earth-embedding anchor with removable underground conduit panels with a fixture base mounted thereto;
FIGS. 5 a - c show various attachments that can be mounted onto variations of the present invention to secure various devices;
FIG. 6 shows a variation where the mountable substrate-penetrating earth-embedding anchor device can be assembled from multiple pieces into a single unit; and
FIG. 7 shows the mountable substrate-penetrating earth-embedding anchor device in position securing an attachment fixture in the ground without the use of separate fasteners.
DETAILED DESCRIPTION
The present invention will be described more fully hereinafter with reference to the accompanying drawings, where preferred alternatives are shown. The disclosures may, however, be embodied in many different forms and should not be construed as limited to the examples or illustrations set forth. Rather, these examples and illustrations are provided so that this disclosure conveys the scope of the inventions provided herein to those skilled in the field. Like numbers refer to like elements throughout.
FIG. 1 shows a preferred, but not limiting, view of an installation apparatus 7 comprising an installation bar 18 with handles 12 at each end. Each handle 12 has a handle tip 10 that is preferably slightly wider at its base than the width of handles 12 . Installation bar 18 preferably has a region called the spirit level attachment platform 16 that acts as the attachment site of the spirit level 14 . Installation bar protrusions 20 project from installation bar 18 and are preferably dimensioned to engage installation apparatus 7 to mountable substrate-penetrating earth-embedding anchor 9 (shown in FIG. 2 ), by inserting installation bar protrusions 20 into the elongated insertion sites 28 located on the mountable head 26 . Fasteners 50 are preferably placed over a portion of the installation bar protrusions 20 that extend through and past the mountable head 26 , preventing dislodgement of installation apparatus 7 from anchor 9 . This preferred diagram of installation apparatus 7 shown in FIG. 1 is shown for non-limiting, illustrative purposes only. For example, a simplified installation apparatus is contemplated, whereby such apparatus 7 is a substantially linear rod made from a suitably durable material (e.g. metal, wood, plastic, alloy, composite, etc. or combinations thereof), with the rod passing through openings made in the wall of the anchor 9 or otherwise attaching to anchor 9 . In such an example (not shown), rotational motion and torque would be applied to the device by pushing on one side of the rod, while pulling on the other side of the rod to drive the earth-embedding device clockwise or counterclockwise (depending on the desired orientation of the drill threads 42 (see FIG. 2 ), and downward into and through a substrate surface.
FIG. 2 shows a mountable substrate-penetrating earth-embedding anchor 9 comprising a mountable head 26 with multiple elongated insertion sites 28 , a mountable head rim 24 , and a cavity opening 22 into the anchor body. According to one embodiment, the depth of the elongated insertion sites 28 is less than the height of the mountable head rim 24 . Mountable head rim 24 is preferably a rim extension of mountable head 26 that is integral with the manufacture of the head 26 , or that is otherwise attached to head 26 , such that the thickness or height of the mountable head rim 24 is greater than the thickness of mountable head 26 alone. One preferred form of mountable head 26 has mountable head rim 24 that is preferably dimensioned to be approximately at least about equal in height to installation bar protrusions 20 in FIG. 1 , such that, with the insertion of installation bar protrusion 20 into elongated insertion site 28 , the installation bar protrusions 20 do not extend below mountable head rim 24 in a horizontally flat view plane. This orientation is desirable so that the protrusions to not come into contact with the substrate or otherwise impede the implantation of the mountable substrate-penetrating earth-embedding anchor 9 . In addition, the dimension of the rim 24 can be selected for the purpose of keeping any bolting assemblies from view when the mountable earth-embedding anchor 9 is in its final installed position. In other variations, where such decorative concerns are not present, the rim may be substantially equivalent to the thickness of the mounting head 26 , or any height (thickness) as desired.
The mountable head further comprises cavity opening 22 into the portion of anchor 9 that connects the first portion 30 of anchor 9 to the outside environment above mountable head 26 . Therefore, according to one variation shown in FIGS. 1-4 , anchor 9 is substantially hollow at least from the area of the mounting head 26 and extending a predetermined distance into the body of anchor 9 . First body portion 30 of anchor 9 is connected to, or integral with, a second body portion 34 of anchor 9 , such that there is an open path to the outside environment above mountable head 26 . Second body portion 34 of anchor 9 preferably comprises a housing that comprises, or is bounded by, at least one perforated removable panel 36 along its walls. Preferably, above and between each of the removable panels 36 are perforated removable anchor sites 38 (all panels and anchor sites not shown). As partially shown in FIGS. 3 and 4 , in one variation of the present invention, anchor 9 comprises four removable panels 36 and twelve removable anchor sites 38 . A tail section 40 is connected to, or integral with, second body portion 34 . The tail section 40 has a first diameter near its point of attachment to second body portion 34 and a second diameter at its end distal from the second body portion 34 . This disparity in diameters preferably results in narrowing taper that ends at the tip of anchor 9 . Outwardly extending earth-plowing attachments 42 , or threads, are affixed to or manufactured integral with the outside of the tail 40 in a spiraling fashion from the portion of tail 40 closest to second body portion 34 of anchor 9 , and tapering to a point at the distal end of tail 40 to achieve and facilitate a screw-like or drill effect. This preferred diagram of mountable earth-embedding anchor 9 shown in FIG. 2 is for non-limiting illustrative purposes only.
FIG. 3 shows a perspective view of a mountable substrate-penetrating earth-embedding anchor 9 of the present disclosure in the ground 8 with an installation apparatus 7 attached to anchor 9 via mounting head 26 . An underground conduit 32 is shown attached to each side of anchor 9 at the previous locations of two of the removable panels 36 . (See FIGS. 2-4 ). FIG. 3 also shows a partial cut-away view inside anchor 9 and one underground conduit 32 . FIG. 3 illustrates how materials from underground conduit 32 can enter and exit mountable earth-embedding anchor 9 . FIG. 3 , in the cut-away section, shows cables 44 , 46 , and 48 entering second body portion 34 of anchor 9 through a panel opening 60 effected by the removal of removable panel 36 . Cables 44 , 46 and 48 extend from and through second body portion 34 and upwardly into first body portion 30 of anchor 9 . It is understood that multiple cables may extend from a single conduit 32 into the anchor 9 through a single panel opening, or from multiple conduits 32 into the anchor 9 through multiple panel openings 60 . This preferred drawing of one variation of the present invention is for illustrative and non-limiting purposes only.
FIGS. 4 and 5 a - c show a non-limiting and nonexclusive representation of different types of devices that can be mounted on mountable substrate-penetrating earth-embedding anchor 9 by attaching the base of the devices to the mountable head 26 of anchor 9 . For example, decorative mounting base 52 , mounting brace 54 , round device mounting base 56 , and square device mounting base 58 are exemplary and non-exclusive illustrations of mounting bases used, for example, in installation of lamp posts, street lights, water fountains, photovoltaic ground mount systems, benches, mailboxes, etc. These bases can all attach to mountable head 26 by any secure attachment means, such as, for example, screws, bolts, etc. This preferred drawing of mountable earth-embedding anchor 9 with attached decorative mounting base 52 , and the other bases shown in FIG. 4 and mounting braces shown in FIGS. 5 a - c are for non-limiting, illustrative purposes only.
A further variation is shown in FIG. 6 where the mountable substrate-penetrating earth-embedding anchor 9 can comprise multiple pieces that can be assembled before or after installation. For example, tail section 40 , itself, can be attached to a manual or automated drive assembly (not shown) for the purpose of driving tail section 40 into a substrate such as, for example, the ground. Once the tail section is driven into place in a given substrate, the body portion 34 can attach to either first portion 30 and then tail section 40 , or to tail section 40 , and then first section 30 . It is understood that according to this variation, the multiple pieces can be joined by any permanent or removable means, such as for example, interlocking features, compression or frictional fit, use of fasteners, pins, bolts, screws and the like, etc., as would be readily understood by one skilled in the field.
FIG. 7 shows the mountable earth-embedding anchor 9 in use for the purpose of anchoring mounting brace 54 into the ground. In this variation, the downward anchoring force of the mountable earth-embedding anchor 9 , itself, provides adequate force to secure the mounting brace 54 without the use of additional fasteners, although such fasteners could optionally be used in addition. Though not shown, it is understood that mountable earth-embedding anchor 9 may be driven further into the ground such that the mountable head 26 is substantially in intimate contact with a surface of the mounting brace 54 .
By way of example, operation of preferred variations of the present invention will be presented in accordance with the representative installation of an outdoor electrical lamp post at a residence. As shown in FIG. 4 , a lamp post has a decorative mounting base 52 with screws, washers, bolts, nuts, etc. (not shown) for anchoring the base 52 to a mountable earth-embedding anchor 9 . For this particular task, the user desirably makes an 18 inch trench using a shovel or trencher, etc. Proper wiring is done at the power supply side and placed inside an underground conduit 32 that runs in the trench and stops at the lamp post installation site. The user then places a mountable earth-embedding anchor 9 in the appropriate upright position. For this application, the mountable earth-embedding anchor 9 and installation apparatus is preferably made of hot-dipped galvanized steel, but is understood to be made from any suitably durable material such as, for example, steel, iron, aluminum, other metals, alloys, solid wood or laminate wood, plastics, composite materials, etc., and combinations thereof. Installation apparatus 7 is then placed into position on the anchor 9 with the installation bar protrusions 20 positioned into opposing elongated insertion sites 28 on the mountable head 26 . Fasteners 50 are optionally then placed over the portion of the installation bar protrusions 20 that extend outwardly from the other side of mountable head 26 to secure the installation apparatus 7 to mountable earth-embedding anchor 9 . For this application, the fasteners 50 are preferably durable rubber bands that fit tightly around installation bar protrusions 20 , although any removable securing means may be used as would readily be understood by one skilled in the field.
The mountable earth-embedding anchor 9 and installation apparatus 7 complex is then positioned at the desired location of the lamp post installation. The end of the tail 40 is firmly impaled into the substrate surface manually, such as, for example “by hand”. The location of each removable panel 36 relative to the spirit level 14 or handles 12 is noted. Holding each of the two installation apparatus handles 12 with one hand, the user uses the spirit level 14 to insure that the mountable earth-embedding anchor 9 and installation apparatus 7 is substantially perpendicular to the ground. The user then rotates the mountable earth-embedding anchor 9 and installation apparatus 7 in a clockwise direction while applying a downward force sufficient to drive the mountable earth-embedding anchor 9 into the ground.
While the preceding protocol illustrates the manual installation of the mountable earth-embedding anchor 9 , it is understood that automated augers, drilling devices, and various other machineries and automations with appropriate attachments may be used to drive the mountable earth-embedding anchor 9 into a final desired position in a substrate.
For one exemplary, non-exclusive, lamp post installation, the mountable earth-embedding anchor 9 has a first body portion 30 that is selectively dimensioned and therefore long enough, such that the removable panels 36 have their lowest portion slightly below 18 inches when the lowest edge of the mountable head rim 24 touches the ground. Some dirt may be removed from the trench until the outside of the second portion of body is visualized. When the mountable head rim 24 is substantially flush with the ground, the user rotates the installation apparatus 7 until one of the removable panels is centered at the opening of the 18 inch deep trench. The user looks at the spirit level 14 to make sure the mountable head 26 is substantially horizontal and then applies upward force on the handles 12 to make certain that the mountable earth-embedding anchor 9 is securely anchored in the substrate. According to one variation, in order to disengage the installation apparatus 7 from the mountable earth-embedding anchor 9 , the user plants one or both feet on the edge of mountable head 26 and applies upward force on the handles 12 adequate to disengage the apparatus 7 from the fasteners 50 . The handle tips 10 will help prevent a user's hands from slipping off, as the handle tips 10 are preferably slightly wider at their base than the width of handles 12 . If the user is still having a difficulty disconnecting installation apparatus 7 from anchor 9 , the user can forcibly remove the fasteners from installation bar protrusions 20 prior to exerting the force to remove the installation apparatus from the anchor 9 .
The installation apparatus or other device then may be used to disengage the removable panels 36 from the second body portion 34 by extending the apparatus 7 into the cavity opening 22 in anchor 9 and forcibly disengaging the removable panel 36 from the second body portion 34 of anchor 9 . After disengaging the perforated removable panel 36 into the inside of second body portion 34 , the user passes, for example, cable 44 from the conduit 32 in the trench through the panel opening 60 made by removal of the removable panel 36 . The cable 44 is passed from the panel opening 60 through to the cavity 22 opening into first body portion 30 of anchor 9 . See FIG. 3 . The decorative mounting base 52 is placed over the mountable head 26 and the black cable 44 is pulled therethrough and wired appropriately to the lamp light fixture. The user then secures the decorative mounting base 52 to the mountable head 26 using the already in place hardware (screws, bolts, nuts, etc.). The rest of the lamp post assembly is completed and the user fixes the underground conduit 32 to the panel opening 60 . The user fills the trench with dirt and finishes with some minor landscaping.
Different materials, sizes, shapes, and interconnections can be used for all components of mountable earth-embedding anchor 9 and installation apparatus 7 . For example, the length, width, depth, height, and thickness of any component of mountable earth-embedding anchor 9 and installation apparatus 7 can vary as desired. Furthermore, different number of components, such as for insertion sites 28 or for removable panels 36 , can be used in the manufacture of mountable earth-embedding anchor 9 and installation apparatus 7 , as desired.
In addition, the tail portion 40 of the mountable earth-embedding anchor 9 may incorporate earth-plowing features, or screw-like threads 42 oriented to allow for counter-clockwise rotational installation into a substrate (as opposed to the orientation of the threads 42 shown in the FIGS. that allow for clockwise rotational installation). Further, variations of the tail section 40 of the mountable earth-embedding anchor 9 may not incorporate the earth-plowing feature, or screw-like threads 42 . For example, the present invention contemplates variations where the mountable earth-embedding anchor 9 may be driven manually or mechanically directly into a substrate to a final installation position with no rotational force applied. In this variation, the tail section 40 may be substantially smooth (without thread-like features), and may incorporate different features and dimension to assist in installation, etc. Therefore it will be understood that the tail section, while shown in the FIGS. as possessing a tapered orientation, may instead be substantially linear throughout its length, with its outer diameter being substantially constant throughout its length. Still further, variations are contemplated where the tail section may or may not be tapered, relative to its width, along its length, but may or may not have its diameter vary along its length along one or more axes, to achieve, for example, a chisel-like cutting edge to assist in its installation, for example, while being forcibly driven into a substrate.
Still further, the present disclosure contemplates a variation where the earth-embedding anchor 9 does not comprise an installation head. In this variation, it is understood that the anchor 9 is driven manually or mechanically into the ground with or without rotation force, such as, for example, via a manual or automated jackhammer, sledgehammer or similar type of device, etc.
It is further understood that, in further variations, different component parts of the earth-embedding anchor 9 may be made from the same or different materials. In other words, depending on the desired use, the earth-embedding anchor 9 may be one integral piece, or may be assembled from multiple piece, and the pieces may be made from the same or different materials, such as, for example, hot-dipped galvanized steel, steel, iron, aluminum, other metals, alloys, solid or laminate wood, plastics, composite materials, etc., and combinations thereof. Still further, if the earth-embedding anchor 9 is being used to secure a fixture that does not require the internal passage of, for example, utility cables, wires, etc., or allow for a fluid flow therethrough, the components may be substantially hollow or substantially solid as desired.
Both the mountable earth-embedding anchor 9 and installation apparatus 7 can be manufactured in any manner, by hand or machine, as one integral piece or in separate components that can be assembled together. For example, the mountable head 26 , first body portion 30 , second body portion 34 , tail 40 , and earth-plowing attachments 42 can be manufactured from one piece of metal integrally, and may be machined or molded, etc., or may be assembled as separate pieces of metal that are assembled by any method, such as, for example, welding etc., as would be readily understood by one skilled in the field. In terms of usage, the mountable earth-embedding anchor 9 and installation apparatus 7 are not limited by the examples illustrated in this application. The mountable substrate-penetrating earth-embedding anchor 9 and installation apparatus 7 can be used for mounting devices in earthen surfaces, sandy surfaces, rocky surfaces, wooden surfaces, concrete, plastic, underwater, etc. The mountable earth-embedding anchor can be coated with various materials alone or in combination, such as, for example, silicone, Teflon®, etc., for better handling, performance and ease of installation, etc. Furthermore, two or more bases can be mounted onto mountable head 26 , substantially simultaneously. For example, decorative mounting base 52 can be mounted over a previously installed device mounting base 56 . This is possible because the elongated insertion sites 28 can be made to accommodate the insertion of two or more screws. Alternatively, the decorative mounting base 52 can be rotated and attached to mountable head 26 using different elongated insertion sites 28 . It is understood that this invention is not limited to the variations described above.
It is further understood that, while embodiments of the present invention have been described as employing manual installation, various automated means may be employed for installation. Any high torque motorized or hydraulic means for effecting and transferring rotational force to the present invention to effect the desired installation is contemplated as would be readily understood by one skilled in the field.
While the preferred variations and alternatives of the present disclosure have been illustrated and described, it will be appreciated that various changes and substitutions can be made therein without departing from the spirit and scope of the disclosure. Accordingly, the scope of the disclosure should only be limited by the accompanying claims and equivalents thereof.
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Methods and apparatuses are disclosed for the rapid and precise removable installation of a substrate-penetrating device that facilitates underground delivery of various utilities to and/or from devices mounted thereon.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. application Ser. No. 07/617,030 filed Nov. 21, 1990, now abandoned.
FIELD OF THE INVENTION
THIS INVENTION relates to pesticidal compositions. In particular, it is directed to compositions containing both fumigant and residual pesticidal ingredients which function first to exterminate quickly any pests immediately present but then leave a residual protection against pests in the area or on the surfaces to which the composition has been applied.
BACKGROUND OF THE INVENTION
There are many domestic and commercial applications wherein areas and surfaces must be protected against infestation by insects and other pests. For example, household cupboards, wardrobes, pantries and the like must be protected against invasion by ants, cockroaches and other pests. Similarly, in commercial premises and establishments such as restaurants, cafes and the like it is essential, and often mandatory under government health regulations, that areas used for the storage of food and/or the preparation and serving of meals be kept pest free.
Of particular concern are German cockroaches. These pests have a marked resistance to most of the known pesticides, including the synthetic pyrethroids. Conventional treatments only remove this species of cockroach for a period between several days and three months. Further, conventional treatments do not affect any eggs which may have been deposited by the female cockroach. Accordingly, the eggs hatch and re-infestation occurs.
In the past, organo phosphates were the preferred choice for the extermination and control of these pests, although they have been virtually superceded today by synthetic pyrethroids and carbamates. However, two well-known organo phosphates still in use are dichlorvos and chlorpyrifos. Dichlorvos is commonly used as a fumigant and thus used when it is necessary to kill pests already present in an affected area. Chlorpyrifos is a residual and is, therefore, utilised to keep an already cleared area free from pests. It is primarily used as a surface spray for short to medium-term residual control. Commercial suppliers of chlorpyrifos estimate its effective life to be approximately three (3) months. Nevertheless, individually, neither dichlorvos nor chlorpyrifos are considered to be very effective.
It is also known to provide a pesticidal composition which is a combination of fumigant and residual ingredients. In fact, dichlorvos has been used as an additive to a residual-type pesticide. Although when used as such an additive, dichlorvos does reduce the "knockdown" time required to eliminate existing pests, it does not increase the effective life of the residual ingredient to which it has been added. For this reason, dichlorvos is rarely used now in the pest control industry as the extra expense incurred in its inclusion in the composition to reduce the immediate numbers of pests present is not outweighed by any lasting advantage of the residual component.
Further, a disadvantage of the residual chlorpyrifos is that it is readily removed by cleaning of treated surfaces, such cleaning, of course, being a regular occurrence in food storage, preparation and serving areas.
Yet another disadvantage of prior pesticidal compositions, whether they contain residual ingredients or not, is that a pest usually must remain in a treated area for a sufficient period for the pesticidal composition to be effective. If the pest remains for that sufficient period, then often enough contact with the active ingredient has been made to eradicate the pest, even if the pest first leaves the treated area before dying. On the other hand, if the pest leaves the treated area before sufficient contact is made with the active ingredient, then the pest may again return to the area as it is unaware that that environment is hostile to it.
SUMMARY OF THE INVENTION
It is a general object of the present invention to overcome, or at least ameliorate, one or more of the above problems and to provide a pesticidal composition containing both fumigant and residual ingredients which not only quickly exterminates existing pests but which also leaves a residual pesticidal protection which is not readily removed by conventional cleaning processes.
The present inventors have discovered that the general object can be achieved by first mixing dichlorvos and chlorpyrifos together and then subjecting the mixture to microwave radiation.
Thus according to a first aspect of the present invention, there is provided a pesticidal composition, said composition comprising dichlorvos and chlorpyrifos which have been added together and then subjected to microwave radiation.
In addition to the active ingredients, the compositions of the present invention may optionally include other, non-active ingredients, such as the usual diluents and carriers.
For example, the life of the composition can be further extended by the addition of a high molecular weight polymer to adjust the viscosity of the composition.
Another optional feature of the compositions of the present invention is the addition of a pest attractant, for example, a sweetening agent.
According to a second aspect of the present invention, there is provided a process for the preparation of a pesticidal composition, said processing comprising:
1) mixing together dichlorvos and chlorpyrifos; and
2) subjecting the thus obtained mixture to microwave radiation;
whereupon the resultant composition may have added, optionally, any required diluent, carrier or other ingredient.
Preferably, the composition also includes a high molecular weight polymer. More preferably, this high molecular weight polymer is polyvinyl alcohol (PVA).
Optionally, the composition may include sugar as a sweetening agent to attract pests to the treated area.
DESCRIPTION OF THE INVENTION
Examples of the compositions of the present invention and methods for their preparation will now be described.
In these examples, a reference to chlorpyrifos concentrate is a reference to the commercially available concentrate of chlorpyrifos (450 gm/l) in xylene (300 gm/l), with the balance being emulsifiers and/or other non-active components; a reference to dichlorvos concentrate is a reference to the commercially available concentrate of dichlorvos (505 gm/l) in xylene (455 gm/l), with the balance being emulsifiers and/or other non-active components; and a reference to microwave radiation is a reference to microwave irradiation of 12 cms wavelength at 600 watts for 20 seconds.
EXAMPLE 1
Commercially available dichlorvos (150 ml) and chlorpyrifos (150 ml) concentrates are mixed together and then subjected to microwave radiation. The mixture is diluted with 9 litres of water.
EXAMPLE 2
Commercially available dichlorvos (100 ml) and chlorpyrifos (100 ml) concentrates are mixed together and then subjected to microwave radiation. The mixture is diluted with 9 litres of water.
EXAMPLE 3
Polyvinyl alcohol (100 ml) was added to the composition of Example 1.
EXAMPLE 4
Commercially available dichlorvos (120 ml) and chlorpyrifos (180 ml) concentrates are mixed together, subjected to microwave radiation and added slowly to polyvinyl alcohol (200 ml) in water (2 L) with agitation and then further diluted with water (8 L). Sugar (400 g) dissolved in hot water is added as a sweetening agent which attracts pests to the area to be treated.
To establish the benefit of subjecting the mixtures of dichlorvos and chlorpyrifos to microwave radiation, a further composition was prepared whereby commercially available dichlorvos (150 ml) and chlorpyrifos (150 ml) concentrates were simply mixed together and added to 9 litres of water. The results of using this composition on commercial and residential properties are presented in Table 1.
The results of using the compositions of the present invention as described in Examples 1 and 2 above are presented in Tables 2 and 3 respectively.
TABLE 1__________________________________________________________________________PESTICIDAL COMPOSITION - 150 mls Dichlorvos + 150 mls Chlorpyrifos mixedand agitated then added to 9 liters of water. INI- INI- PERFORMANCEPROPERTY DATE TIME DESCRIPTION TIAL TIAL 3 6 9 12 15 18ADDRESS OF JOB OF JOB OF INFESTATION K.O. KILL mths mths mths mths mths mths__________________________________________________________________________La Rustica 19/06/89 11:30 pm Heavy Infestation 10-20 100% No No Minor RenewedRestaurant of German secs Activity Activity Activity ContractSurfers Paradise CockroachesBelisimo Restaurant 20/06/89 11:00 pm Moderate Infestation 10-20 100% No Minor No No RenewedBroadbeach of German & secs Activity Activity Activity Activity Contract Oriental Serviced CockroachesOcean View Motel 23/06/89 9:30 am German 10-20 100% No Minor No Minor RenewedCoolangatta Cockroaches - secs Activity Activity Activity Activity Contract Moderate Infestation Serviced in rooms Heavy Infestation in RestaurantTunnel Nightclub 26/06/89 10:00 am Moderate 10-20 100% Minor No Minor RenewedSurfers Paradise Infestation - secs Activity Activity Activity Contract German, American, Serviced Serviced Australian CockroachesSam-The-Wok 27/06/89 9:00 am Moderate Infestation 10-20 100% No No No RenewedRestaurant of German secs Activity Activity Activity ContractChevron Island CockroachesTandoori Taj 01/07/89 11:30 pm Heavy Infestation - 10-20 100% No No Minor RenewedRestaurant German, American, secs Activity Activity Activity ContractSurfers Paradise Oriental Serviced CockroachesChevron Island 05/07/89 6:00 am Heavy Infestation 10 secs 100% Minor No No No RenewedCoffee Shop of German Activity Activity Activity Activity Contract Cockroaches ServicedThe Avenue 14/07/89 6:00 am Moderate 10-20 100% No Minor No RenewedRestaurant & Bar Infestation - German secs Activity Activity Activity ContractSurfers Paradise American, Serviced AustralianFrog Hollow 15/07/89 11:00 am Heavy Infestation 10 secs 100% No No Minor RenewedHouse Boat of German Activity Activity Activity ContractSanctuary Cove Cockroaches__________________________________________________________________________
TABLE 2__________________________________________________________________________PESTICIDAL COMPOSITION - 150 mls Dichlorvos + 150 mls Chlorpyrifos mixed,agitated and microwavedthen added to 9 liters of water. INI- INI- PERFORMANCEPROPERTY DATE TIME DESCRIPTION TIAL TIAL 3 6 9 12 15 18ADDRESS OF JOB OF JOB OF INFESTATION K.O. KILL mths mths mths mths mths mths__________________________________________________________________________Stage Door Theatre 20/06/89 12:30 pm Heavily Infested with 5-10 100% No No No No No NoRestaurant German & Australian secs Activity Activity Activity Activity Activity ActivityChevron Island CockroachesGrapevine 25/06/89 10:00 am Very Heavy 5-10 100% No No No No No NoRestaurant Infestation of German secs Activity Activity Activity Activity Activity ActivitySouthport CockroachesCharlies Restaurant 26/06/89 6:00 am Moderate Infestation 5-10 100% No No No RenewedSurfers Paradise of German secs Activity Activity Activity Contract CockroachesFawity Tacos 17/07/89 10:30 am Moderate Infestation 5-10 100% No No No No No RenewedRestaurant of German & secs Activity Activity Activity Activity Activity ContractMain Beach American CockroachesMexican Kitchen 17/07/89 11:30 pm German Cockroaches - 5-10 100% No No No RenewedRestaurant Heavy Infestation secs Activity Activity Activity ContractBundall in dishwasher.Copper Pan 19/07/89 7:00 am Moderate Infestation 5-15 100% No No No No RenewedRestaurant of German, American secs Activity Activity Activity Activity ContractBroadbeach & Oriental Cockroaches.Residential Property 19/07/89 9:30 am Heavy Infestation of 5-10 100% No No No No No NoThornton Street, German & American secs Activity Activity Activity Activity Activity ActivitySurfers Paradise Cockroaches.Pellermans Hotel 24/07/89 10:15 pm Heavy Infestation - 5-20 100% No No No RenewedNerang German, Australian, secs Activity Activity Activity Contract Oriental & American.Cornelius Cruise 19/08/89 8:30 am Very Heavy 5-20 100% No No No No No NoVessel Infestation - All secs Activity Activity Activity Activity Activity ActivityMariners Cove Species.__________________________________________________________________________
TABLE 3__________________________________________________________________________PESTICIDAL COMPOSITION - 100 mls Dichlorvos + 100 mls Chlorpyrifos mixed,agitated and microwavedthen added to 9 liters of water. INI- INI- PERFORMANCEPROPERTY DATE TIME DESCRIPTION TIAL TIAL 3 6 9 12 15 18ADDRESS OF JOB OF JOB OF INFESTATION K.O. KILL mths mths mths mths mths mths__________________________________________________________________________Sweethearts Cafe 01/09/89 7:00 pm Heavy Infestation of 10-15 100% No No No RenewedSurfers Paradise German Cockroaches secs Activity Activity Activity ContractAls Coffee Lounge 02/09/89 3:00 pm Heavy Infestation of 10-15 100% No No Minor RenewedSouthport German & American secs Activity Activity Activity Contract CockroachesCommercial Hotel 05/09/89 7:00 am Moderate Infestation - 10-15 100% No No No RenewedNerang All Species secs Activity Activity Activity ContractDraculas Theatre 16/09/89 9:00 am Heavy Infestation - 10-15 100% No No Minor RenewedRestaurant All Species Secs Activity Activity Activity ContractBroadbeachCity Fisheries 18/09/89 7:20 am Heavy Infestation of 10-15 100% No No No No RenewedAshmore German Cockroaches. secs Activity Activity Activity Activity ContractRunaway Bay 27/09/89 9:00 pm Heavy Infestation of 10-15 100% No No No RenewedPoultry German Cockroaches. secs Activity Activity Activity ContractRunaway BayCoolangatta Senior 06/10/89 4:00 pm Very Heavy 10-15 100% No No No No RenewedCitizens Club Infestation - All secs Activity Activity Activity Activity ContractCoolangatta SpeciesResidential Property 10/10/89 11:00 am Moderate Infestation 10-15 100% Minor No No No No RenewedAmalfi Street of German & secs Activity Activity Activity Activity Activity ContractIsle of Capri American Cockroaches.Residential Property 14/10/89 10:00 am Moderate Infestation 10-15 100% No Minor No No RenewedRiver Road of German & secs Activity Activity Activity Activity ContractCypress Gardens American Cockroaches.__________________________________________________________________________
Clearly, the quantity required of the compositions of the present invention will vary dependent on the size of the area to be heated. However, as a general illustration of quantities required, the 9 litres of Example 1 will treat 200 sq.m.
From the results presented in Tables 1 to 3, the following should be noted:
(a) The compositions of the present invention are clearly superior to the comparative example. Re-infestation of the treated area occurs within 3 to 6 months using the comparative example, in contrast to the present invention wherein there is no sign of re-infestation at 9, 12, 15 or 18 months.
In fact, it is anticipated that the compositions of the present invention will remain effective past 18 months--the results presented in Tables 2 and 3 were truncated simply because re-treatment was undertaken to ensure that re-infestation would not occur again, even though there was no indication that the effectiveness of the current treatment had lapsed.
(b) The average effectiveness of the comparative example is 7 months, whereas it is 16 months for Example 1 of the present invention and 10 months for Example 2 of the present invention.
(c) The results obtained from Example 2 of the present invention, when compared to the comparative example, establish that microwave irradiation of a mixture of dichlorvos and chlorpyrifos enables a 30% reduction in active ingredients to provide a 40% increase in effective life of the treatment.
It should also be noted that the alcoholic composition of Example 3 can be conveniently applied to light covers whereupon the heat emitted by lights when in operation releases the dichlorvos thus killing mosquitoes and other flying insects which are attracted to the lights.
Major advantages of the present invention thus include (1) the compositions exhibit a synergistic effect on the properties of the respective components either individually or as a mixture; (2) significantly less quantities of individual ingredients are required to achieve this synergistic effect; and (3), although not wishing to be bound by theory, the presence of the composition in the treated area appears to prevent female pests from depositing eggs thereon, thus significantly reducing the likelihood of re-infestation.
A further advantage is that the compositions provide a positive repelling effect. Due to the efficacious residual action of the present invention, pests such as cockroaches which take in air from underneath their bodies and thus have their lungs in close proximity to the treated surface, become immediately aware that the environment is hostile resulting in a retreat by the pest.
By using the compositions of the present invention, effective and continual protection against insects such as cockroaches, mosquitoes, ants and midges can be achieved, although it will be appreciated that the above examples are given by way of exemplification of the invention only, and that changes may be made to the details set out therein without departing from the scope of the invention as defined in the following claims.
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The pesticidal composition of the invention comprises dichlorvos and chlorpyrifos. The composition is prepared by combining the components together and then subjecting the mixture to microwave radiation. The resultant composition exhibits a synergistic effect on the individual properties of the respective components which not only quickly exterminates existing pests but which also leaves a residual pesticidal protection which is not readily removed by conventional cleaning processes. The composition is particularly effective against cockroaches.
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FIELD OF THE INVENTION
The present invention relates to a chuck for a bottle capper and more specifically to certain new and useful improvements in a torque trigger and means for controlling the amount of torque applied to a cap held in the jaws of a chuck prior to the chuck jaws releasing.
BACKGROUND OF THE INVENTION
There are a number of bottle capping machines currently used to apply screw caps onto bottles. In general such machines employ a reciprocating mechanism to reciprocate a screw cap applying spindle assembly through a capping cycle. A screw cap chuck, typically constructed of a tool grade steel, is attached to the spindle. These machines operate at a predetermined downward stroke while applying a pre-determined torque to the screw cap. The operating height of the chuck is usually adjustable to allow for various bottle heights. An example of such an apparatus is shown in U.S. Pat. No. 3,031,822 issued May 1, 1962, in the name of George H. Dimond entitled Chuck for Capping Machines. The basic design shown by this patent is still in use today in capping machines made by Figgie International Inc.
The primary elements of the screw-on capping chuck, of the type first described in U.S. Pat. No. 3,031,822, are chuck jaws, jaw bell, a stripper, and a stem. The jaws are retained in the bell by the stem which is associated with a torque trigger through a spring coupling. An adaptor connects the chuck to a spindle sleeve and transmits the rotary motion of the spindle sleeve to the torque trigger. A push rod extends through the sleeve and is adapted to actuate the stripper. The chuck jaws are opened by reciprocal movement of the spindle sleeve upward forcing the stripper between the chuck jaws. The cap is then picked up by reciprocal movement of the spindle sleeve downward onto the cap which displaces the stripper, snapping the jaws closed. The cap is then screwed onto the container. Opening of the jaws to release the capped container is accomplished by the torque opening feature of the torque trigger.
The torque trigger is provided with two flat rectangular lugs that rest in stair-like slots carved into the sleeve of the jaw bell. The torque trigger is, through moving closer to the bell via the force of the spring, adapted to actuate the stripper to open the jaws a sufficient amount to release the capped container.
In the chuck's rest position, the torque trigger is positioned in the lower slot of the bell's collar and due to the torque in the spring is forced against the back of the slot. The stripper is forced into the jaws by the trigger and spring. In operation, the unit is first "reset" whereby the chuck is reciprocated back against the push rod which forces the stripper fully down between the chuck jaws. At the same time the stem and bell are forced down relative to the torque trigger which allows the lugs to rotate up to the next stair step in the slot via the torque in the spring. At this point the stripper is fully wedged between the jaws and held in place by the pressure of the jaws. The chuck is then reciprocated downward to pick up a cap. The cap displaces the stripper upward into the bell, at which point the jaws snap shut via the action of the spring acting against the stem. At this point the stripper rides freely atop the cap and the torque trigger is still positioned on the upper platform of the bell sleeve. The chuck is then brought over the container to which the cap is to be affixed and is reciprocated down onto the container.
When the resistance between the cap and the container overcomes the torque of the spring, the jaws cease rotating, which causes the stem and bell to stop rotating. The torque trigger continues its rotation against the torque of the spring, causing the lug to move into the lower slot, which forces the stripper to push the jaws apart, freeing the cap. The chuck is now in the rest position and ready for another cycle.
To adjust the torque in the chuck, it must first be removed from the adaptor sleeve and the spring either wound or unwound to increase or decrease the amount of resistance needed to overcome the torque in the spring.
There are a number of applications for machines of this type where high speeds and precise torque are required. For example, the pharmaceutical industry makes extensive use of these machines when packaging chemicals for distribution. However, due to the nature of the coupling between the spring and the stem it has been impossible to visually set a chuck for a certain torque. Rather, each chuck must be individually tested and adjusted prior to use. Likewise, each chuck must be tested and set when adjustments need to be made. Further, chucks made in accordance with the prior art are also limited in the size caps they can apply, due to the tendency of the lugs to shear off when subjected to high torque when resetting after applying large caps such as to laundry detergent bottles which require that the spring be tightly wound.
DESCRIPTION OF THE PRIOR ART
Applicant is aware of the following U.S. Patents concerning capping machines.
______________________________________Patent No. Expires Inventor Title______________________________________3,031,822 2-21-1979 Dimond CHUCK FOR CAPPING MACHINES3,405,499 10-15-1985 Dexter TORQUE LIMITING APPARATUS3,537,231 11-03-1987 Dimond BOTTLE CAPPER3,805,488 04-23-1994 Holstein CAPPER CHUCK DEVICE3,975,886 08-24-1993 Waters CAPPING MACHINE3,984,965 10-12-1993 Sonnenberg DEVICE FOR APPLYING CAPS TO BOTTLES4,084,392 04-18-1995 Von Hagel APPARATUS FOR PRINTING AND FEEDING CAPS TO A BOTTLE CAPPING MACHINE4,099,361 07-11-1995 Dix APPARATUS FOR A METHOD OF CLOSING CONTAINERS4,178,733 12-18-1996 Dankert TORQUE OPEN CAPPING CHUCK IMPROVEMENT4,267,683 05-19-1998 Harrington COUPLING MECHANISM FOR A CAPPING MACHINE4,658,565 04-21-2004 Westbrook CAPPING MACHINE4,662,153 05-05-2004 Wozniak ADJUSTABLE CONTAINER CAPPING APPARATUS4,756,137 07-12-2005 Lanigan CAPPING MACHINE4,793,120 12-27-2005 Herzog CLUTCH AND CAP DISC ASSEMBLY4,794,801 01-03-2006 Andrews BOTTLE CAP REMOVAL TORQUE TESTER4,905,477 03-06-2007 Margaria CLOSURE APPLYING APPARATUS5,054,261 10-08-2008 Gilbertson CAP CHUCKS FOR USE WITH BOTTLE CAPPING MACHINES______________________________________
Dimond U.S. Pat. No. 3,031,822 is the basic design for a chuck for capping machine, which is still in use today. The present invention is an improvement over several aspects of this chuck. Specifically, the present invention provides a mechanism for accurately and precisely setting the release torque along with a strengthened and more reliable torque trigger.
Dexter U.S. Pat. No. 3,405,499 shows a torque limiting apparatus which uses fluid pressure to maintain the chuck in a fixed angular relationship to the spindle. The cap is then released when the fluid pressure is overcome by the torque between the cap and the container being capped. This obviously bears no relationship to the purely mechanical means utilized in the present invention.
Dimond U.S. Pat. No. 3,537,231 discloses a turret type container capper for selectively applying both screw-on and roll-on caps to containers. This disclosure is limited to the machine which uses chucks similar to that described in Dimond's earlier patent '822.
Holstein U.S. Pat. No. 3,805,488 shows a chuck capper device wherein the closer cap retaining jaws are movable by a toggle link arrangement to retain a closure cap therebetween responsive to an externally applied force, and wherein the jaws have torque transfer means adapted for releasing the closure cap after a predetermined rotational torque has been applied. Unlike the present invention, Holstein utilizes two racheted jaws, one of which is connected to a toggle linkage member. When the predetermined torque is reached, a torque transfer arm causes a trip cam to engage a roller member connected to the toggle linkage arm, thereby causing the jaws to rachet open.
Waters U.S. Pat. No. 3,975,886 discloses a capping machine for applying caps to containers. This disclosure relates more to method for feeding caps to a chuck as opposed to the chuck mechanism itself.
Sonnenberg U.S. Pat. No. 3,984,965 discloses a device for engaging a bottle cap and turning it on the thread finish of a bottle. It specifically relates to the shapes of the jaws gripping the bottle cap.
Von Hagel U.S. Pat. No. 4,084,392 relates to an apparatus for filling, capping and dating thin-walled plastic milk bottles. Von Hagel's capping machine operates under gravitational forces, at low pressure, without the need for any for any springs, snap rings or similar elements to assist in engaging or disengaging a cap.
Dix U.S. Pat. No. 4,099,361 discloses an apparatus for applying closures to filled bottles. This disclosure is directed towards an apparatus which utilizes chucks as opposed to chucks themselves, and more specifically to the torque opening means thereof.
Dankert U.S. Pat. No. 4,178,733 discloses a chuck for a bottle capper, generally in accordance with the Dimond disclosure, wherein a mechanism to prevent the chuck jaws from twisting or cocking is disclosed. Specifically, a ball bearing is provided to ride between the jaw bell and the chucks to maintain alignment therebetween.
Harrington U.S. Pat. No. 4,267,683 discloses a coupling mechanism for interconnecting a chuck with the chuck capping machine, and is not related to the actual chuck itself.
Westbrook U.S. Pat. No. 4,658,565, of which the present inventor is listed as a co-inventor, discloses a capping machine for applying plastic screw-on caps having tamper evident bands to flexible sided round containers. This disclosure is directed toward the capping machine as a whole and is only peripherally related to chucks.
Wozniak U.S. Pat. No. 4,662,153 discloses an apparatus for applying container caps of different sizes to containers having a micro torque adjustment. The torque release is set by controlling the frictional relationship between two washers. The adjustment of torque is accomplished through increasing the pressure imparted by a spring on the top of one of these washers. This obviously has no relationship to the means disclosed in the present invention.
Lanigan U.S. Pat. No. 4,756,137 discloses a capping machine which utilizes interchangeable chucks.
Herzog U.S. Pat. No. 4,793,120 discloses a cap disc clutch mechanism which utilizes a stack of sixteen discs to open the jaws in response to a predetermined torque. This is obviously unrelated to the torque opening mechanism of the present invention.
Andrews U.S. Pat. No. 4,794,801 discloses a bottle cap removal torque sensor used to test the application torque of a chuck capping machine, and is obviously unrelated to the present invention.
Margaria U.S. Pat. No. 4,905,447 discloses a closure applying apparatus suitable for use in a capping machine for placing on a container having a threaded neck portion and an annular collar below the neck portion, a one piece tamper evident screw-type capsule made of rigid plastic material. The capsule has a lower skirt portion which is connected to the main capsule via thin frangible bridge portions. Margaria is an improvement to the chuck capping device disclosed in Dimond '822 for preventing fracture of the bridges during the capping operation.
Gilbertson U.S. Pat. No. 5,054,261 discloses an improved bottle capping chuck compatible with existing capping machines in which the chuck defines a frusto-conical throat surface for gripping the bottle cap. The chucks according to Gilbertson are of one-piece design and contain no moving parts. Obviously this disclosure is unrelated to the improved torque trigger and index torque release apparatus of the current invention.
SUMMARY OF THE INVENTION
The invention provides apparatus for precisely adjusting the torque at which the torque trigger releases and an improved torque triggering mechanism.
The invention provides apparatus to allow setting and adjusting the torque of the spring accurately and precisely. Two indexed collars on the stem head allow a user of the chuck to calibrate the collar for an at rest setting, and by rotating the collars in relationship to one another the user can adjust the tension in the spring. The adjustment made subsequent to calibration can be done on a visual basis without the need for constant testing.
To allow the chuck to be used on caps requiring high torque during their application, vertical pins are set into the torque trigger which present a strong surface to the back of the slot during reset.
OBJECTS OF THE INVENTION
The principal object of the invention is to provide an improved apparatus for accurately and precisely adjusting the torque setting on a capping chuck.
A further object of this invention is to provide an improved torque trigger capable of withstanding high torques.
Another object of the invention is to provide apparatus for allowing multiple capping chucks to be set to a single torque setting.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects will become more readily apparent by referring to the following detailed description and the appended drawings in which:
FIG. 1 is a cross-sectional view of the invented apparatus in the "gripping" position.
FIG. 2 is a cross-sectional view of the apparatus in the "rest" position.
FIG. 3 is a cross-sectional view of the apparatus in the "reset" position.
FIG. 4 is isometric view of the invented torque control apparatus.
FIG. 5 is a side view of the torque trigger according to the present invention.
FIG. 6 a bottom view of the torque trigger according to the present invention.
FIG. 7 is a side cross-sectional of the torque trigger according to the present invention.
FIG. 8 a side cross-sectional view of the jaw bell according to the present invention.
FIG. 9 is a top view of the jaw bell according to the present invention.
DETAILED DESCRIPTION
Referring to the drawings and in particular to FIGS. 1 through 3, the chuck of the closure-applying apparatus according to the present invention is inserted into a reciprocating coupling mechanism which imparts constant rotation to torque trigger 22, via bayonet lugs 50. The torque trigger is connected via wound spring 18 to a clamp collar 14, which in turn is fixed to a hollow jaw stem 20 via stem head 10 that extends back through spring 18 into a hollow slot 48 in torque trigger 22 and then through an opening 58 in the top of chuck bell 28. Inside the bell the stem forms a disk 21, which hold the tops of the chuck jaws 30 against the inside of the bell. These jaws have fulcrums 31 integrally formed on surfaces opposite where the disk of the sleeve presses. Stripper 32 is positioned in the hollow cavity of the stem extending through bell opening 58 into the bell where it flattens into a disk. By actuating stripper 32, chuck jaws 30 are forced open and closed, as discussed hereinafter. The shaft 31 of the stripper has cross pin 24 inserted through it which extend through two vertical oval holes 19 in stem 20 and is situated within bell sleeve 29. Jaw bell 28 and jaws 30 are connected to the disk 21 of the jaw stem 20 via a system of pins so that when the stem rotates, the jaws and bell will also rotate. Extending through the jaw stem is an actuator rod (not shown) which is fixed in place relative to the chuck. The function of the actuator rod will be described hereinafter.
Turning now to the torque trigger, and referring in particular to FIGS. 5 through 7, the invention calls for the use of two vertical pins 46, instead of the lugs present in the prior art. As can be seen in FIG. 7, the pins are set oppositely into the body of the trigger and extend out by a predetermined amount. As shown in FIGS. 8 and 9, the jaw bell sleeve has been modified by thickening it and adapting it to accept torque trigger pins 46 by forming two opposite upper platforms 52 adjacent to two lower platforms 54 within jaw bell sleeve 29. The pair of upper and lower platforms are so formed that when torque trigger 22 is resting on the pair of upper platforms 52 a clockwise (as seen in FIG. 9) twist of the trigger will bring the pins over the pair of lower platforms 54, allowing trigger 22 to drop and come to rest upon bell sleeve 29.
In operation, the chuck starts in the "rest" position as shown in FIG. 2, wherein torque trigger 22 is riding on top of jaw bell sleeve 29 and due to the torque in spring 18, pins 46 are being forced toward the lower wall of upper platform 52. Cross pin 24 is forced toward the bell 28 by the force of spring 18 acting upon trigger 22 causing stripper 32 to separate jaws 30.
Referring to FIG. 3, the unit is first placed into the "reset" position wherein the chuck is ready to accept a cap. This is accomplished by reciprocating the chuck back against the push rod (not shown) which forces stripper 32 fully down between the chuck jaws 30 which open via fulcrum 31. At the same time, stem 20 is forced down relative to torque trigger 22 allowing pins 46 to move up parallel to the pair of upper platforms. At this point, the torque in spring 18 causes the stem and therefore the bell to rotate clockwise (FIG. 9) which brings the pair of upper platforms 52 under pins 46 which are now being pressed against the back wall of the upper platforms within jaw bell sleeve 29. At this point stripper 32 is fully wedged between jaws 30 and the cross pin 24 is pressed against the top of bell 28. The chuck is then reciprocated downward to pick up a cap.
The act of picking up a cap displaces the stripper 32 up into bell 28 allowing jaws 30 to snap shut via the action of spring 18 acting against the stem 20 placing the unit in the "gripping" position, see FIG. 1. At this point, stripper 32 is riding freely atop the cap- The chuck is then brought over the container to which the cap is to be affixed and is reciprocated down, while rotating, onto the container.
When the resistance between the cap and the container overcomes the preset torque of spring 18, jaws 30 cease rotating, which in turn causes bell 28 to stop rotating. Torque trigger 22, driven by the coupling mechanism, continues its rotation against the torque of the spring causing pins 46 to move over and down into the into the pair of lower platforms 54, forcing stripper 32 to push jaws 30 apart, freeing the cap. The chuck is now back into the rest position and ready for another cycle.
As shown in FIG. 4, an apparatus 16 to adjust the torque in spring 18 is provided which attaches to stem 20. In the preferred embodiment the torque adjusting apparatus comprises four components: stem head 10, clamp collar 14, scale collar 12, and retainer 26. As shown in FIG. 4, stem head 10 has a cylindrical shape with two sections of differing diameter. The section with the larger diameter is threaded to screw over stem 20 and acts as a base on which clamp collar 14 is seated. Seated above clamp collar 14 is scale collar 12. Retainer ring 26 is provided to hold both collars on the stem head.
Clamp collar 14 is provided with a notch adapted to seat spring 18. Clamp collar 14 is also provided with clamping bolt 38 which is used to securely clamp the ring onto stem head 10. Clamp collar 14 is marked with index line 36 the use of which is explained hereinafter.
Scale collar 12 is tapped to allow a set screw to fix the collar in place relative to stem head 10. As no torque will be imparted to the scale collar by spring 18 a simple set screw is sufficient to anchor it in place. Scale collar 12 is marked with index lines 34 whose use is explained hereinafter. When assembled as in FIG. 4, the torque control apparatus allow the user to calibrate and set the application torque quickly and efficiently.
In operation, both collars are loosened and allowed to rotate freely. The clamp collar 14 will be oriented in its "rest" position wherein the spring is at rest and under no torque. The first index mark 35 on the scale collar 12 is then brought into alignment with the index 36 on the clamp collar 14. The scale collar is then clamped into place. The torque control is now calibrated and can be adjusted by rotating the clamp collar 14 until the index mark 36 is aligned with the predetermined index mark 34 on the scale collar.
Using this system, testing to determine torque level only needs to be performed once. Thereafter the unit only needs to be calibrated and then set to the mark corresponding to the appropriate application torque.
SUMMARY OF THE ACHIEVEMENT OF THE OBJECTS OF THE INVENTION
From the foregoing, it is readily apparent that I have invented an improved apparatus for calibrating and setting the application torque for capping chucks faster and more economically than heretofore has been possible. Further it is readily apparent that I have invented an improved torque trigger apparatus capable of withstanding high impact forces.
It is to be understood that the foregoing description and specific embodiments are merely illustrative of the best mode of the invention and the principles thereof, and that various modifications and additions may be made to the apparatus by those skilled in the art, without departing from the spirit and scope of this invention, which is therefore understood to be limited only by the scope of the appended claims.
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An improved chuck for a bottle capper having a torque trigger with vertically set trigger pins capable of withstanding high torques prior to shearing. Further an apparatus to precisely set the application torque of the capping chuck is provided. This apparatus uses a stem head about which a clamp collar and a scale collar are placed. The clamp collar rides below the scale collar and receives the spring. The scale collar is situated above the clamp collar and provides index markings by which to adjust the clamp collar rotationally around the stem head thereby increasing or decreasing the application torque.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates in general to a heddle adapted for use in mechanical looms, and more particularly, to leno heddles for use in combination with dupe heddles for producing a leno weave.
[0002] A loom is a machine used to weave together warp and weft threads to make fabric. There are known a number of mechanical looms which produce various woven patterns having different characteristics. One such loom is referred to as a leno loom for producing a leno weave. A leno weave is a weave in which two warp threads are twisted around the weft thread to provide a strong fabric. The twisted warp threads grip tightly about the weft thread which produces a durable fabric with almost no thread slippage or misplacement of threads, particularly suitable for use in carpet backing material. To produce a leno weave, the loom is threaded with the shuttle weft thread and the dupe warp threads. The dupe warp threads can be of similar or lesser weight and strength to the weft thread. The weft thread is woven into the shed, and for each weft shuttle, the warp threads are twisted interchangeably to produce a figure eight pattern.
[0003] Two of the many mechanical components of the leno loom for weaving the warp and weft threads are the leno heddle and the dupe heddle. By way of example, a typical leno loom includes a pair of leno heddles, which are interconnected at a medial location by the dupe heddle. The leno heddle includes a pair of elongated shanks coupled together forming a space therebetween for receiving a portion of the dupe heddle. The ends of the leno heddle include eyelets for coupling the heddle to an upper and lower heddle support bar. The heddle support bar is received within the eyelets for positioning the heddles within the leno loom during the weaving operation. The pair of shanks may be maintained in an assembly relationship by interfitting elements, such as disclosed in Kramer, U.S. Pat. No. 4,572,241.
[0004] The number of leno heddles used in a leno loom varies depending upon the width of the fabric being woven. It is not unusual to have hundreds of leno heddles attached to the heddle support bars within the leno loom. Like other machine parts, the heddles are subject to wear and breakage, especially at their eyelet ends. When such a heddle has broken, it has heretofore been necessary to stop the loom, and remove the broken heddle for replacement. This can be particularly difficult and time-consuming when the broken heddle is in the middle of other heddles, which may have to be removed from the heddle support bars before the broken heddle can be replaced. To overcome this problem, there is known from Thorpe, U.S. Pat. No. 2,691,389, a repair head which can be attached to the upper end of the heddle shank after removal of the broken eyelet end. The repair head, however, is typically bulky compared to the original heddle shank, and in general, can catch on the other adjacent heddles during operation of the loom.
SUMMARY OF THE INVENTION
[0005] In accordance with one embodiment of the invention, there is disclosed and described a heddle for a loom, comprising an elongated first shank having spaced apart ends and an opening therebetween; and an elongated second shank overlying the first shank, the second shank having spaced apart ends releasably attached to the first shank and a transition region extending through the opening in the first shank.
[0006] The ends of the second shank are attached to the first shank inwardly of the ends of the first shank. The first shank includes first and second sides, the second shank having a first leg between one end thereof and the transition region overlying the first side of the first shank and a second leg between the other end thereof and the transition region overlying the second side of the first shank.
[0007] One end of the first shank includes an opening having a shape and one end of the second shank has a corresponding shape, wherein the shape comprises a T-shape. Another end of the first shank includes an opening having a shape and another end of the second shank has a corresponding shape, wherein the shape comprises a rectangular shape. The first shank has a length generally greater than a length of the second shank.
[0008] In accordance with another embodiment of the invention, there is disclosed and described a heddle for a loom, comprising an elongated first shank having opposing first and second sides, spaced apart ends, and an opening therebetween; an elongated second shank passing through the opening of the first shank and having a first leg overlying the first side of the first shank and a second leg overlying the second side of the first shank, the second shank having spaced apart ends releasably attached within respective openings provided inwardly of the ends of the first shank.
[0009] In accordance with still another embodiment of the invention, there is disclosed and described a heddle for a loom, comprising an elongated first shank having first and second spaced apart ends, a first heddle support bar opening adjacent the first end of the shank, a second heddle support bar opening adjacent the second end of the shank, a first shank opening adjacent the first heddle support bar opening, a second shank opening adjacent the second heddle support bar opening, and a third opening between the first and second shank openings; and an elongated second shank having third and fourth spaced apart ends and a transition region therebetween, wherein when the first and second shanks are assembled, the third end of the second shank is removably received within the first shank opening and the fourth end of the second shank is removably received with the second shank opening with the transition region passing through the third opening.
[0010] The first shank includes first and second sides, the second shank having a first leg between the third end thereof and the transition region overlying the first side of the first shank and a second leg between the fourth end thereof and the transition region overlying the second side of the first shank.
[0011] The first end of the first shank includes an opening having a shape and the third end of the second shank has a corresponding shape, wherein the shape comprises a T-shape. The second end of the first shank includes an opening having a shape and the fourth end of the second shank has a corresponding shape, wherein the shape comprises a rectangular shape.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Various embodiments of the present invention will now be described with reference to the appended drawings. It is appreciated that these drawings depict only exemplary embodiments of the invention and are therefore not to be considered limiting of its scope.
[0013] FIG. 1 is a top plan view of an unassembled leno heddle formed from a pair of elongated shanks;
[0014] FIG. 2 is a side elevational view of one end of the first shank;
[0015] FIG. 3 is a side elevational view of the other end of the first shank;
[0016] FIG. 4 is a top plan view of the leno heddle of FIG. 1 shown in assembled relationship;
[0017] FIG. 5 is a top plan view of one end of the leno heddle in assembled relationship as shown in FIG. 4 ;
[0018] FIG. 6 is a side elevational view of the assembled end of the leno heddle as shown in FIG. 5 ;
[0019] FIG. 7 is a top plan view of the other end of the leno heddle as shown in assembled relationship in FIG. 4 ;
[0020] FIG. 8 is a top plan view of a dupe heddle; and
[0021] FIG. 9 is a top plan view of a leno heddle assembly including a pair of leno heddles and a dupe heddle.
DETAILED DESCRIPTION
[0022] In describing the preferred embodiments of the invention illustrated in the drawings, specific terminology will be used for the sake of clarity. However, the invention is not intended to be limited to the specific terms so used, and it is to be understood that each specific term includes all equivalents that operate in a similar manner to accomplish a similar purpose.
[0023] Referring to the drawings wherein like reference numerals represent like elements, there is shown in FIG. 1 a leno heddle in unassembled relationship and generally designated by reference numeral 100 . The leno heddle may be referred to hereinafter as simply the heddle 100 . The heddle 100 includes an elongated configured first shank 102 and an elongated configured second shank 104 as shown in unassembled relationship. By way of example, the shanks 102 , 104 may be made from 301 stainless steel having a thickness of about 0.023 inches. The shanks 102 , 104 can be fabricated using various machine techniques, for example, laser cutting, stamping, progressive tooling, and the like.
[0024] Shank 102 includes a transition region in the area generally designated by reference numeral 106 and a pair of spaced apart ends generally designated by reference numerals 108 and 110 . The transition region 106 includes an opening 112 , which although shown and described as rectangular, may be of other shapes such as geometric or nongeometric as will be understood from a further description of the present disclosure. The shank section extending generally from the transition region 106 to the end 108 defines a first leg 114 . In a like manner, the shank section extending generally from the transition region 106 to the second end 110 forms a second leg 116 . The first end 108 may be formed with a C-shaped opening 118 having its longitudinal axis extending in the longitudinal direction of the first leg 114 . In addition to a C-shaped opening 118 , the opening may also be of other shapes, for example, J-shaped, circular or oval shaped, and the like. Various shaped openings are shown in Baumann et al., U.S. Pat. No. 6,230,756, the disclosure of which is incorporated herein by reference.
[0025] A configured opening 120 is provided in leg 114 inwardly adjacent opening 118 . By way of one example, the opening 120 , as shown in FIGS. 1 and 2 , has a T-shape. In this regard, the leg 114 includes an angled portion 122 adjacent the first end 108 . The configured opening 120 is formed within the angled portion 122 extending into the first end 108 . The T-shape of the configured opening 120 is formed by the opening having an enlarged rectangular end 124 . Although shown and described as T-shaped, the opening 120 may be of other shapes as will be understood from a further description of the present disclosure. For example, any shape that will perform a similar function to capture and retain the end of the second shank 104 , as to be described, may be used.
[0026] Referring to FIGS. 1 and 3 , second end 110 likewise may include a C-shaped opening 126 having its longitudinal axis extending in the longitudinal direction of the second leg 116 . Here again, although shown as a C-shaped opening 126 , the opening can also have other shapes, such as J-shaped, circular or oval shaped, and the like. The second leg 116 , inwardly of the second end 110 , includes an angled portion 128 having an opening 130 . The opening 130 , although illustrated as rectangular, can have other geometric or nongeometric shapes which will be understood from a further description of the present disclosure.
[0027] The second shank 104 , as shown in FIG. 1 , includes a transition region of reduced width generally designated by reference numeral 132 and a pair of space apart first and second ends generally designated by reference numerals 134 and 136 . A first leg 138 is generally defined extending between the transition region 132 and the first end 134 . Likewise, a second leg 140 is generally defined extending between the transition region 132 and the second end 136 . The transition region 132 is configured at an angle such that the first and second legs 138 , 140 are arranged extending generally in parallel spaced apart planes, See FIG. 4 . The first end 134 may be configured to have a shape corresponding to the shape of the opening 120 , by way of example, a T-shape. In this example, the T-shape is formed by a main body 142 having an enlarged rectangular head 144 thereby representing the letter T. Other shapes are contemplated as will be understood from a further description of the present disclosure. For example, any shape that will perform a similar function to be captured and retained by the opening 120 in the first shank 102 may be used. The size of the T-shaped first end 134 is generally slightly smaller than the size of the corresponding T-shaped opening 120 . The second end 136 of the second shank 104 includes an elongated extending tab 146 . Although the tab 146 is shown as having a generally rectangular shape, other shapes are contemplated as will be understood from the following description of the present disclosure.
[0028] Referring now to FIGS. 4-6 , there is shown the first and second shanks 102 , 104 in assembled relationship to form a leno heddle 100 by way of one example. The second shank 104 is inserted through the opening 112 in the first shank 102 until aligned with the transition region 132 , with the first and second legs 138 , 140 arranged in parallel offset planes on opposite sides of the first shank 102 . In this regard, as shown in FIG. 4 , the first leg 138 of the second shank 104 is arranged overlying and in alignment with one side of the first leg 114 of the first shank 102 , while the second leg 140 of the second shank is arranged overlying and in alignment with the opposite side of the second leg 116 of the first shank. The legs 114 , 138 of the first and second shanks 102 , 104 provide a slight space 148 therebetween for receiving a portion of the dupe heddle as to be described hereinafter.
[0029] Referring more specifically to FIGS. 5 and 6 , the first end 134 of the second shank 104 is releasably attached to the first end 108 of the first shank 102 . In this regard, the T-shaped end 142 , 144 of the second shank 104 is first aligned overlying the corresponding T-shaped opening 120 in the first shank 102 . The T-shaped end 142 , 144 is passed through the T-shaped opening 120 , and then, longitudinally moved in a direction away from the first end 108 of the first shank 102 until the enlarged head 144 of the T-shaped end is stopped by portions of the first shank 102 formed by the angled portion 122 . The enlarged head 144 by abutting the angled portion 122 precludes the second shank 104 from sliding longitudinally toward the second end 110 of the shank 102 .
[0030] Referring to FIG. 7 , the second end 136 of the second shank 104 is similarly releasably attached to the second end 110 of the first shank 102 . In this regard, the tab 146 of the second shank 104 is inserted through the opening 130 within the angled portion 128 of the first shank 102 . The tab 146 extends beyond the extent of the opening 130 , overlying a portion of the second end 110 of the first shank 102 adjacent opening 126 , completing the assembly of the leno heddle 100 .
[0031] The assembled leno heddle 100 may be used with a dupe heddle for forming a leno weave. A dupe heddle 150 , by way of one example, is shown in FIG. 8 . The dupe heddle 150 includes a pair of spaced apart elongated legs 152 , 154 , which terminate at respective J-shaped ends 156 , 158 . The other ends of the legs 152 , 154 form an eyelet 160 adapted for receiving the warp thread to be twisted about the weft thread during the weaving process. Another example of a dupe heddle 150 is disclosed in Hockemeyeer et al., U.S. Pat. No. 6,116,291.
[0032] Referring now to FIG. 9 , there is shown a leno heddle assembly 162 for use in a mechanical loom for producing a leno weave using the leno heddles 100 in accordance with the present invention. A pair of leno heddles 100 are arranged side by side in alignment with one another. The upper ends 108 of the heddles 100 are slidably supported by upper leno heddle support bars 164 via the openings 118 . Likewise, the second ends 110 of the heddles 100 are slidingly supported by lower leno heddle support bars 166 via the openings 126 . The legs 153 , 154 of the dupe heddle 150 are passed through the space 148 formed between the assembled shanks 102 , 104 . The legs 152 , 154 extend longitudinally and outwardly of the shanks 102 , 104 with the J-shaped ends 156 , 158 positioned adjacent the ends 110 of the leno heddles 100 . The J-shaped ends 156 , 158 receive dupe heddle support bars 168 . The use of a leno heddle assembly 162 in a leno loom for forming a leno weave is considered known to those having ordinary skill in the art. Accordingly, a description of using the leno heddles in a leno loom is not required for a complete understanding of the construction and operation of the leno heddles in accordance with the present disclosure.
[0033] As previously noted, a leno loom may include hundreds of leno heddles 100 arranged as shown in FIG. 9 . The second shank 104 can be easily and quickly removed and replaced from within the heddle with minimal loom downtime by reversing the assembly procedure described hereinabove. In this regard, it is not required that the entire leno heddle 100 be removed from the upper and lower heddle support bars 164 , 166 .
[0034] 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 to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.
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A leno heddle includes a pair of elongated shanks, which are removably assembled together in overlying relationship. One of the shanks has configured ends to be removably received within corresponding openings in the other shank. The shank having configured ends can be replaced within the leno heddle without having to remove the other shank from its coupled relationship with the loom's upper and lower leno heddle support bars.
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CROSS-RELATED REFERENCE SECTION
This application is a Divisional application of U.S. patent application Ser. No. 10/462,397, filed Jun. 16, 2003 now U.S. Pat No. 7,183,426, which is a Continuation of U.S. patent application Ser. No. 08/705,157, filed Aug. 29, 1996, now abandoned, which is a CIP of U.S. patent application Ser. No. 08/477,912, filed Jun. 7, 1995, now abandoned, which is a Divisional of U.S. patent application Ser. No. 08/375,187, filed Jan. 18, 1995, now abandoned, which is a Continuation of U.S. application Ser. No. 08/267,500, filed Jun. 29, 1994, now abandoned, which is a Continuation of U.S. patent application Ser. No. 08/120,640, filed Sep. 13, 1993, now abandoned, which is a Continuation of U.S. patent application Ser. No. 07/871,403, filed Apr. 21, 1992, now abandoned, all of which are incorporated herein by reference.
TECHNICAL FIELD
The present invention relates to the field of polymer chemistry and, more specifically with regard to the field of cascade or dendritic polymer chemistry. These polymers are based upon the application of mathematical progressions to organic synthesis and thereby possess well-defined molecular topologies.
BACKGROUND OF THE INVENTION
The field of cascade polymer chemistry is expanding the traditional synthetic limits into the meso-macro-molecular frontier. Such polymers possess well-defined molecular topologies as they can be constructed in discrete layers rendering upon the molecule discrete, symmetric and consistent chemical characteristics.
These polymeric structures provide specific micellar molecules.
The synthesis and spectral features of cascade polymers, also referred to as arborols possessing two-, three- and four-directional microenvironments with functionalized polar outer surfaces, have been recently reported (1-8). Depending on their molecular shape, many of these macromolecules aggregate to form gels or show novel micellar characteristics in aqueous solution (3,7,8). In view of an interest in generating a spherical hydrophilic surface with a compact lipophilic core, the present invention provides a cascade system which in one embodiment emanates from a central adamantane core. This core includes bridgehead positions which have suitable geometry to mimic a tetrahedral nucleus and can be envisioned as an extended methane core. Such a core is an ideal starting point toward four-directional cascade polymers.
In constructing such spherical polymers, several further problems were uncovered. One such problem related to the generation of a tri-branched monomer which would not cyclize. More specifically, to provide tri-valent branching from a single branch of a polymer, at least two qualities are required. First, there must be directionality such that the monomer combines with the branch so as to expose three branch binding sites for further tiering of the macromolecule. The branches of the macromolecule extending from a central core must also extend sufficiently to be able to allow further reactions therewith for the additional tiering while not cyclizing onto themselves. Cyclizing removes branches from being chemically reactive thereby causing a dead-end to the tiering process. For example, the following reaction sequence generated the polymeric product set forth below.
Attempted oxidation of compound 11 by a RuO 2 procedure of Irngartinger, et al. (9) resulted in limited success in that complete oxidation was not reproducible.
Applicant herein provides novel monomers which are ideal in that they do not cyclize and further can be used in a cascade system for producing macromolecular monomers through tetradirectional polymers, particularly on an adamantane, methane equivalent, or four-directional core.
Further, the present invention provides novel four-directional spherical dendritic macromolecules based on adamantane made in accordance with the novel method set forth herein.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is a method forming an amine monomer of the formula
by the steps of reacting nitromethane and CH 2 ═CHCO 2 -TBu by nucleophilic addition to form the triester nitrotrialkanoate of the formula
and reducing the nitrosubstituent to said amine monomer.
Further in accordance with the present invention the novel amine monomer can be used to create several novel one, two, three, or four-directional polymers based on the adamantane, or similar core.
DETAILED DESCRIPTION OF THE INVENTION
The present invention generally will provide a monomer of the formula
wherein R is selected from the group consisting essentially of NH 2 and NO 2 . This novel compound is a building block for novel cascade polymers made in accordance with the inventive method set forth below. Products made in accordance with the present invention can be used in various fields, such as pharmaceutical chemistry, as micelles. However these compounds are used to make unimolecular micelles as opposed to multi-molecular micelles, previously known in the art.
These monomeric micelles generally have a core and branching which leads from the core. In accordance with the present invention, the branching can be tetra-directional extending from the four bridgehead positions of the core and can be tiered or layered such that a first layer of branching can be combined with the core and then subsequent layers can be added to provide a well-defined molecular topology.
More specifically, as discussed above, attempted oxidation of the arborol of the formula
by the RuO 2 procedure discussed above met with limited success in that complete oxidation was not reproducible. To circumvent this problem as well as to shorten the overall iterative procedure, the novel building block di-tert-butyl 4-amino-[2-(tert-butoxycarbonylethyl]-heptanedioate was prepared by the following scheme.
A key factor was the bulky nature of the tert-butyl ester, so it was necessary to prevent lactam formation during reduction of the nitro functionality. That is, the following reaction did not occur under the condition conducted in accordance with the present invention.
An attempt to synthesize the nitro ester precursor by modification of the procedure reported by Bruson and Riener(10) using tert-butyl acrylate in place of the acrylonitrile resulted in a poor yield of about 5%. To circumvent this sluggish nucleophilic addition, the reaction temperature was elevated during the initial addition phase and then maintained at about 70° to 80° C. for one hour. This modification resulted in a 72% yield of the desired triester, which was confirmed by 13 C NMR by the peaks for the quaternary and carbonyl carbons at 92.1 and 170.9 ppm, respectively. The 1 H NMR spectrum showed a singlet at 1.45 ppm assigned to (CH 3 ) 3 CO in a multiplet at 2.21 ppm for the methylene protons. Analysis of the crystal structure ultimately confirmed the analysis.
The prior art discusses diverse reduction conditions for the conversion of nitroalkanols to aminoalkanols(11). The use of platinum, palladium, or Raney nickel catalyst all resulted in very poor yields and gave mostly recovered nitrotrialkanoate compound. However, a reduction with specially generated T-1 Raney nickel by the process of Domingues, et al. (12) at elevated temperatures (ca. 60° C.) gave an 88% yield of the aminoester after purification. Successful reduction was confirmed by 13 C NMR by an upfield shift for the quaternary carbon at 52.2 ppm. The 1 H NMR spectrum of the aminotrialkanoate showed a singlet at 1.44 ppm for the tert-butyl group, multiplets at 1.68 and 2.26 ppm for the methylene protons and a broad singlet at 5.49 ppm for the amino moiety.
Since related alkyl esters of the aminotrialkanoate could not be prepared because of facile intramolecular lactam formation during the hydrogenation of the nitro moiety, the tert-butyl ester is ideal in that no cyclization was observed. The advantages of the tert-butyl ester are: a) reduced number of overall steps for cascade synthesis; b) easy preparation on a large scale; c) facile hydrolysis to the desired acids in nearly quantitative yield; and d) the poly tert-butyl esters were easily purifiable solids.
An example of the use of the tert-butyl ester in a cascade synthesis is as follows. Treatment of adamantanecarbonyl chloride with the aminotrialkanoate as set forth above furnished 71% yield of the desired triester (amine monomer) of the formula
This structure was confirmed by 13 C NMR by the peaks at 172.8 (ester), 177.4 (CONH), and 56.7 ppm (side-quaternary carbon). Hydrolysis of the ester to a triacid was accomplished with about 100% yield by treatment with formic acid. It was identical in all respects to a sample prepared by the above procedure. Application of peptide coupling procedures known in the art of the acid with the aminotrialkanoate in the presence of DCC and 1-hydroxybenzotriazole in dry dimethyl formamide (DMF) afforded a 61% yield of a nonaester(13). The following scheme summarizes the reaction sequence
The presence of the structure was confirmed by 13 C NMR showing two carbonyl peaks at 172.6 (ester) and 177.0 ppm (CONH) as well as the peaks for the side-chain quaternary carbons at 57.6 and 57.0 ppm thereby confirming the transformation. The specific assignment of internal and external methylene signals was based on the intensity ratios as well as the fine shape, the internal methylenes being broader. The final acid was obtained in a 95% yield by the treatment of the ester with formic acid. The absence of the tert-butyl groups in the NMR spectra and the shift for the carbonyl, 172.6 ppm (ester) to 177.6 ppm (acid) supports the conclusion that hydrolysis occurred.
A large scale preparation of the nitrotriester and its subsequent reduction to the amine has been developed. Specifically, the nitrotriester 1 was prepared via treatment of nitromethane with slightly more than three equivalents of tert-butyl acrylate in dimethoxyethane (DME). Trace yellow impurities produced in the reaction were easily removed by recrystallization. Removal of these colored contaminants circumvents chromatographic purification of the desired monomer 2.
Hydrogenation of the nitrotriester 1 to the aminotriester 2 at slightly elevated temperature presented a serendipitous exception to the reduction products of known tertiary, γ-nitroester (Weis et al., 1995). All previously known examples of such reductions readily cyclize to afford the corresponding 2,2′-disubstituted pyrrolidones. Therefore, catalytic hydrogenation conducted under carefully controlled temperature conditions using freshly prepared T-1 Raney Nickel at 45-55° C. provided (ca. 90%) the pure monomer 2.
The crystalline amine 2 is stable for prolonged periods when stored at ≦15° C., however the presence of solvent or extended storage at 25° C. can result in the formation (about 5-7% over several months) of di-tert-butyl 5-oxo-2,2-pyrrolidinedipropionate (3) (Young, 1993). Attempts to recrystallize 2 were initially frustrated by the thermal cyclization at elevated temperatures, which further dictated that in vacuo solvent removal be performed below 50° C. Subsequently, it has been determined that aminoester 2 can be cyclized quantitatively in the solid state at 105-110° C.; while in solution, cyclization occurs at 65-80° C.
Experimental Section
General Comments. Melting point data were obtained in capillary tubes with a Gallenkamp melting point apparatus and are uncorrected. 1 H and 13 C NMR spectra were obtained in CHCl 3 , except where noted, with Me 4 Si as the internal standard (δ=0 ppm), and recorded at either 80 or 360 MHz. Infrared spectral data were obtained on an IBM −38 spectrometer. Elemental analyses were performed by MicAnal Laboratories in Tucson, Ariz.
Di-tert-butyl 4-Nitro-4-[2-tertbutoxycarbonyl)ethyl]heptanedioate. A stirred solution of MeNO 2 (6.1 g, 100 mmol), Triton B (benzyltrimethylammonium hydroxide, 50% in MeOH; heated to 65° to 70° C. tert-Butyl acrylate (39.7 g, 310 mmol) was added portion wise to maintain the temperature at 70° to 80° C. Additional Titon B (2×1 mL) was added when the temperature started to decrease; when the addition was completed, the mixture was maintained at 70° to 75° C. for one hour. After concentration in vacuo, the residue was dissolved in CHCl 3 (200 mL), washed with 10% aqueous HCl (50 mL) and brine (3×50 mL), and dried MgSO 4 ). Removal of solvent in vacuo gave a pale yellow solid, which was crystallized (95% EtOH) to solid, which was crystallized (95% EtOH) to afford a 72% yield of the triester, as white microcrystals: 33 g; mp 98-100° C.; 1 H NMR δ 1.45 (s, CH 3 , 27 H), 2.21 (m, CH 2 , 12 H); 13 C NMR δ 27.9 (CH 3 , 29.7 CH 2 CO), 30.2 (CCH 2 ), 80.9 CCH 3 ), 92.1 (O 2 NC), 170.9 (CO); IR (KBr) 1542 (NO 2 ), 1740 (CO) cm −1 . Anal. Calcd. for C 22 H 39 O 8 N: C, 59.35; H, 8.76; N, 3.14. Found: C, 59.27; H, 9.00; N, 3.14.
Di-tert-butyl 4-Amino-4-[2-(tert-butoxycarbonyl)ethyl]heptanedioate. A solution of the above synthesized nitro triester (4.46 g, 10 mmol) in absolute EtOH (100 mL) with T-1 Raney Ni 12 (4.0 g) was hydrogenated at 50 psi and 60° C. for 24 hours. The catalyst was cautiously filtered through Celite. The solvent was removed in vacuo, affording a viscous liquid, which was column chromatographed (SiO 2 ), eluting with EtOAc to give a 88% yield of the amino triester as a white crystalline solid: 3.7 g; mp 50-52° C.; 1 H NMR δ 1.44 (s, CH 3 , 27 H), 1.78 (m, CH 2 , 12 H); 13 C NMR δ 27.8 (CH 3 ), 29.8 (CH 2 CO), 34.2 (CCH 2 ), 52.2 (H 2 NC), 80.0 (CCH 3 ), 172.8 (CO); IR (KBr) 1745 (CO) cm −1 . Anal. Calcd. for C 22 H 41 O 6 N: C, 63.58; H, 9.95; N, 3.37. Found: C, 63.72; H, 10.05; N, 3.38.
1-[[N-[3-(tert-Butoxycarbonyl)-1,1-bis[2-tertbutoxycarbonyl)ethyl]propyl]amino]carbonyl]adamantane. A solution of 1-adamantanecarbonyl chloride (1 g, 5 mmol), amine monomer (2.1 g, 5 mmol), and Et 3 N (600 mg, 6 mmol) in dry benzene (25 mL) was stirred at 25° C. for 20 hours. The mixture was washed sequentially with aqueous NaHCO 3 (10%), water, cold aqueous HCl (10%), and brine. The organic layer was dried (Na 2 SO 4 ) and then concentrated in vacuo to give residue which was chromatographed (SiO 2 ), eluting first with CH 2 Cl 2 to remove some by-products and then with EtOAc to give a 71% yield of the ester as a white solid: 2 g; mp 84-86° C.; 1 H NMR δ 1.46 (s, CH 3 , 27 H), 1.68-2.1 (m, CH, CH 2 , 27 H), 4.98 (bs, NH, 1 H); 13 C NMR δ 28.0 (CH 3 ), 28.2 (γ-CH), 29.8, 30.1 (NHCCH 2 CH 2 CO), 36.4 (δ-CH 2 ), 39.2 (β-CH 2 ), 41.2 (α-C), 56.7 (NHC), 80.5 (CCH 3 ), 172.8 (COO), 177.4 (CONH); IR (KBr) 3350, 2934, 2846, 1740, 1638, 1255k 1038 cm −1 , Anal. Calcd. for C 33 H 55 O 7 N: C, 68.58; H, 9.60; N, 2.43. Found: C, 68.36; H, 9.66; N, 2.36.
1-[[N-]3-[[N-[3-(tert-Butoxycarbonyl)-1,1-bis[2-(tert-butoxycarbonyl)ethyl]propyl]-amino]carbonyl]-1,1-bis[2-[[N-[3-(tert-buxtoxycarbonyl)-1,1-bis[2-(tert-buxtoxycarbonyl)-ethyl]propyl]amino]carbonyl]ethyl]propyl]amino]carbonyl]adamatane. A mixture of the triacid 1-[[N-[3-carboxyl-1,1-bix(2-carboxyethyl)propyl]-amino]carbonyl]adamantane (400 mg, 1 mmol) amine monomer (1.45 g, 3.5 mmol), DCC (620 mg, 3 mmol), and 1-hydroxybenzotriazole (400 mg, 3 mmol) in dry DMF (15 ml) was stirred at 25° C. for 48 hours. After filtration of the dicyclohexylurea, the solvent was removed in vacuo. The residue was dissolved in CH 2 Cl 2 (50 mL) and sequentially washed with cold aqueous HCl (10%), water, aqueous NaHCO 3 (10%), and brine. The organic phase was dried (Na 2 SO 4 ). Removal of solvent in vacuo gave a thick viscous residue, which was flash chromatographed (SiO 2 ) eluting first with EtOAc/CH 2 Cl 2 (1:1) then with 5% MeOH in EtOAc, furnished A 61% yield of the ester, as a white solid: 970 mg; mp 115-118° C.; 1 H NMR δ 1.42 (s, CH 3 , 81 H), 1.64-2.20 (m, CH, CH 2 , 63 H), 5.58 (bs, NH, 4H) 13 C NMR δ 27.9 (CH 3 ), 28.4 (γ-CH), 29.6, 30.0 (NHCCH 2 CH 2 COO), 31.6, 32.2 (NHCCH 2 CH 2 CONH), 36.6 (γ-CH 2 ), 39.2 (β-CH 2 ), 41.1 (α-C), 57.0 (NHCCH 2 CH 2 COO), 57.6 (NHCCH 2 CH 2 CONH), 80.3 CCH 3 ), 172.6 (COO), 177.0 (CONH); IR (KBr) 3348, 2936, 2850, 1740, 1665, 1260, 1040 cm −1 . Anal. Calcd. for C 87 H 148 O 22 N 4 : C, 65.22; H, 9.31; N, 3.50. Found: C, 65.41; H, 9.30; N, 3.39.
1-[[N-[3-[[N-[3-Carboxy-1,1-bis(2-carboxyethyl)propyl]amino]carbonyl]-1,1-bix[2-[[N-[3-carboxy-1,1-bix(2-carboxyethyl)propyl]-amino]carbonyl]ethyl]propyl]amino]carbonyl]-adamantane. A solution of the above tert-butyl ester (800 mg, 500 μmol) in formic acid (96%, 5 mL) was stirred at 25° C. for 12 hours. The solvent was removed in vacuo to give a residue; toluene (5 mL) was added and the solution was again evaporated in vacuo to azeotropically remove residual traces of formic acid. The resulting white solid was extracted with warm acetone (5×50 mL). The combined extract was filtered (SiO 2 ), eluting with acetone. The residue obtained after concentration was dissolved in aqueous NaOH (10%) and acidified with concentration HCl to give 95% yield of the acid as a white solid: 520 mg, mp 346° C. dec; 1 H NMR (Me 2 SO-d 6 ) δ 1.82-2.40 (m, CH, CH 2 , 63 H), 4.45 (bs, OH, 9 H, exchanged with D 2 O), 6.28 (bs, NH, 4H); 13 C NMR (Me 2 SO-d 6 ) δ 29.6 (γ-CH), 30.2 (NHCCH 2 CH 2 COOH), 31.0, 32.4 (NHCCH 2 CH 2 CONH), 37.8 (δ-CH 2 ), 40.1 (β-CH 2 ), 42.5 (α-C), 58.0 (NHCCH 2 CH 2 CONH), 58.4 (NHCCH 2 CH 2 COOH), 177.6 (COOH), 179.8 (CONH); IR (KBr) 3360, 3340-2600, 2900, 1744, 1690, 1245, 1090 cm −1 . Anal. Calcd. for C 51 H 76 O 22 N 4 : C, 55.83; H, 6.98; N, 5.11. Found: C, 55.71; H, 7.04; N, 4.98.
The monomers of the present invention can be used for the design and synthesis of novel dendritic polymers which are one, two, three, or four-directional. In accordance with the present invention, the monomers can be used to synthesize four-directional spherical dendritic macromolecules based on adamantane. The use of the aminotrialkanoate monomer offers several advantages. The t-butyl ester intermediates are easily purified solids. Further, only two steps are required to progress from generation to generation.
A specific example of a synthesis is as follows. An acid chloride of the following formula
is treated with the aminotrialkanoatee present invention to afford a dodecaester of the following formula
wherein R=t-Bu.
The dodecaester was hydrolyzed in good yield with 96% formic acid to yield the corresponding dodecaacid.
Addition of further tiers was easily obtained by the coupling of the dodecaacid and further layers of the aminotrialkanoate with DCC an 1-HBT to afford the ester wherein R=TBU. Upon hydrolysis, the ester quantitatively generated the corresponding next tiered polyacid.
A specific example of the method of forming the above-mentioned acid moiety is as follows.
1,3,5,7-Tetrakis{[N-[3-(tert-butoxycarbonyl)-1,1-bis[2-(tert-butoxycarbonyl)ethyl]propyl]amino]carbonyl}-adamantane. A mixture of adamantanetetra-carboxylic acid (78 mg, 250 μmol) and freshly distilled SOCl 2 (2 mL) was refluxed for 4 hours. Excess of SOCl 2 was removed in vacuo, benzene (5 mL) was added, and the solution was concentrated in vacuo to yield the corresponding tetraacyl chloride, as a white solid.
Crude 1,3,5,7-Tetrakis(chlorocarbonyl) adamantane, amine monomer (450 mg, 1.1 mmol), and Et 3 N (110 mg, 1.1 mmol) in dry benzene (10 mL) were stirred at 25° C. for 20 hours. Additional benzene (40 mL) was added, and the mixture was sequentially washed with aqueous NaHCO 3 (10%), water, cold aqueous HCl (10%), and brine. The organic phase was dried (Na 2 SO 4 ) and then concentrated in vacuo to furnish a viscous oil, which was chromatographed (SiO 2 ), eluting with 5% MeOH in EtOAc to generate a 61% yield of the dodecaester, as a white solid: 290 mg; mp 105-107° C.; 1 H NMR δ 1.40 (s, CH 3 , 108 H), 172 (s, CH 2 , 12 H), 2.24 (m, CH 2 , 48 H), 5.88 (bs, NH 4 H); 13 C NMR δ 28.1 (CH 3 ), 30.0, 30.4 (CCH 2 CH 2 COO), 39.0 (β-CH 2 ), 42.8 (α-C), 57.1 (HNC), 80.2 (CCH 3 ), 173.1 (COO), 177.6 (CONH); IR (KBr) 3348, 2930, 2845, 1740, 1645, 1260, 1038 cm −1 . Anal. Calcd. for C 102 H 172 O 28 N 4 : C, 64.38; H, 9.12; N, 2.95. Found: C, 64.52; H, 8.91; N, 2.86.
1,3,5,7-Tetrakis{[N-[3-carboxy-1,1-bis(2-carboxyethyl)propyl]amino]carbonyl}-adamantane. A solution of the dodecaester (190 mg, 100 μmol) in formic acid (96%, 2 mL) was stirred at 25° C. for 20 hours. Excess solvent was removed in vacuo, and toluene (3×2 mL) was added. The solvents were removed in vacuo to give a 94% yield of the dodecaacid, as a white solid: 115 mg; mp 282-284° C. dec; 1 H NMR (D 2 O) δ 1.84 (s, CH 2 , 12H), 2.34 (m, CH 2 , 48H); 13 C NMR (D 2 O) δ 30.1 (CCH 2 CH 2 COOH), 38.8 (β-CH 2 ), 42.7 (α-C), 58.6 (HNC), 177.8 (COOH), 180.4 (CONH); (KBr) 3360, 3330-2600, 2903, 1745, 1690, 1245, 1090 cm −1 . Anal. Calcd. for C 54 H 76 O 28 N 4 : C, 52.75; H, 6.23; N, 4.56. Found: C, 52.59; H, 6.22; N, 4.51.
1,3,5,7-Tetrakis{[N-[3-[[N-[3-(tert-butoxycarbonyl)-1,1-bis[2-(tert-butoxycarbonyl)-ethyl]propyl]amino]carbonyl]-1,1-bis[2-[[N-[3-(tert-butoxycarbonyl)-1,1-bis[2-(tert-butoxycarbonyl)ethyl]propyl]amino]carbonyl]-ethyl]propyl]amino]carbonyl}adamantane. A mixture of the dodecaacid (74 mg, 60 μmol), the amine monomer (330 mg, 790 μmol), dicyclohexyl-carbodiimide (DCC; 150 mg, 720 μmol), and 1-hydroxybenzotriazole (100 mg, 740 μmol) in dry DMF (3 mL) was stirred at 25° C. for 48 hours. After filtration of dicyclohexylurea, the solvent was removed in vacuo to give a residue, which was dissolved in EtOAc (25 mL) and was sequentially washed with cold aqueous HCl (10%), water, aqueous NaHCO 3 (10%), and brine. The organic phase was dried (Na 2 SO 4 ) and concentrated in vacuo, and the residue was chromatographed (SiO 2 ), eluting first with EtOAc/CH 2 Cl 2 (1:1) to remove some impurities and then with 5% MeOH in EtOAc to furnish a 58% yield of the ester, as a white solid: 200 mg; mp 138° C.; 1 H NMR δ 1.40 (s, CH 3 ); 13 C NMR δ 28.1 (CH 3 ), 30.0 (CCH 2 CH 2 CONH), 29.8, 30.2 (CCH 2 CH 2 COO), 38.9 (β-CH 2 ), 42.4 (α-C), 57.2 (CCH 2 CH 2 COO), 57.6 (CCH 2 CH 2 CONH), 80.0 (CCH 3 ), 172.8 (COO), 177.8 (CONH); IR (KBr) 3350, 2938, 2846, 1740, 1680, 1260, 1045 cm −1 . Anal. Calcd for C 318 H 544 O 88 N 16 : C, 63.64; H, 9.14; N, 3.74. Found: C, 63.28; H, 8.96; N, 3.77.
1,3,5,7-Tetrakis{[N-[3-[[N-[3-carboxy-1,1-bis(2-carboxyethyl)propyl]amino]carbonyl]-1,1-bis[2-[[N-[3-carboxy-1,1-bis(2-carboxyethyl)-propyl]amino]carbonyl]ethyl]propyl]amino]-carbonyl}adamantane. A solution of the ester (150 mg, 25 μmol) in formic acid (96%, 2 mL) was stirred at 25° C. for 20 hours. Workup and purification, similar to that of the dodecaacid, gave (95%) the corresponding acid, as a very hygroscopic solid: mp 350-354° C. dec; 1 H NMR (D 2 O) δ 1.80 (s, CH 2 , 12 H), 2.18-2.41 (m, CH 2 , 192 H) 13 C NMR (D 2 O) δ 30.2 (CCH 2 CH 2 COOH), 30.8, 31.6 (CCH 2 CH 2 CONH), 39.1 (β-CH 2 ), 42.8 (α-C), 58.1 (CCH 2 CH 2 CONH), 58.5 (CCH 2 CH 2 COOH), 178.0 (COOH), 180.2 (CONH); IR (KBr) 3360, 3340-2600, 2920, 1745, 1685, 1240, 1060 cm −1 .
Large Scale Preparation of Di-tert-butyl 4-[2-(tert-butoxycarbonyl)ethyl]-4-nitroheptane-dicarboxylate (1). A 5-liter 3-necked flask, equipped with a 500 mL addition funnel, a thermometer, a reflux condenser and a 2-inch magnetic stirring bar was charged with 1,2-dimethoxyethane (DME, 500 mL) and MeNO 2 (122 g, 108.3 mL, 2 mol). The solution was heated to 65-70° C., and Triton-B (20 mL, 40% in MeOH) was added. Tert-butyl acrylate (794 g, 908 mL, 6.20 mol) was added at such a rate to maintain a temperature of 75-85° C. The addition was completed within 2 to 2.5 hours. When the temperature was maintained at 70-80° C. for two hours, the solution was decanted from insoluble polymeric material (which adheres to the wall of the flask) and concentrated in vacuo. The resulting light yellow residue was dissolved in ether (2.5 L), washed with ice cold 10% aqueous HCl (2×200 mL), an aqueous saturated NaHCO 3 (2×200 mL), and water (2×200 mL), then dried and clarified [Na 2 SO 4 (100 g) with celite (10 g)]. The ether was removed in vacuo to give a solid mass, which was dissolved in warm ethanol (ca. 1.3 L). The solution was allowed to cool and maintained at 0° C. for 24 hours. The resultant colorless crystals, were collected, washed with precooled methanol (500-600 mL) to remove any residual colored impurities, and dried in vacuo to afford 668-721 g (75-81%) of the white crystalline 1; mp 99-100° C., lit (Newkome et al., 1991) mp 98-100° C. 1 H NMR: δ 1.45 (s, CH 3 , 27H), 2.21 (m, CH 3 , 27H), 2.21 (m, CH 2 , 12H); 13 C NMR: δ 27.9 (CH 3 ), 29.7 (CH 2 CO), 30.2 (CCH 2 ), 80.9 (CCH 3 ), 92.1 (CNO 2 ), 170.9 (CO 2 ).
Di-tert-butyl 4-[2[(tert-butoxycarbonyl)ethyl]-4-aminoheptanedicarboxylate (2)
A. Preparation of T-1 Raney Nickel Catalyst (Dominguez et al., 1961). Caution should be maintained as this catalyst is easily handled when wet; however, it is extremely pyrophoric when dried and exposed to air. To 705 mL of water in a 2 L beaker rapidly stirred using a 2-inch magnetic stirring bar was added NaOH pellets (75 g). After dissolution, aluminum nickel alloy [30 g, Aldrich Chemical Co. (22,165-1), Raney R-type alloy] was added in one portion to the hot solution. There was a vigorous evolution of hydrogen and the temperature rose to ca. 85-90° C.; stirring was continued for one hour. The beaker was covered with a watch glass, and the supernatant alkaline solution was carefully decanted from the black catalyst. Distilled water (300-400 mL) was added, stirred for one to two minutes, and then decanted. This procedure was repeated four times. The catalyst was transferred into a 250 mL beaker and washed with absolute ethanol (5×150-200 mL); each time the catalyst was allowed to settle before the supernatant ethanol was decanted. The moist catalyst was used immediately.
B. Reduction Procedure. To a Parr hydrogenation bottle was added ethanol (25 mL), followed by the above freshly prepared catalyst [which should be covered (50-100 mL) with ethanol to ca. 75% of the total flash volume. The hydrogenation was performed at an initial pressure of 60 psi at 50-55° C., and generally required 45-75 minutes. Nitrotirester 1 is quite insoluble in ethanol while amine 2 is soluble. External cooling may be necessary so that the temperature does not exceed 55° C. The catalyst was removed by filtration through a sintered glass funnel, then washed with ethanol (50-80 ml) (Catalyst Destruction). If there are traces of catalyst in the filtrate, filtration must be repeated. The solvent was removed in vacuo (0.1 mm) to yield an oil, which was transferred to a crystallizing dish and allowed to solidify in vacuo to give 41.5-44.1 g (89-93%) of 2 as a white crystalline mass, mp 51° C., lit. (Newkome et al., 1991) mp 51-52° C. 1 H NMR: δ 1.44 (s, CH 3 , 27 H), 1.78 (m, CH 2 , 12H); 13 C NMR: δ 27.8 (CH 3 ), 29.8 (CH 2 CO), 34.2 (CCH 2 ), 52.2 (CNH 2 ), 80.0 (CCH 3 ), 172.8 (CO 2 ); MS m/e 415.4 (M + +1, 20).
Amine 2 can be cyclized upon heating to 110° C. for 48 hours to yield (100%) lactam 3, mp 132-133° C., lit. (Young, 1993) mp 131-132° C. 1 H NMR: δ 1.44 (s, CH 3 , 18 H), 1.83 (t, J=7.2 Hz, CH 2 CO, 4H), 1.92 (t, J=8.0 Hz, CH 2 CONH, 2H), 2.26 (t, J=7.2 Hz, CCH 2 , 4H), 2.38 (5, J=8.0 Hz, CCH 2 CH 2 CH 2 CONH, 2H), 6.92 (s, NH, 1H); 13 C NMR: δ 27.9 (CH 3 ), 30.1 (CH 2 O), 30.2, 30.25 [CH 2 CH 2 (ring)], 34.6 (CH 2 CH 2 CO 2 ), 60.6 (HNC), 80.6 (CO 2 C), 172.3 (CO 2 ), 177.2 (CONH); IR 1723, 1707 (C═O cm −1 . Anal. Calcd. for C 18 H 31 NO 5 ; C, 63.32; H, 9.15; N, 4.10. Found: C, 63.52; H, 9.25; N, 4.28.
The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation.
Obviously many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described.
REFERENCES
1. Newkome, G. R.; Yao, Z.-q.; Baker, G. R.; Gupta, V. K. J. Org. Chem. 1985, 50, 2003.
2. Newkome, G. R.; Baker, G. R.; Saunders, M. J.; Russo, P. S.; Gupta, V. K.; Yao, Z.-q. Y.; Miller, J. E.; Bouillion, K. J. Chem. Soc., Chem. Commun. 1986, 752.
3. Newkome, G. R.; Baker, G. R.; Aria, S.; Saunders, M. J.; Russo, P. S.; Theriot, K. J.; Moorefield, C. N.; Rogers, L. E.; Miller, J. E.; Lieux, T. R.; Murray, M. E.; Phillips, B.; Pascal, L. J. Am. Chem. Soc. 1990, 112, 8458.
4. Newkome, G. R.; Yao, Z.-q.; Baker, G. R.; Gupta, V. K.; Russo, P. S.; Saunders, M. J.; J. Am. Chem. Soc. 1986, 108, 849.
5. Newkome, G. R.; Hu, Y.; Saunders, M. J.; Fronczek, F. R. Tetrahedron Lett. 1991, 32, 1133.
6. Newkome, G. R.; Moorefield, C. N.; Baker, G. R.; Johnson, A. J.; Behera, R. K. Angew. Chem. 1991, 103, 1205; Angew. Chem., Int. Ed. Engl. 1991, 30, 1176.
7. Newkome, G. R.; Moorefield, C. N.; Baker, G. R.; Saunders, M. J.; Grossman, S. H. Angew. Chem. 1991, 103, 1207; Angew. Chem., Int. Ed. Engl. 1991, 30, 1178.
8. Newkome, G. R.; Lin, X. Macromolecules 1991, 24, 1443.
9. Ingartinger, H.; Reimann, W. J. Org. Chem. 1988, 53, 3046.
10. Bruson, H. A.; Riener, T. W. J. Amer. Chem. Soc. 1943, 65, 23.
11. Gakenheimer, W. C.; Hartung, W. H. J. Org. Chem. 1944, 9, 85. Noland, W. E.; Kneller, J. F.; Rice, D. E. Ibid. 1957, 22, 695. Fanta, P. E.; Smat, R. J.; Piecz, L. F.; Clemens, L. Ibid. 1966, 31, 3113. Controulis, J.; Rebstock, M. C.; Crooks, H. M., Jr. J. Am. Chem. Soc. 1949, 71, 2463. Wheatly, W. B. Ibid. 1954, 76, 2832. Newman, M. S.; Edwards, W. M. Ibid. 1954, 76, 1840. Herz, W.; Tocker, S. Ibid. 1955, 77, 3554. Baer, H. H.; Fischer, H. O. L. Ibid. 1960, 82, 3709.
12. Domingues, X. A.; Lopez, I. C.; Franco, R. J. Org. Chem. 1961, 26, 1625.
13. Bodanszky, M.; Bodanszky, A. The Practice of Peptide Synthesis in Reactivity and Structure Concepts in Organic Chemistry ; 1984; Vol. 21, p. 145.
14. C. D. Weis and G. R. Newkome, Synthesis, 1053 (1995).
15. J. K. Young, Ph. D. (USF) Dissertation, 1993.
16. G. R. Newkome, R. K. Behera, C. N. Moorefield, G. R. Baker, J. Org. Chem., 56 , 7162 (1991).
17. Catalyst destruction following the hydrogenation can be effected by direct addition of the moist material to a 5%. aqueous HCl solution.
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A method for forming cascade polymers specifically utilizing the amine monomer of the formula
The monomer is made by initially reacting nitromethane and CH 2 ═CHCO 2 — TBu by nucleophilic addition to form the triester nitrotrialkanoate of the formula
and then reducing the nitrosubstituent to afford the said amine monomer.
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BACKGROUND OF THE INVENTION
The invention concerns a winding configuration for a cryomagnet with at least one winding section, said section consisting of a parallel connection of a winding made from wire which is superconducting at the operating temperature and a winding made from normally conducting wire.
Such a winding configuration is known in the art from DE-A 35 32 396. This known winding configuration exhibits many winding sections each of which consists of a parallel connection of a winding made from wire which is superconducting at the operating temperature and a winding made from normally conducting wire. The individual windings each form a layer of the winding configuration and two separated layers are connected in parallel to form a winding section. The layers formed from normally conducting windings are composed of copper wire and serve not only the purpose of guaranteeing good quench dispersion, but also function as bindings which prevent an unacceptable stretching of the superconducting wire windings due to tensile stresses occurring in the superconducting wire.
The size of the known winding configuration with the described construction is determined by two factors, namely by the limiting value for the product between the current density and the magnetic field strength, and the cross section of the normally conducting material necessary for current take-over in case of a quench. The cryomagnet winding configuration sizes stemming from these factors impact on the weight, especially in cases involving cryomagnets with large inner diameters such as those used in magnetic resonance imaging. Winding configurations for superconducting tomography magnets achieve a weight on the order of several metric tons, so material costs represent a significant factor in the costs of the winding configuration. Moreover, problems associated with mounting such winding configurations in a cryostat increase with the weight of the winding configuration. Accordingly, measures which allow a reduction in the weight of such winding configurations would abate many problems associated with the construction of cryomagnets and, at the same time, lead to cost savings.
Known in the art from patents DE-A 26 02 735, DE-A 33 29 390 and from the scientific technical journal "IEEE Transactions on Magnetics " MAG -23 (1987), pages 914 through 917, as well as from the article "Large Superconducting Magnets for M.H.D." by Z. J. J. Stekly on pages 112-114 in the Journal "Cryogenic Engineering, The Proceedings of the First Cryogenic Engineering Conference held in Tokyo and Kyoto, Japan on Apr.9-13, 1967", are various ready-made superconductor wires of cables with which winding configurations for cryomagnets can be manufactured. Each of these ready-made wires or cables is so dimensioned as to satisfy the requirements on superconductivity and normal conductivity as well as on mechanical stability. In manufacturing a complete winding configuration for a cryomagnet, each part of the ready-made wire or cable must satisfy the most stringent mechanical requirements occurring within the entire winding configuration since in using these types of ready-made wire or cable, a position dependent variation within the winding structure is not possible. This represents, likewise, a substantial design restriction for the winding configuration in its entirety. Furthermore, these types of ready-made wire are too expensive for the manufacture of winding configurations with large inner diameters such as those needed in tomography magnets.
Various cryomagnet winding configuration structures are known in the art from the technical publication "The Review of Scientific Instruments" 36 (1965), pages 825 through 830. One of the known winding configurations has a foil layer between two respective winding layers, which can be strengthened with a metal mesh. If present, this type of metal mesh strengthened foil located between two counter-wound layers effects a stable mechanical localization of the individual layer windings against each other, such that springing of windings against each other due to the axial forces which occur should be avoided. The avoidance of such a springing of windings is necessary in order to exclude the occurrence of a thereby caused quench release. The metal mesh within the foil is, however, necessarily put into place between the winding layers without being stretched in the circumferential direction and, therefore, does not serve as radial mechanical support for the underlying winding wire.
With respect to this prior art, it is the purpose of the present invention to further develop a winding configuration of the above mentioned kind in such a way that said winding can be economically manufactured with substantially reduced volume.
SUMMARY OF THE INVENTION
The winding configuration according to the invention permits the use of a superconducting wire with a very small ratio between copper cross section and the cross section of the superconducting filaments in comparison to said ratio in superconducting wires of prior art since the size of the superconducting wires is determined only by its current carrying capability function. The windings from normally conducting copper wire or from a material with a conductivity better than 5.8×10 7 Sm -1 must only serve thermal conductivity and current take-over functions in the event of normal conduction, that is to say if a quench occurs within the superconducting wire, without having to take on the additional task demanded by prior art of providing sufficient mechanical support for the superconducting wire. The mechanical support function is essentially taken over by the windings made from steel wire or from a material with a modulus of elasticity which is higher than that of copper at the operating temperature of the winding configuration. Through this separation of functions among the three different wires, the winding configuration according to the invention can optimize each individual wire for its function. In this manner, it is possible according to the invention to reduce the total number of windings or the total number of winding layers within the winding configuration, to effect a substantial savings in volume, and to decrease the weight of the winding configuration according to the invention in comparison to prior art configurations.
As mentioned, in winding configurations of prior art, the copper cross section used is not, in its entirety, necessary in order to take on the current occurring in case of a quench since by using a special winding configuration design, in case of a quench the occurrence of a rapid even distribution of current in the normally conducting wire winding can be provided for without local current peaks which, in turn, would require a very large copper cross section in order to prevent local over-heating and resulting damage. In so far as the normally conducting wire is necessary in order to mechanically strengthen the winding configuration, said wire can also be replaced with another material of higher modulus of elasticity (E-modulus) the necessary amount of which is therefore less than that of the copper wire used up to now for this purpose. In this manner, a noteworthy result is already accomplished if the E-modulus of the material used is at least 1.2 times the E-modulus of copper.
In addition to mechanical strengthening, it also turns out to be possible using such a material to increase, above previous levels, the limiting value for the product between the amount of current flowing through the coil and the magnetic field strength. In this way, the windings made from superconducting wire can be arranged in closer proximity to another and, if appropriate, the strength of the current flowing through the magnet coil can be increased so that the volume of the winding configuration can be reduced. In this way substantial material savings can be achieved and problems associated with producing a stable winding configuration and with the mounting of said configuration in a cryostat can be reduced.
The winding configuration according to the invention need, by no means, be homogeneous in the axial and radial directions, rather the cross section density of the three individual wires can vary as a function of position. Through variation of the individual number of windings per cross section surface for the individual wire types, the average current density in the radial and axial directions can be varied, which, in turn, gives the designer increased freedom in coil design while fulfilling the field homogeneity requirements. Accordingly, it is sufficient for the winding configuration according to the invention to only have a specific structure within one axial and radial winding section.
Through the use of a ferromagnetic steel for the steel wire winding, a charging of the coil leads to a saturated magnetization of the ferromagnetic wire winding which, in turn, contributes to the entire magnetic field strength in a predeterminable manner. This additional magnetic field allows a homogeneous field to be achieved even with coils whose lengths are shortened with respect to coil lengths necessary when using non-ferromagnetic steel. All together, through these means, the tensile load acting on the individual wires under operating conditions turns out to be lower.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment according to prior art and embodiments according to the present invention will be illustrated in detail below through reference to the accompanying illustrations.
FIG. 1. a lengthwise cut through a cryomagnet winding configuration.
FIG. 2. expanded view of a winding section in the vicinity of region II according to FIG. 1 with winding layer arrangements of prior art.
FIG. 3. a first embodiment of a winding configuration according to the invention in a representation corresponding to FIG. 2.
FIG. 4. through 8. second through sixth embodiments of the winding configuration according to the invention in a representation corresponding to the section of FIG. 2.
DETAILED DESCRIPTION
FIG. 1 is a rendering of the typical construction of a tomography system cryomagnet winding configuration. In this winding configuration, the winding is distributed among four chambers 1, 2, 3, 4, which are located on the circumference of coil spool 5. The coil formed by the windings arranged in the chambers 1 through 4 has an overall length of L=1700 mm and an inner diameter of D=1080 mm. The magnetic field in the inner center of the winding configuration has a strength of 3.65 Tesla, whereas the maximum field strength occurring within the winding in the direction of the coil axis has a value Bmax of 4.74 Tesla.
According to prior art, it is possible that the winding configuration of such a coil has the construction represented in FIG. 2. The windings which are arranged in the individual chambers on the coil spool 5 each consist of sixty layers of normally conducting copper wire 11 and of wire 12 which is superconducting at the operating temperature. The wires used have a stripped-wire cross section of 1.5 mm each and, when varnished, a cross section of 1.6 mm. As can be seen from FIG. 2, the copper wire and the superconducting wire in the winding configuration are present in the ratio 3:1, and namely in the form of two layers 13 each of bifilar wound copper wire and superconducting wire alternating with two layers 14 each of copper wire. The cross section ratio between copper and superconductor in the superconducting wire is 1.8.
A winding configuration constructed in this fashion has a weight of 2.8 metric t, of which 0.7 metric t are due to the superconducting wire and 2.1 metric t to the copper wire. The operating current IN is 557 A, while the critical current IC at the mentioned maximum field within the winding of 4.7 Tesla is 1300 A. Therewith results a relative current load IN/IC=0.43.
With these values, as a result of Lorentz forces, there turns out to be a maximum free tensile stress in the superconducting wire of
o=IN*Bmax*r/q=800 MPa.
In this relationship, r is the radius of the winding at the position of the maximum magnetic field and q the cross sectional area of the superconducting wire. As a result of the binding action of the copper wire both in the bifilar layers 13 as well as in the layers 14 made from pure copper, that is to say through the support of inner loaded layers by outer unloaded layers, there results a reduced tensile stress in the superconducting wire ##EQU1## Whereby, v designates the number of normally conducting windings per superconducting winding.
A winding configuration designed in accordance with the invention can be derived from the winding configuration designed according to prior art that is represented in FIG. 2, if one replaces both copper wire layers 14 with a single layer 15 made from 1.6 mm diameter steel wire. Since the E-modulus of steel is about twice as large as the E-modulus of copper, the single steel wire layer 15 has the same binding action as the double layer 14 made from copper wire which is present in the winding configuration of FIG. 2. In this manner, the number of winding configuration layers is reduced from sixty to forty five, namely to fifteen double layers 13 made from bifilar lain copper wire 11 and superconducting wire 12 alternated with one layer 15 each of steel wire 16. The double layers 13 and the single layer 15 sequences repeat themselves in the radial direction forming layer groups 17. Because of the reduction in the number of winding configuration layers in comparison to prior art, the weight of the winding is reduced to 2.1 metric t from which, in turn, 0.7 metric t result from the weight of the superconducting wire, but only 0.7 metric t from the weight of the copper wire, and likewise 0.7 metric t from the steel wire. In this manner, in comparison to a winding of conventional construction, a savings of 25% in both volume as well as in weight is achieved. As a result, substantial savings in material costs are realized and problems associated with the mounting of the windings in the cryostat are diminished. In consequence of the reduced weight, the support elements with which the winding configuration is fixed in the cryostat can be mechanically weaker, that is to say, of reduced cross section. In this manner, the heat transfer from the inside to the outside of the cryostat is, in turn, diminished so that, herewith, as well as in consequence of the reduced outer surface of the cryostat resulting from its reduced diameter, a reduction in helium consumption is achievable.
In the modified embodiment shown in FIG. 4, a layer group 17 includes an innermost layer of normally conducting wire 11, a superconducting wire layer 12 surrounding said normally conducting wire layer, and a layer made from steel wire 16 encasing the layer group 17.
In the third embodiment shown in FIG. 5, lain in every layer are a steel wire 16, a superconducting wire 12, and a normally conducting wire 11. In this case, the layer group 17 is reduced to a single layer. The superconducting, normally conducting, and steel wires of neighboring layers are, for practical reasons, slightly displaced with respect to the layers lying beneath them.
Likewise, it is possible according to the third embodiment of FIG. 6 to assemble a layer group 17 from an inner layer comprised of bifilar wound superconducting wire 12 and normally conducting wire 11, and from a corresponding outer layer of steel wire 16.
In the fifth embodiment, the winding configuration according to the invention includes a layer group 17 of a bifilar wound inner layer of steel wire and superconducting wire enclosed by an additional layer of normally conducting wire.
In the sixth embodiment according to FIG. 8, a layer group is comprised of an inner layer of superconducting wire 12 enclosed in a bifilar wound outer layer of steel wire and normally conducting wire.
Every arbitrary arrangement of the winding made from superconducting wire 12, normally conducting wire 11, and steel wire 16 within a layer group leads, in a similar fashion, to the purpose according to the invention of reducing the volume and weight of the entire winding configuration. The individual wires 11, 12, 16 can each be optimized for their respective functions of superconducting current carrying capability, normally conducting current carrying capability, and heat conduction capability as well as mechanical stability.
As a variation on the embodiments shown, the layer groups can also be comprised of more than two or three single layers.
The number of winding of normally conducting wire 11, of superconducting wire 12, and of steel wire 16 per lengthwise cross section through the winding configuration can vary as a function of position in the axial direction as well as in the radial direction. In this manner, it is in particular possible to effect a position dependent change in the average current density within the winding configuration. This leads to increased freedom in laying out the winding design while maintaining the principal requirement of magnetic field homogeneity.
The normally conducting wire 11 can, as is usually the case, be made from copper. Likewise, as far as the purpose of the present invention is concerned, another material with a conductivity better than 5.8×10 7 Sm -1 can be used.
In all embodiments, in place of the steel wire 16, a wire can be used which is made from a material with a modulus of elasticity higher than that of copper at the operating temperature of the winding configuration which corresponds to a few Kelvin.
Instead of stainless steel as material for the steel wire 16, ferromagnetic steel can be used. At high operating field strengths the ferromagnetic steel experiences magnetic saturation and thereby furnishes a self-contribution to the entire magnetic field of pre-determinable size. This allows a shortening of the entire coil while maintaining a homogeneous magnetic field and a reduction in the tensile force on the individual wires 11, 12, 16.
Clearly, the invention is not limited to the embodiments shown, rather variation therefrom are possible without leaving the confines of the invention. The wire which is superconducting at the operating temperature, the normally conducting wire, and the support layers can be arranged in numerous variable ways. This is the case so long as the requirement is satisfied that, with the configuration chosen, the product between the current density and the magnetic field strength does not exceed the limiting value given by the coil construction, the cross section of normally conducting material is sufficiently large to carry the operating current when bringing-up the magnet as well as in case of a quench, and finally that the configuration of the winding made from normally conducting wire guaranties a rapid dispersion of the quench, whereby the inserted layers made from a material with a high modulus of elasticity are so arranged that they optimally support the winding made from superconducting wire independent of the electrical conductivity.
Since the normally conducting wire no longer serves a substantial support function, said wire can be composed of a material which, although having good electrical conductivity, does not exhibit a particularly high modulus of elasticity as is, for example, the case with aluminum. The utilization of aluminum would result in a further significant reduction in the weight of such a winding configuration, since the specific weight of aluminum is significantly less than that of copper, and due to the better conductively, a smaller aluminum wire cross section could even be chosen. It is furthermore clear that the insert layers composed of a material with a high modulus of elasticity need not be restricted to steel wire, rather that filaments from other substances with high modulus of elasticity, in particular from fiber-reinforced plastics, could be utilized as well. Finally, it would be possible to surround the entire winding configuration with an additional casing made from a material with a high modulus of elasticity.
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Winding arrangements for cryomagnets have a winding of superconducting wire (12) connected in parallel to a winding of normally conducting wire (11) which, in the event of a quench, conducts the operating current and mechanically stabilizes the winding arrangement. Independently of this, the size of such a winding arrangement depends primarily on the tensile forces exerted on the wires and on the modulus of elasticity of the material of the wire. The size of such a winding arrangement is a significant factor in its cost and should therefore be reduced. According to the invention, the winding arrangement has a plurality of groups (17) arranged in radially repetitive layers inside the winding section, in which each winding of superconducting wire surrounds windings of a normally conducting wire and windings of steel wire or of a wire with a high modulus of elasticity.
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FIELD OF THE INVENTION
[0001] The present invention relates to a method of applying absorbent gelling material (AGM) granules onto an carrier layer for use in an absorbent article, particularly diaper for babies or adults, training pants, pull-up diapers (diaper pants), sanitary napkins, panty liners or the like. These articles typically comprise the carrier layer with the AGM particles deposited thereon by indirect printing together with further layers making up the complete article.
BACKGROUND OF THE INVENTION
[0002] The term “AGM granules” as used herein includes materials capable of absorbing and storing a high amount of liquid compared with the volume thereof “AGM” is the abbreviation of Absorbent Gelling Materials. These materials are mainly formed by superabsorbent polymers. In the present context the AGM material may be used as granules of different particle size including powder like materials or a mixture of powder material and granules of different particle size or forms (e. g. fibers).
[0003] AGM materials of this kind are usually embedded into absorbent pads of melt blown fibers or cellulose fibers (or similar fibrous materials and combinations thereof) or directly deposited onto a non-woven carrier layer. The present invention is applicable to both of these methods. This kind of “absorbent article” may be used for example for manufacturing a diaper, a sanitary towel or even a liquid gathering article of any kind.
[0004] Various approaches have been proposed for obtaining AGM granule distribution on a substrate having a predetermined pattern and thickness profile. These approaches include blowing an airborne mixture of AGM granules and fibers through a conduit onto a vacuum drum. Methods of this kind only allow a limited control of the pattern and the distribution of the thickness of the AGM over the surface onto which the AGM is distributed.
[0005] Particularly in case of low or no cellulose fiber containing absorbent cores, having AGM granules as the only liquid storage material, AGM granule distribution with accuracy with respect to shape and discreetness is highly important.
[0006] In this context it should be mentioned that it is possible to use single or multi piece cores, one layer of AGM or several layers on top of each other overlapping or besides each other. This also allows to use different AGM's in different layers. Thus the possibilities of variation of the achieved product are nearly endless. However, high accuracy of the granule distribution is important.
SUMMARY OF THE INVENTION
[0007] Thus the present invention is directed to a method for applying AGM granules onto a surface with high accuracy of the distribution, pattern and the amount of AGM material on the surface by indirect printing. Such a process method can be used in an application of AGM particles requiring accurate, print like positioning of granules or powders on a carrier layer. One particular application may be the making of primarily AGM/glue comprising cores for disposable diapers or parts of such cores.
[0008] According to a first embodiment of the present invention, the indirect printing method according to the invention is characterized in that
the AGM granules are taken up by a transfer device from a bulk storage of AGM granules, said transfer device having recesses on the surface thereof, the number, size and position of which determining the amount and pattern of AGM granules taken up by the transfer device, the transfer device being moveable from the bulk storage to a position passed by the carrier layer (transfer or meeting position), means being provided for retaining the AGM granules inside said recesses during movement of the transfer device to said meeting (or transfer) position, and means being provided for expelling said AGM granules onto the carrier layer in said transfer position.
[0014] The invention further refers to an apparatus, particularly an apparatus for conducting the method according to the invention.
[0015] In the following indirect printing shall mean the transfer of AGM which is separated from the bulk storage of AGM before it is in contact with the carrier layer. Direct printing means that the AGM is not separated from the bulk storage of AGM before it is in contact with the carrier layer. This is not included in the present invention.
[0016] The present invention provides a method and apparatus which significantly increases AGM deposition accuracy. The standard deviation achieved so far has been reduced to about 1/4 of what has been achieved with advanced prior technology. Thus diaper cores having an accurate distribution profile of AGM in the lateral and the longitudinal direction can be obtained. The method according to the invention allows especially deposition of AGM granules on fast moving carrier layers at surface speeds of 1 m/sec up to 3 m/sec, preferably up to 5 m/sec, or even 10 msec and even more preferably up to 15 m/sec with high accuracy. Because of the accuracy of the deposition of AGM granules, the invention allows manufacturing of e. g. an absorbent core without cellulose or similarly absorbent and/or hydrophilic fibers in diapers which results in extreme core thinness and improved comfort and fit in use for the articles.
[0017] The term “transfer device” as used herein includes any moveable member being capable of taking up AGM granules in a predetermined shape and a thickness profile and depositing the granules-without amending the configuration thereof-on a carrier substrate.
[0018] A preferred embodiment of the transfer device is a patterned rotary drum or roll, which is called “printing roll” or “transfer roll” in the present context because the transfer of a pattern of AGM granules can be comparable with printing. Another embodiment would be a moveable belt having recesses on the surface and being moved between the AGM granule bulk storage and the transfer position.
[0019] The term “bulk” or “bulk storage” of AGM granules refer in the present context to any kind of supply of granules, particularly a hopper.
[0020] “Retaining means” are provided to keep the AGM granules taken up by the recesses of the transfer device in these recesses during movement from the bulk to the transfer position where the granules are delivered to the carrier layer. In one preferred embodiment the retaining means is a belt, which is guided along the surface of the transfer device, particularly the printing roll, on the way from the bulk to the transfer position. Other possible embodiments, which are particularly preferred are vacuum means for keeping the AGM granules in the recesses. Also the use of an electrostatic field is possible
[0021] “Expelling means” in the present context means delivering the AGM granules in the transfer position as defined above to a carrier substrate. For delivering the granules, the granules may be expelled by air jets or an electrostatic field or just by gravity.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The above and further features, aspects and advantages of the present invention will become better understood with regard to the following description making reference to the accompanying drawings.
[0023] FIG. 1 illustrates one embodiment of the present invention;
[0024] FIG. 2 is a diagrammatic illustration of the embodiment of FIG. 1 showing an additional detail;
[0025] FIG. 3 illustrates a modification of the embodiment of FIG. 2 ;
[0026] FIG. 4 corresponds to FIG. 2 with a modification of one feature;
[0027] FIG. 5 again corresponds to FIG. 2 with a modification of one feature;
[0028] FIG. 6 again corresponds to FIG. 2 with a modification of one feature;
[0029] FIG. 7 shows an embodiment being a combination of FIGS. 3 and 6 ;
[0030] FIG. 8 shows another embodiment of an apparatus according to the invention and for conducting the methods according to the invention;
[0031] FIG. 9 is a cross section along line 9 - 9 of another embodiment of the invention shown in FIG. 10 .
[0032] FIG. 10 is a front view from the left side in FIG. 9 .
DETAILED DESCRIPTION OF THE INVENTION
[0033] FIG. 1 shows a hopper ( 10 ) filled with a bulk of AGM material ( 12 ). The hopper ( 10 ) has a supply opening ( 14 ) on the upper side and a delivery opening ( 16 ) at the bottom. The hopper forms one embodiment of what is called “bulk” in the present context.
[0034] A printing roll ( 18 ) enters into the opening ( 16 ) in the hopper ( 10 ) in a way that the bottom of the hopper surrounding the opening ( 16 ) closely follows the contour of the roller ( 18 ) and an unintended drop out of AGM granules is prevented.
[0035] The printing roll ( 18 ) is provided with holes or recesses ( 22 ) on the surface thereof which are filled with AGM granules from the lower end ( 20 ) of the bulk of AGM material ( 12 ) in the hopper ( 10 ), while the surface of the roll ( 18 ) passes through the AGM material ( 12 ) inside the hopper ( 10 ). The number, the size and the position of the recesses ( 22 ) are selected such that the volume and the pattern of the recesses correspond to the intended pattern and thickness profile of the AGM material which is to be received by the printing roll and to be transferred to a carrier layer as will be explained below.
[0036] The printing roll ( 18 ) forms one embodiment of a transfer device according to the present invention. Another embodiment could for instance be formed by a belt having recesses in the surface thereof for receiving AGM material.
[0037] A rotatable printing roll however may be a preferred embodiment.
[0038] The AGM granules are taken up by the recesses ( 22 ) of the printing roll ( 18 ) when one of the recesses ( 22 ) on the transfer roll ( 18 ) is in this loading position. The AGM granules are retained in these recesses on the way from the hopper ( 10 ) to a position called “transfer or meeting position” herein where the printing roll ( 18 ) which is rotated in counter clockwise direction in FIG. 1 is in a position immediately opposite the surface of a carrier layer ( 24 ). The carrier layer ( 24 ) is supported by a rotating support roll ( 25 ).
[0039] The carrier layer is for instance a non-woven web onto which the AGM granules are expelled or laid down (by gravity) from the printing roll. For holding the AGM granules on the carrier layer ( 24 ), glue is preferably sprayed onto the carrier layer ( 24 ) upstream the transfer position between the printing roll ( 18 ) and the carrier layer ( 24 ), which upstream position is designated by reference numeral ( 26 ). Because the glue is applied in this upstream position ( 26 ) onto the carrier layer ( 24 ), the AGM granules are retained on the carrier layer ( 24 ). A particularly preferred glue for retaining the AGM granules on the carrier layer ( 24 ) is a micro fiber glue with very thin fiber made by spraying a hot melt adhesive material through respectively thin nozzles. Such nozzles are commercially available from Nordson Company, Dawsonville, Ga., USA.
[0040] It is preferred that the support roll ( 25 ), which could alternatively also be provided by a moving belt, is also holding the AGM particles down onto the carrier, especially by use of a pressure differential (vacuum) through a screen forming the cylindrical surface of the support roll ( 25 ). In another position downstream the transfer position between the printing roll ( 18 ) and the carrier layer ( 24 ), which position is designated by ( 28 ), glue is—preferably but optional—sprayed onto the AGM granules on the carrier layer ( 24 ), which glue preferably is also a microfilament glue entering like fibers between the granules of the AGM to hold the whole deposit together. In an alternative embodiment it is also possible to apply a cover layer carrying glue onto the AGM granules.
[0041] When large amounts of glue are applied at positions ( 26 ) and/or ( 28 ) it is advantageous to use materials for the cylindrical support roll surface, which have a low or no tendency to accumulate adhesive residue. This can be Teflon™ coated surfaces or if a belt instead of a support roll is used, silicon rubber materials. Especially in case the carrier layer ( 24 ) is exposed to a vacuum on the inside of the support roll the surface of the support roll can be made of a silicon rubber screen (preferably metal reinforced).
[0042] As shown in FIG. 1 , in this particular embodiment the printing roll ( 18 ) is moving through the AGM material by rotation of the roll in the counterclockwise direction designated by the arrow in FIG. 1 , AGM granules are taken up in the recesses ( 22 ) of the roll, but there is of course a certain risk that additional AGM granules beyond those filling the recesses are carried out of the hopper between the surface of the printing roll ( 18 ) and adjacent edge of the bottom of the hopper. Therefore, scraping means ( 19 ) are provided at this edge one example of which is shown in FIG. 2 .
[0043] In FIG. 2 those members or elements which have been already described in connection with FIG. 1 , are designated by the same reference numerals.
[0044] The scraping means ( 19 ) in FIG. 2 are formed by a doctor blade ( 30 ) having a scraping edge ( 32 ) being in close contact with the surface of the printing roll ( 18 ). The distance between the doctor blade ( 30 ) and the printing roll ( 18 ) should be above 0 mm to prevent excess pressures and damage to the equipment and the AGM particles. The particle size mix is one of the factors to consider when selecting the scraping blade distance. E.g. very large AGM particles with mean diameter of 900 micrometer and above would need a spacing of less than 900 micrometer. The upper useful spacing limit should be about 1 mm with the preferred spacing between 0.01 and 0.5 mm, more preferably between 0.03 and 0.1 mm to ensure good scraping at extended production runs.
[0045] FIG. 3 illustrates an embodiment corresponding to the embodiment of FIG. 2 but additionally showing retaining means for retaining the AGM granules in the recesses (not shown) provided in the surface of the printing roll ( 18 ) on the way from the hopper ( 10 ) to the transfer position.
[0046] One possibility to hold the AGM granules in the recesses may be a vacuum applied to the inner side of the printing roll ( 18 ) in combination with suction holes (not shown) in the bottom of the recesses. Another embodiment of retaining means as shown in FIG. 3 is formed by an endless belt ( 34 ) which is moved together with the rotation of the printing roll ( 18 ) along with the surface thereof from a position immediately downstream the doctor blade to a position immediately upstream the transfer position where the granules are transferred to the carrier layer ( 24 ) not shown in FIG. 3 . The belt is driven around an upper and a lower guide roll ( 36 , 38 ) in the upper and lower position of the path of the belt adjacent the printing roll ( 18 ) and around a third guide roll spaced from the surface of the printing roll and forming a triangle with the other guide roll ( 36 , 38 ). The belt ( 34 ) may be driven by driving one of these three rolls to move the belt ( 34 ) in the direction marked by arrows. Alternatively, the belt may be idling and moved by contact with the surface of the printing roll ( 18 ).
[0047] FIG. 4 shows an alternative embodiment of the scraping means ( 19 ) of FIGS. 2 and 3 . The reference numerals of FIGS. 2 and 3 are also used in FIG. 4 for corresponding parts. Instead of the doctor blade of FIGS. 2 and 3 , the embodiment of FIG. 4 is provided with an air jet box ( 40 ) arranged in the position of the doctor blade ( 30 ) of FIGS. 2 and 3 and ejecting air under pressure opposite to the moving direction of the surface of the printing roll ( 18 ), as shown in FIG. 4 , to keep the AGM granules back from the gap between the air jet box and the surface of the printing roll 18 .
[0048] The embodiment of FIG. 5 which again basically corresponds to the foregoing embodiments of FIGS. 2 to 4 shows another modification of the scraping means ( 19 ) which in this case are formed by a rotatable brush ( 42 ) in the position of the doctor blade mentioned before to keep the AGM granules back from leaving the hopper 10 by rotation in counter clockwise direction.
[0049] FIG. 6 again shows another embodiment of the scraping means ( 19 ), which in this case is formed by a moveable belt running around a lower and an upper guide roll ( 46 , 48 ) one of which may be driven by a suitable drive not shown. The belt ( 44 ) moves on the side of the AGM materials substantially vertically upward as shown by the arrow and returns down on the outer side of the hopper ( 10 ).
[0050] The belt ( 44 ) lifts the AGM material on the inner side of the hopper ( 10 ) to keep the AGM material away from leaving the hopper through the gap between the surface of the printing roll and the belt ( 44 ).
[0051] FIG. 7 shows an embodiment which is substantially a combination of the embodiments of FIGS. 3 and 6 , comprising a belt ( 34 ) for retaining the AGM granules in the recesses of the printing roll and another belt ( 44 ) with the function of scraping means as discussed in connection with FIG. 6 .
[0052] FIG. 8 shows an embodiment the hopper ( 50 ) of which is formed as a fluidized bed for keeping the AGM granules in a floating state. The printing roll designated by ( 18 ) in this case rotates through the fluidized granules which are taken up by the recesses in the surface of the printing roll ( 18 ).
[0053] AGM granules extending beyond the recesses or adhering to the surface of the printing roll ( 18 ) outside the recesses are stripped away from the printing roll by a doctor blade ( 54 ) acting as scraping means and being arranged in a position immediately upstream the meeting position designated by ( 55 ) in this case where the printing roll is positioned immediately opposite the carrier layer ( 24 ) supported by the lay down drum. In the positions ( 26 , 28 ) upstream and downstream the meeting position there are position glue heads ( 56 , 58 ) for applying glue onto the carrier layer ( 24 ) in the position ( 26 ) and onto the deposited AGM granules in the position ( 28 ) applied onto the carrier layer. In this case, the printing roll immerges into the AGM bulk storage from the top.
[0054] In preferred embodiment, the system shown in FIG. 8 further comprises an airborne particle cycling system ( 51 , 52 , 57 ). In this system particles are transported from a location close to the meeting position ( 55 ) along conducts ( 51 , 52 ) in the direction of arrow ( 53 ) to a return conduct end ( 57 ). In this way the particles are prevented from being stuck or settling in the region of meeting position ( 55 ) due to agitation reduction in that region of the fluidized bed. The particle cycling system usually can be operated by an air current in the pipe transporting the particles along the conducts.
[0055] In FIG. 9 , there is shown an indirect particle printing station comprising an AGM supply ( 70 , 72 , 74 ) connected to a stator housing ( 68 ), centrifugal roll ( 60 ) having its axis ( 80 ) along a horizontal line from left to right in FIG. 9 . FIG. 9 is a cross section view along line 9 in FIG. 10 , which is showing a side view of the particle printing station of FIG. 9 . In FIG. 10 the carrier onto which AGM is deposited is shown on a transport cylinder also referred to a support roll ( 25 , partially shown). The centrifugal roll ( 60 ) comprises a central portion ( 62 ) of cylindrical form and two frustoconical inlet portions ( 64 , 66 ) on both sides thereof in axial direction. The inlet portions ( 64 , 66 ) are connected with an AGM supply system ( 68 ) formed by a supply tube ( 70 ) divided in two branch tubes ( 72 , 74 ) which are connected with the inlet portions ( 64 , 66 ) of the centrifugal roll ( 60 ) at their axial ends. Thus AGM is supplied through the supply tube ( 70 ) into the branch tubes ( 72 , 74 ) and transported in the inlet portions ( 64 , 66 ) by centrifugal forces and finally into the central portion ( 62 ) of the centrifugal roll. At this position the AGM leaves the centrifugal roll and the stator ( 68 ) and, still by centrifugally created pressure is pressed against the inside of the screen printing roll ( 82 ) which is partially covered on the outside with a belt ( 86 ).
[0056] This printing roll is provided with openings (not shown) in the circumferential wall forming a pattern of suitable shape and size through which, at each rotation of the centrifugal roll, AGM granules leave the printing station and are deposited without contact on a carrier layer ( 24 ) (as shown in FIG. 10 ).
[0057] The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”
[0058] Every document cited herein, including any cross referenced or related patent or application, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.
[0059] While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.
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The present invention relates to a method of applying absorbent gelling material (AGM) granules by indirect printing onto an carrier layer for use in an absorbent article, particularly diaper for babies or adults, training pants, pull-up diapers (diaper pants), sanitary napkins, panty liners or the like. These articles typically comprise the carrier layer with the AGM particles together with further layers, making up the complete article.
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BACKGROUND OF THE INVENTION
Automatic one-step buttonholing devices, in themselves, are not new. U.S. Pat. No. 3,596,618 by Goldbach, discloses one such device which utilizes a wheel in contact with the the workpiece for metering the size of the buttonhole being sewn. Another device disclosed in U.S. Pat. No. 3,656,443 by Ross, consists of a slide attachable to the presser bar. This slide travels along with the workpiece and through a set of linkages determines the size of the buttonhole. Both of the aforementioned devices, as well as many others, require additional, and in some cases, cumbersome hardware just for sizing the buttonhole. This additional hardware can be expensive to manufacture and may, after use, require calibration and repair. In addition, these devices place a maximum limit on the desired buttonhole.
SUMMARY OF THE INVENTION
The object of this invention is to provide a buttonholing device which is capable of measuring a buttonhole with a minimum amount of additional hardware and which places no limitation on the size of the buttonhole. These objects are achieved by placing gate means, such as two electrical contacts in close proximity of each other, on the bottom of a standard presser foot. By applying a pair of gate closing elements on the workpiece indicating the top and bottom of the buttonhole, when the gate means ride over the gate closing elements, a circuit is excited which then actuates a buttonholing assembly.
With the above and additional objects and advantages in view as will hereinafter appear, this invention will be described in reference to the accompanying drawings of the preferred embodiment.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevation of a sewing machine having the invention incorporated therein.
FIG. 2 is a top perspective view of sewing machine presser foot with the electrical contacts of the invention installed. Also shown is the relative positioning of the pieces of conductive material on the work piece.
FIG. 3 is a bottom view of the presser foot showing the electrical contact in position.
FIG. 4 is a cross-sectional view of the presser foot taken along line 4--4 of FIG. 3.
FIG. 5 is a schematic of the electrical control circuit to which the contacts are connected.
FIGS. 6A, 6B, 6C and 6D show in sequential steps the formation of a buttonhole.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The buttonholing device of this invention, as illustrated in FIG. 1, is embodied in a zig-zag vertical cam stack sewing machine which comprises a frame including a bed 10, a hollow-standard 12 rising from the bed 10, a bracket arm 14 extending from the hollow-standard 12 and terminating in a sewing head 16 which overhangs the bed 10. Journaled in the bracket arm 14 is a main shaft 18 which carries a balance wheel 20. A drive motor (not shown) is preferably carried within the rear portion of the hollow-standard 12.
Within the sewing head 16, the main shaft 18 carries a conventional crank mechanism 22 for imparting endwise reciprocating motion to a needle bar 24 to the end of which a needle 26 is clamped. To provide for zig-zag stitching, the needle bar 24 is endwise slidable in a spherical bearing 28 in the lower extremity of the sewing head 16 and is slidably constrained in a similar spherical bearing 30 in a gate 32 to which is imparted a lateral jogging motion by a needle jogging mechanism (not shown). The needle jogging mechanism includes provisions for controlling the neutral position of needle vibration, and provides for the sewing of cam controlled patterns of zig-zag stitching, having controls 34 and 36 for adjusting the same. Handle 38 is provided for adjusting the bight of the needle jogging mechanism.
Also located within the sewing head is a presser bar 40 which is spring biased toward the material being sewn. Pivotally attached to the end of the presser bar 40 is a sensing presser foot assembly 42 which forms a part of this invention.
Cooperating with the needle 26 in the formation of stitches is a conventional loop taker (not shown) which may be driven in timed relation with the needle reciprocation by means connecting the looptaker with the main shaft 18. Also driven from the main shaft 18 is a work-feeding mechanism (not shown) having a regulating handle 44 attached thereto for adjusting both the direction and length of feed for each stitch.
In the sewing machine, the standard 12 and the bracket arm 14 are formed in the front wall with an opening 46 which is closed by a cover 48 through which the controls 34 and 36 for cam follower position selection, controller 38 for width of zig-zag stitching and the feed-regulating handle 44 project. Any desired indicia may be provided on the cover 48 for facilitating the setting of the controls, and as illustrated in FIG. 1, special indicia 50 may be provided to facilitate the settings necessary for use of the buttonholing device.
The construction of the sewing machine thus far described is similar to that described in greater detail in U.S. Pat. No. 2,862,468 by Johnson, which is modified to include the cam follower position selecting mechanism which is described in greater detail in U.S. Pat. No. 3,503,530 by Buan, to both of which reference may be had.
The buttonholing device, as shown in FIG. 1, comprises a sensing presser foot assembly 42 which provides sensing pulses at pre-set intervals, a buttonholing assembly 100 coupled to the sewing machine controls, having a repetitive sequence of modes of operation, each of which results in the stitching of a discrete portion of a buttonhole, and an indexing mechanism which, upon activation, advances the buttonholing assembly 100 from one mode to the next, and an electrical control circuit 120 having a first stage for detecting sensing pulses from the presser foot assembly 42 and a second stage for activating the indexing mechanism of the buttonholing assembly 100.
The buttonholing assembly 100 and the electrical control circuit 120 are the same as that described in U.S. Pat. No. 3,596,618 by Goldbach et al, to which reference may be had for greater detail.
As shown in FIGS. 2, 3, and 4, the presser foot assembly 42 comprises a base plate 52, preferably made of plastic, having a bifurcated front portion 54 and a solid rear portion 56. Both the front and rear portions, 54 and 56, respectively are turned upward to prevent the presser foot assembly 42 from catching the material being sewn.
The bifurcation 58 in the front portion 54 terminates in an enlarged sewing eye 60 located near the center of the base plate 52 through which the needle 26 travels in the formation of stitches. The base plate 52 is also formed with a boss 62 located to the rear of the sewing eye 60 transverse to the width of the base plate 52. The boss 62 has a slot 64 formed therein at its center and transverse to the slot 64 a pin 66 is secured in the boss 62 for pivotally attaching the presser foot assembly 42 to the presser bar 40.
The base plate 52 is further formed having two holes 68 and 70 in close tandem proximity of each other. The actual location of the holes 68 and 70 is not important, however, in this embodiment, the holes 68 and 70 lie to the right of and substantially adjacent to the sewing eye 60.
Two electrical contacts 72 and 74, having lead wires 76 attached thereto, are secured in the holes 68 and 70, respectively, by any suitable means, such as epoxy cement, such that the electrical contacts 72 and 74 are in contact with the material being sewn. In this embodiment, a hole 78 is formed in the boss 62 for directing the lead wires 76 out of the line of sight of the operator.
Referring to FIG. 5, the lead wires 76 are connected to the electrical control circuit 120 at the point 122.
The buttonholing assembly 100 is coupled to the sewing machine controls for feed regulation and neutral needle position by means of a cam arrangement 102 which is driven is increments by a linkage 104 connected to the feed mechanism. A lever 106 engages the buttonholing assembly 100 and activates the electrical control circuit 120 through switch 124. The lever 106 along with a knob 108, for adjusting the initial position of the cam arrangement 102, protrude through the cover 48 allowing access by the operator. Reference may be made to U.S. Pat. No. 3,596,618 for a detailed description of both the buttonholing assembly 100 and the electrical control circuit 120.
To form a buttonhole, the operator first affixes to the material two small pieces of conductive material 150 and 151 each alongside the opposite extremity of the location of the slit or hole 160 which after being edged by stitching 170 will be cut to define the buttonhole. The pieces of conductive material 150 and 151 may be metal foil having a pressure sensitive adhesive coating on one side. It will be noted in FIGS. 6A to D that the stitching 170 proceeds beyond the conductive material 150 and 151 at each end of the buttonhole. The operator then moves lever 106 engaging the buttonholing assembly 100 and then turns knob 108 to its starting position which may be marked by indicia 50 on the front cover 48. Controls 34 and 36 are also set to indicia 50 at this time.
Using the piece of conductive material 151 as a guide, the operator lowers the presser foot assembly 42 and then starts the sewing machine which automatically forms the rounded top of the buttonhole (FIG. 6A). After forming the rounded top portion, the operation of the buttonholing assembly 100 is suspended allowing the operator to sew a straight line of zigzag stitches (FIG. 6B). When the contacts 72 and 74 touch the second piece of conductive material 150, a pulse is sent out reactivating the buttonholing assembly 100 which then forms the rounded bottom portion of the buttonhole (FIG. 6C). At the completion of the rounded bottom portion, again the operation of the buttonholing assembly 100 is automatically suspended allowing the operator to sew a straight line of zigzag stitches to complete the buttonhole (FIG. 6D). To prevent overshooting the end of the buttonhole, when the contacts 72 and 74 touch the piece of conductive material 151, the sewing machine is stopped until the operator either reinitializes the buttonholing device using knob 108 or disengages the same by moving lever 106. Let it be known that although pulses are sent out by the presser foot assembly 42 when the contacts 72 and 74 touch the piece of conductive material 151 at the start of the buttonhole and at the completion of the rounded top portion and when the contacts 72 and 74 touch the second conductive piece of material 150 at the completion of the rounded bottom portion of the buttonhole, these pulses do not affect the operation of the buttonholing device.
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An automatic buttonholing device which uses a specially modified presser foot into which electrical contacts are inserted for actuating an electromechanical buttonholing assembly. The operator places small conductive markers on the fabric at the top and bottom of the desired buttonhole location. When the contacts on the presser foot ride over the markers, a circuit is completed and proper steps in the buttonholing sequence are initiated.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of hand operated sponge squeeze mops which retain a sponge.
2. Description of the Prior Art
In general, various types of hand operated regular sponge mops or squeeze sponge mops are known in the prior art.
The hand operated regular sponge mop or squeeze sponge mop includes a generally rectangular-shaped main body having an upper or top surface which includes a handle receiving section which receives an elongated handle which is grasped by a user when operating the sponge mop and to which a sponge is retained on an underside of the main body. A rotatable squeeze section is hingeably attached to the main body and is pressed against the sponge to wring the sponged dry after it has been dipped in water with cleaning solution and used to clean or scrub a surface such as a dirty floor.
As described above, the main body also has a flat lower or bottom surface with a disposable cleaning sponge retained by a pair of spaced apart plastic bases molded into a top surface of the sponge, each plastic base retaining a threaded shaft which threaded shafts
respectively extend through respective aligned openings in the main body and then each respective shaft is retained by respective mating fasteners such as a nut with a mating threaded interior opening by which the sponge is retained onto the main body.
One common problem with all prior art hand operated regular sponge mops and squeeze sponge mops is that when the sponge is very dirty after cleaning operations, the user must use at least one of his/her hands to grasp the dirty sponge after the retaining nuts are removed from their respective threaded shafts and remove the sponge from the regular sponge mop or squeeze sponge mop. Therefore, the user is exposed to the filth and dirt on the disposable sponge. There is a significant need for an improved apparatus which eliminates the requirement for a user to grasp the dirty sponge by hand when removing it from the regular sponge mop or squeezes sponge mop and replacing it.
SUMMARY OF THE INVENTION
The present invention is a hand operated squeeze sponge mop with a unique disposable sponge assembly where the sponge has a pair of collars retained on a surface molded onto the sponge. Each collar has a notch. Each collar is respectively retained in a housing on the main body of the squeeze mop which housings each respectively support a spring biased trigger mechanism which has an arm ending in a tooth which respectively engages a notch in a collar. Adjacent each collar are a pair of posts which respectively retain a compression force spring which is affixed at a spring top to a lower post on the underside of the main body. Each compression force spring exerts a downward force against the sponge. The sponge is retained in a closed position against the lower surface of the main body by a respective tooth of each respective trigger mechanism engaged in a respective notch of a respective notched collar to overcome the downward force of the force compression springs. When the respective trigger is pressed down to overcome a biasing spring force which caused the teeth to be engaged with the notches, the downward spring force of the force compression springs cause the sponge to move away from the main body so that the dirty sponge falls away into a trash receptacle without requiring a user to handle the dirty sponge.
It is an object of the present invention to provide a mechanism on a hand operated sponge mop including a standard sponge mop and a squeeze sponge mop which retains a sponge in a manner which enables the sponge after it has been used and become dirty to be released and fall into a trash receptacle without a user's hand touching the dirty cleaning sponge.
It is also an object of the present invention to provide a mechanism for a hand operated sponge mop which includes a spring force to push downwardly on the sponge to enable the dirty sponge to be separated from the engagement members which retain the cleaning sponge onto the main body of the sponge mop so that the connection is released, enabling the sponge to be released without requiring a human hand to touch a dirty sponge.
It is a further object of the present invention to provide ratchet teeth retaining members to prevent the force compression springs from causing the sponge to move downwardly to be discarded until the ratchet teeth retaining members are manually released.
Further novel features and other objects of the present invention will become apparent from the following detailed description, discussion and the appended claims, taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring particularly to the drawings for the purpose of illustration only and not limitation, there is illustrated:
FIG. 1 is a top perspective view of the present invention main body of a hand operated squeeze sponge mop illustrating the retainer for a hand retaining assembly which retains a collar into which an elongated handle is retained, and a pair of housings for retaining the operational mechanisms of the present invention including a top perspective view of each trigger mechanism respectively retained on the top of a housing, also illustrating the hingeably attached squeeze member;
FIG. 2 is a top plan view of the present invention main body of a hand operated squeeze sponge mop illustrating the retainer for a hand retaining assembly which retains a collar into which an elongated handle is retained, and a pair of housings for retaining the operational mechanisms of the present invention including a top perspective view of each trigger mechanism respectively retained on the top of a housing, also illustrating the hingeably attached squeeze member;
FIG. 3 is a rear top perspective view of a cleaning sponge with a surface attached onto the top surface of the sponge, the surface retaining a pair of oppositely disposed notched collars, each notched collar having pair of spring retaining posts on opposite sides of each notched collar;
FIG. 4 is an exploded view including a top perspective view of the present invention main body of a hand operated squeeze sponge mop illustrating the retainer for a hand retaining assembly which retains a collar into which an elongated handle is retained, and a pair of housings for retaining the operational mechanisms of the present invention including a top perspective view of each trigger mechanism respectively retained on the top of a housing, also illustrating the hingeably attached squeeze member and a front top perspective view of a cleaning sponge with a surface attached onto the top surface of the sponge, the surface retaining a pair of oppositely disposed notched collars with the notches on the opposite sides of the collars as illustrated in FIG. 3 , each notched collar having pair of spring retaining posts on opposite sides of each notched collar, with the sponge assembly removed from the main body;
FIG. 5 is a front perspective view of the present invention main body of a hand operated squeeze sponge mop illustrating the retainer for a hand retaining assembly which retains a collar into which an elongated handle is retained, and a pair of housings for retaining the operational mechanisms of the present invention including a top perspective view of each trigger mechanism respectively retained on the top of a housing, also illustrating the hingeably attached squeeze member with sponge retained onto the main body;
FIG. 6 is a cross-sectional view taken along line 6 - 6 of FIG. 5 ;
FIG. 6A is a cross-sectional view taken along line 6 A- 6 A of FIG. 5 ;
FIG. 6B is cross-sectional view taken along line 6 B- 6 B of FIG. 5 ;
FIG. 7 is a rear cutaway view taken along line 7 - 7 of FIG. 5 , with the view rotated 180 degrees counterclockwise to more clearly illustrate the trigger and tooth mechanism;
FIG. 8 is a cross-sectional view taken along line 8 - 8 of FIG. 5 showing the sponge in the retained condition in housing 10 ;
FIG. 8A is a cross-sectional view taken along line 8 A- 8 A of FIG. 5 showing the sponge in the retained condition in housing 10 A;
FIG. 9 is a cross-sectional view taken from FIG. 8 but showing the trigger mechanism released so that the sponge retaining plate pins and collar are moving away from the underside of the plate and are released to be disposed of in the trash; and
FIG. 9A is a partial cross-sectional view taken from FIG. 8A but showing the trigger mechanism released so that the sponge retaining plate pins and collar are moving away from the underside of the plate and are released to be disposed of in the trash.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Although specific embodiments of the present invention will now be described with reference to the drawings, it should be understood that such embodiments are by way of example only and merely illustrative of but a small number of the many possible specific embodiments which can represent applications of the principles of the present invention. Various changes and modifications obvious to one skilled in the art to which the present invention pertains are deemed to be within the spirit, scope and contemplation of the present invention as further defined in the appended claims.
Referring to FIG. 1 and FIG. 2 , there is respectively illustrated a top perspective view and a top plan view of the present invention incorporated into a portion of the main body 100 of a hand operated squeeze sponge mop 110 illustrating a pair of housings 10 and 10 A which respectively retain the operating mechanism of the present invention, also illustrating the top of a trigger mechanism 70 and 70 A respectively retained on the top of each housing 10 and 10 A and which trigger mechanism retains a notched collar as will be described. Illustrated in FIGS. 1 and 2 is a handle retaining member 120 affixed to the main body 100 , the handle retaining member including a collar 130 into which an elongated handle (not shown) is retained. Also illustrated is a squeeze member 150 having a handle 160 and a multiplicity of openings 170 , the squeeze member 150 rotatably attached by hinges 180 to a rear edge 102 of the main body 100 .
Referring to FIG. 3 , there is illustrated a rear top perspective view of a cleaning sponge 200 with a surface member 60 attached onto the top surface 210 of the sponge 200 . The surface member 60 retains a pair of oppositely disposed notched collars 20 and 20 A. Each notched collar 20 and 20 A includes an exterior surface 22 and 22 A which respectively contain a notch or tooth receiving member 24 and 24 A. Each notched collar 20 and 20 A has a pair of spring retaining pins 30 and 32 on opposite sides of notched collar 30 and 30 A and 32 A on opposite sides of notched collar 20 A. The spring retaining pins 30 , 32 , 30 A and 32 A are also retained in surface member 60 .
Notched collar 20 and spring retaining pins 30 and 32 extend perpendicularly to the top surface 62 of surface member 60 . Notched collar 20 A and spring retaining pins 30 A And 32 A extend perpendicularly to the top surface 62 of surface member 60 . The centerline 26 of notched collar 20 and the centerline 26 A of notched collar 20 A are separated by a given distance “DI” The underside 64 of surface member 60 is fused by high heat or otherwise permanently attached to the top surface 210 of sponge 200 .
While surface member 60 is illustrated as one piece, it is also within the spirit and scope of the present invention for the surface member to be formed into two pieces, one piece retaining notched collar 20 and spring retaining pins 30 and 32 and a separate piece retaining notched collar 20 A and spring retaining pins 30 A and 32 A.
Referring to FIG. 4 , there is illustrated an exploded view including a top perspective view of the main body 100 of the hand operated squeeze sponge mop 110 and the squeeze member 150 hingeably attached to the main body 100 as previously described. FIG. 4 illustrates a front view notched collar 20 and spring retaining pins 30 and 32 aligned with housing 10 and notched collar 20 A and spring retaining pins 30 A and 32 A aligned with housing 10 A.
Referring to FIG. 5 , there is illustrated a front perspective view of the present invention main body 100 of the hand operated squeeze sponge mop 110 illustrating the retainer for a hand retaining assembly which retains a collar into which an elongated handle is retained, and a pair of housings 10 and 10 A for retaining the operational mechanisms of the present invention including a top perspective view of each trigger mechanism 70 and 70 A respectively retained on the tops 12 and 12 A of housings 10 — and 10 A, also illustrating the hingeably attached squeeze member with sponge retained onto the main body in the engaged or retained condition.
FIG. 6 is a cross-sectional view taken along line 6 - 6 of FIG. 5 to illustrate a portion of the operating mechanism of the present invention. Trigger mechanism 70 includes a press button 72 having a top surface 74 and a bottom surface 76 , an arcuate bent arm 78 extending from the press button 72 and terminating in a tooth 80 at the distal end 79 of arm 78 . The bent arm 78 also includes a pivot collar 82 with an opening 84 extending through the entire thickness of the pivot collar 82 .
Referring to FIGS. 6 and 6A , housing 10 has a top surface 12 to which is affixed a pair of parallel posts 14 and 18 which extends perpendicularly to the top 12 of housing 10 , each post 14 and 18 has a respective transverse openings 16 and 20 extending from a respective interior surface 13 and 17 of respective posts 14 and 18 , the openings 16 and 20 are aligned. The trigger mechanism 70 is rotatably affixed to the housing 10 by a pivot pin 86 which extends through opening 84 in pivot collar 82 and extends into respective openings 16 and 20 in posts 14 and 18 . A biasing spring 87 is affixed at one end to the bottom surface 76 of press button 72 and affixed at its opposite end to the top surface 12 of housing 10 . The housing also has an opening 8 in wall 6 .
Notched collar 20 extends into an interior opening 4 in housing 10 . The tooth 80 of trigger mechanism 70 extends through opening 8 . The upward force of the biasing spring to be discussed causes tooth 80 to engage notch 24 in collar 20 . In this engaged condition the collar 20 and plate member 60 which is affixed to the sponge is retained against the bottom surface 102 of main body 100 and overcomes the downward force of force springs 90 and 92 .
As also shown in FIGS. 7 and 6B , the housing 10 A retains notched collar 20 A by the identical trigger mechanism affixed to posts 14 A and 18 A. FIG. 7 is a cut away perspective-section taken along line 7 - 7 of FIG. 5 . Trigger mechanism 70 A includes a press button 72 A having a top surface 74 A and a bottom surface 76 A, an arcuate bent a in 78 A extending from the press button 72 A and terminating in a tooth 80 A at the distal end 79 A of arm 78 A. The bent arm 78 A also includes a pivot collar 82 A with an opening 84 A extending through the entire thickness of the pivot collar 82 A.
As shown in FIG. 6B , housing 10 A has a top surface 12 A to which is affixed a pair of parallel posts 14 A and 18 A which extend perpendicularly to the top 12 A of housing 10 A, each post 14 A and 18 A has a respective transverse opening 16 A and 20 A extending from a respective interior surfaced 13 A and 17 A of respective posts 14 A and 18 A, the openings 16 A and 20 A are aligned. The trigger mechanism 70 A is rotatably affixed to the housing 10 A by a pivot pin 86 A which extends through opening 84 A in pivot collar 82 A and extends into respective openings 16 A and 20 A in posts 14 A and 18 A. As shown in FIG. 7 , a biasing spring 87 A is affixed at one end to the bottom surface 76 A of press button 72 A and affixed at its opposite end to the top surface 12 A of housing 10 A. The housing also has an opening 8 A in wall 6 A.
Notched collar 20 A extends into an interior opening 4 A in housing 10 A. The tooth 80 A of trigger mechanism 70 A extends through opening 8 A. The upward force of the biasing spring 87 A causes tooth 80 A to engage notch 24 A in collar 20 A. In this engaged condition the collar 20 A and plate member 60 which is affixed to sponge 200 are retained against the bottom surface 102 of main body 100 .
FIG. 8 is a cross-sectional view taken along line 8 - 8 of FIG. 5 with tooth 80 of a spring biased trigger mechanism 70 engaging a notch 24 in a notched collar 10 as illustrated in FIG. 6 . Force compression spring 90 is retained on pin 30 and retained within opening 4 of collar 10 by upper post 2 . Force compression spring 92 is retained on pin 32 and retained within opening 4 of collar 10 by upper post 3 . With the trigger mechanism 70 as illustrated in FIGS. 6 and 8 , the downward force of the compression springs 90 and 92 is overcome by the biasing spring 86 causing tooth 80 to engage notch 24 in notched collar 10 . As illustrated, the sponge 200 is retained against the underside 106 of main body 100 . FIG. 8A is a cross-sectional view taken along Line 8 A- 8 A from FIG. 5 with the tooth 80 A of a spring biased trigger mechanism 70 A engaging the notch 24 A in the notched collar 10 A as illustrated in FIG. 7 . Force compression spring 90 A is retained on pin 30 A and retained within opening 4 of collar 10 by upper post 2 A. Force compression spring 92 A is retained on pin 32 A and retained within opening 4 of collar 10 A by upper post 3 A. With the trigger mechanism 70 A as illustrated in FIGS. 7 and 8A , the downward force of the compression springs 90 A and 92 A is overcome by the biasing spring 86 A causing tooth 80 A to engage notch 24 A in notched collar 10 A.
Cleaning is then performed until the sponge is wet and dirty and water is wrung out of the sponge 200 by squeeze member rotated to press sponge 200 against the underside 106 of main body 100 with water flowing through openings. The sponge 200 is once against dipped in cleaning water and the cleaning operation continues. When the sponge 200 becomes so dirty that the dirty sponge 202 has to be replaced, the present invention is further utilized.
Referring to FIG. 9 , when a downward force such as from a finger is exerted on top surface 74 of press button 72 to overcome the force of biasing spring 86 , the trigger mechanism 70 rotates about pivot collar 82 and tooth 80 is disengaged from notch 24 of notched collar 20 . Similarly, referring to FIG. 9A , when a downward force is exerted on top surface 74 A of press button 72 A to overcome the force of biasing spring 86 A, the trigger mechanism 70 A rotates about pivot collar 82 A and tooth 80 A is disengaged from notch 24 A of notched collar 20 A.
Therefore, referring to FIGS. 9 and 9A , as a result of the downward force of the compression springs now being free to act, the downward force from compression springs 90 and 90 A exert a downward force on press plate 60 and dirty sponge 202 and therefore, collar 20 , pins 30 and 32 , plate 60 and dirty sponge 202 are pushed away from the underside 106 of main body 100 and in addition, the force of compression springs 90 A and 92 A exert a downward force on plate 60 and sponge 202 and therefore, pins 30 A and 32 A and collar 10 A, plate 60 and dirty sponge 202 are also pushed away from the underside 106 of main body 100 and therefore, the sponge and the attachments are discarded, leaving only the main body and force compression springs 30 , 32 , 30 A and 32 A retained on respective posts 2 , 3 , 2 A and 3 A within the main body 10 and 10 A respectively. As a result, a hand does not have to touch the sponge in order for the sponge to be released and discarded into a trash receptacle, with a new sponge assembly consisting of a new sponge, new plate, new notched collars and new pins to retain the springs is reinserted and affixed as previously discussed.
Of course the present invention is not intended to be restricted to any particular form or arrangement, or any specific embodiment, or any specific use, disclosed herein, since the same may be modified in various particulars or relations without departing from the spirit or scope of the claimed invention hereinabove shown and described of which the apparatus or method shown is intended only for illustration and disclosure of an operative embodiment and not to show all of the various forms or modifications in which this invention might be embodied or operated.
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A hand operated butterfly sponge mop or regular sponge mop with a unique disposable sponge assembly where the sponge is retained by ratchet teeth respectively engaging a notch on a pair of notched collars molded onto the sponge. The sponge is retained in a closed position against the lower surface of the main body by ratchet teeth engaged in notches of a respective notched collar to overcome a force of downward force compression springs. When the respective button attached to a respective tooth is pressed down to overcome a biasing spring force which caused the teeth to be engaged with the notches, the downward spring force of the force compression springs cause the sponge to move away from the main body so that the dirty sponge falls away into a trash receptacle without requiring a user to handle the dirty sponge.
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This application claims priority of U.S. Provisional Patent Application 61/181,099, filed May 26, 2009, the disclosure of which is incorporated herein by reference.
BACKGROUND
The generation of waste, particularly solid waste has become an increasingly worrisome environmental issue. Many landfills are becoming filled to the point where additional waste cannot be deposited therein. In addition, much of today's solid waste is not readily biodegradable, implying that the waste will not decompose in a timely manner. As an alternative, incinerators have been employed to burn solid waste, so as to minimize its physical footprint. However, these incinerators burn the waste and generate air pollutants that require very extensive gas cleanup, create ash that can be hazardous, and produce energy only in the form of heat, which is converted into electricity.
Plasma gasifiers offer an alternative to these current approaches. Plasma gasifiers use intense electrically based heating to enhance a gasification and melting process which produces a synthesis gas (syngas) consisting of hydrogen and carbon monoxide. Inorganic material is converted into a non-leachable glass. After cleaning, the synthesis gas can be preferably converted into a variety of liquid fuels or else combusted to produce electricity. Cleaning of the synthesis gas and recovering heat from the syngas can be a key part of the process.
FIG. 1 shows a representative plasma gasifier system. The plasma gasifier system 100 includes a reactor vessel 110 , which is typically refractory lined. Within the vessel 110 are two or more electrodes 120 a , 120 b that are in electrical communication with one or more power supplies 130 . In some embodiments, one electrode is suspended from the top of the reactor vessel 110 , while the other electrode 120 b is located at the bottom of the vessel. The power supplies create a significant electrical potential difference between the two or more electrodes, so as to create an arc. As waste is fed into the vessel 110 via a waste handler 140 , it is exposed to extreme temperatures, which serve to separate the waste into its component parts.
The bottom of the vessel 110 contains molten metal 145 . An area above the molten material forms an inorganic slag layer 147 . Gasses, such as carbon monoxide and hydrogen gas, are separated and exit the vessel though portal 150 . The gas, commonly known as syngas, exits the vessel 110 at an excessive temperature. Since the gas has not been processed, it is also referred to as dirty syngas. The syngas is cooled in a scrubber unit 180 to allow other particulates in the gas, such as carbon or sulfur to precipitate out of the gas. Halogens and acidic materials are removed from the syngas. The resulting gas is now referred to as clean syngas. The clean syngas can then be used to fuel a boiler or other device.
The plasma gasifier may also include joule heating of the molten material by passage of current between two or more electrodes that are immersed in the molten material 145 .
In some embodiments, it may be advantageous to operate these plasma gasifiers at elevated pressure. While the throughput of the device is partially limited by the plasma power, it is possible to ease the requirements of the upstream/downstream gas handling equipment and the downstream catalyst by operating at elevated pressure of greater than one bar. For a given size, operating at increased pressure results in increased residence time, which is useful in achieving better mixing and increased conversion rates. Alternatively, the gas handling components of the system could be reduced in size, while maintaining a constant residence time, by operating at increased pressure. Operation at a slightly elevated pressure, such as 5 bar, is advantageous, as most of the advantages of higher pressure operation are obtained at this level, including a decrease in equipment size (such as pressure vessels and catalytic reactors used, for example in manufacturing liquid fuels). An optimum pressure range can be up to 10 bar, such as between 3 and 7 bar.
Operation at this higher pressure also helps regenerators used for heat recovery, due primarily to the reduced gas flow rates needed to exchange a given amount of energy.
Operation of a plasma gasifier at high pressure is inhibited by its adverse effect of the plasma characteristics. The high pressure operation of an arc plasma makes breakdown difficult and reduces the cross section of the arc plasma. For gasifier applications, it is disadvantageous that the plasma cross section decreases at elevated pressure with increased impedance. This decrease in size results in increased central temperatures, and increased interaction with the electrode materials. In addition, if the plasma is used to treat gas or liquids, there is reduced interaction with the environment due to the reduced cross sectional area. High pressure operation also results in plasma instability, where continuous plasma operation is difficult and the plasma extinguishes.
Therefore, there is a need for an effective apparatus and method to enable the advantages of high pressure operation, while overcoming the drawbacks listed above.
SUMMARY OF THE INVENTION
The problems of the prior art are overcome by the apparatus and method disclosed herein. The reactor vessel of a plasma gasifier is operated at high pressure. To compensate for the negative effects of high pressure, various modifications to the plasma gasifier are disclosed. For example, gasses are added to the plasma to stable its operation. In another embodiment, means are used to move the slag, allowing more material is exposed to the plasma, resulting in better and more complete processing thereof, and better ingestion of the solid on the surface of the slag. In other embodiments, additional heating, such as microwave heating is used to augment the temperature of the slag.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a plasma gasifier system which can be used with the present invention;
FIG. 2A-C show several embodiments used to inject a plasma gas additive; and
FIG. 3A-B show several embodiments used to launch microwaves into a plasma gasifier.
DETAILED DESCRIPTION OF THE INVENTION
As described above, the use of high pressure within the reactor vessel can have many advantages in the downstream process. However, the use of high pressure adversely affects the plasma size, which reduces the area exposed to the plasma. A number of techniques can be used to improve high pressure operation.
Operation at high pressure is facilitated by combining high pressure with high ambient temperature. This is because the important parameter in determining plasma properties is number density (number of molecules per unit volume), rather than pressure. Thus, by operating at 900 degrees Kelvin and 3 bar, the plasma has comparable properties (size, voltage drop, electric field in the free-plasma region, initial breakdown) to operating at 1 bar and 300 degrees Kelvin. Placing the plasma in a hot environment facilitates initial plasma breakdown, and helps sustain a stable plasma. Combining plasma with oxidation results in improved plasma performance. It is best to apply the oxygen close to the electrode, but sufficiently away to prevent excessive oxidation of the electrode, which can be made of multiple materials, with graphite being a preferred material.
In addition, thermal stratification (where the gas in the region near the plasma is hotter than elsewhere) of the gases, either intentional or naturally occurring, further facilitates the plasma operation.
Gas stratification may also be used to improve high pressure operation. In one embodiment, a gas, different from the bulk of the gas in the gasifier section, is injected in the neighborhood of the electrode that is not submerged. This gas, referred to as the plasma gas additive or simply the gas additive, displaces a fraction of the gasifier gas in the region near the plasma. It is the purpose of the gas additive to stabilize the discharge and facilitate discharge initiation. In some embodiments, the gas additive can be a noble gas, such as Argon or Helium. In other embodiments, it can be a gas with limited thermal conductivity or low ionization energy. In some embodiments, in order to minimize gas dilution, the plasma gas additive does not exceed more than 5% the flow rate of hydrogen rich gas. In one embodiment, the composition of the gas additive comprises one or more of the constituents of the syngas. For example, high temperature carbon monoxide, carbon dioxide, steam, high temperature hydrogen gas or a blend of the above mentioned gases may serve as the plasma gas additive, and be introduced to the gasifier in the region near the plasma zone. However, it is not intended to exclude other high temperature gases, such as the noble gases mentioned above. By injecting the plasma gas additives at high temperature, the mass flow of these gases, for a given gas velocity and pressure, can be decreased, and the high temperature further helps in stabilizing the plasma.
FIGS. 2A-C show an expanded view of the upper electrode of the reactor vessel 110 . As shown in FIG. 2A , the plasma gas additive can be added through ports (lances) 220 separated from, but preferably near the electrode 210 . In another embodiment, the plasma gas additive is added by channels/lances located in the electrode itself. As shown in FIG. 2B , the port/lances 240 for the plasma gas additive can also be through the central region 235 of a hollow cylinder electrode 230 . In another embodiment, the gas additive flows through one or multiple channels 255 along the electrode 250 , terminating in ports/lances 260 . The plasma discharge channel prefers to flow through regions that result in minimization of the electric field along the discharge, and the gas composition and/or temperature can be used to guide the plasma. Since the discharge parameters depend on the ratio of E/N (where E is the electric field and N is the number density of molecules in the gas), providing gradients in the temperature and/or composition can be used to stabilize the plasma operation at higher pressures. The gradients in temperature and/or composition are established by introducing a gas additive that is substantially hotter and/or of different composition than the gasifier gas.
Another method to improve the performance of high pressure gasifiers is to heat the incoming solids, so that when ingested into the liquid phase, the temperature of the liquids are not reduced, but augmented instead. In some embodiments, it may be desirable to maintain the temperature of the liquid in a narrow range to best process the slags. By preheating the solids to the appropriate temperature, it is possible to prevent excursions in the temperature of the slag. For example, if the slag is too cold, the slag viscosity will be too low and ingestion of the solids is difficult/slow. If the slag is too hot, the fluxes desired to make high quality glass may be evaporated from the slag.
The amount of the plasma gas is minimized by the high temperature of the plasma, which increases the viscosity of the gas. Thus, the plasma gas and the gas in its surroundings do not exchange gas efficiently with the background, thus minimizing the gas flow rate required to establish/maintain the gradient in temperature/species, and thus maintain a stable plasma at high pressure. In the case of the hollow cylinder, with plasma additive entering through the central region, as shown in FIG. 2B , the root of the plasma discharge should occur in the inboard zone of the electrode.
Another way to address the issues associated with high pressure plasma gasification is to either move the plasma around, or move the materials that the plasma is treating such that the plasma contacts more of the material. Increased motion of gasses can be achieved by inducing motion in the chamber. In order to move liquids, forces must be applied to the slag/metal layers. Motion can be induced in the liquid if there are currents flowing through it, as is the case when a Joule heating system is used. In the case of the plasma, it is best if the plasma is a transferred discharge, that is, if the slag/metal is effectively one of the electrodes of the arc discharge, with currents flowing through it. By imposing a magnetic field, it is possible to induce motion due to the Lorenz forces generated by the interaction between the current and the imposed magnetic field.
The motion of the slag allows for material to be better incorporated into the slag, including partially melted solids that lie on the surface of the slag. Motion also results in more homogeneous temperatures and composition, due to mass and heat transfer, resulting from either turbulence or shears in the flow.
In the case of DC arc, which is a preferred embodiment, the application of DC magnetic fields will result in motion of the slag. The slag layer 147 (see FIG. 1 ) is highly viscous, and a substantial magnetic field may be needed to create the motion of the slag. In addition, the slag may be stress thinning, that is, a non-Newtonian fluid such that the viscosity decreases as shears occur within the slag. In this case, it may be necessary to apply a larger force to get the slag moving. Once moving, it may be possible to decrease the current of magnetic field that generated the Lorenz force. The DC arc is generated by placing two separated electrodes, with an electric circuit between the two electrodes. The electrically conducting liquid at the bottom of the gasifier serve as one of the plasma electrodes. The electric circuit includes connections to one or more power supplies, controls and safety mechanisms. The DC power supply can be aided by an RF source that is used only to aid in the initial plasma breakdown.
If joule heating is performed with an AC current, it is also possible to generate a DC force if the magnetic field is also AC and synchronized with the current. In this way, the forces remain in the same direction, as both the magnetic field and the plasma current reverse directions simultaneously.
The magnetic field may be created through the use of coils external to the reactor vessel. By controlling the magnitude and direction of the current through the coils, a magnetic field that is synchronized with the current flowing in the slag. In the case of AC, low frequencies are needed such that the magnetic field penetrates through the electrically conducting elements, such as the metallic vessel, or the metal liquid at the bottom of the gasifier.
The motion can be applied to either the slag layer 147 , or on the molten metal layer 145 . It is likely that motion of the molten metal will result in motion of the slag. The plasma may provide very effective heating of the surface of the slag layer, facilitating ingestion of the partially molten solids and decreasing the viscosity of the slag and its surface. With lower viscosity, it is easier to make the slag flow, which may be necessary for continuous processing. In some of the gasification processes, the operating temperature of the slag is selected in order to reduce the viscosity of the slag, so that it can flow. Because of the very localized heating of the plasma, in a plasma based furnace system, it is possible to provide this heating without having to heat the entire gas flow, which may be at lower temperatures.
It is possible to combine synergistically additional heating with the plasma. In particular, microwave heating, such as in the high MHz and low GHz range (S-band), is attractive, because of the availability of inexpensive components, due to the large microwave heating market. Inexpensive, high power sources are available at frequencies up to 10 GHz, such as 460 MHz, 750 MHz, 915 MHz, 2.45 GHz and 5.8 GHz, among others. It is possible to locate the launching structures behind the liner in the gasifier, and thus protect the launching structure from the corrosive high temperature gases in the gasifier. Multiple materials can be used as liners, with adequate transmission at the operating temperatures and frequencies. Alumina has low loss-tangent, even at 2.45 GHz, and even lower at the lower frequencies. Other materials, such as corderiete, may also be used. For best performance, it is best if the liners are not electrically conducting, in order to minimize absorption by the liner. If a conducting liner is used, such as SiC or graphite, it is necessary to provide insulation between different sections of the liner, each section of the liner operating as an antenna, with at least one section connected to the RF source.
FIG. 3A shows the case when the microwave is launched with waveguides, while in FIG. 3B , the microwaves are launched by antennas. Both figures show a top view of the gasifier 300 . The gasifier 300 includes a reactor vessel, with a liner 310 located between the cavity 330 of the vessel and the conductive walls 320 of the vessel. The gasifier chamber 300 is heated with a DC plasma 351 , and in addition with microwaves 345 . The waveguides 340 A, 340 B and 340 C are placed behind a dielectric liner 310 to protect them from the gasifier environment. It is intended to use frequencies such that the cavity 330 formed by the external conducting shell 320 is overmoded. In FIG. 3A , the phases of multiple waveguides 340 A-C are adjusted in order to generate a region of strong electric field 350 , where there is strong heating.
Similarly, in FIG. 3B , the antennas 370 A, 370 B and 370 C, also located behind a dielectric liner 310 , are fed by coaxial feeds 360 A, 360 B and 360 C. The antenna 370 A-C launch microwaves that generate a region of strong electric field 350 . It is possible to use a single waveguide or antenna, but in this case, it may not be possible to scan or vary the region 350 of strong electric fields. The signals fed through different sections can have different amplitudes and/or frequencies. It should be noted that, in both embodiments, the microwaves are adjusted to generate a region of strong electric field 350 . In some embodiments, it is beneficial that the plasma 351 is located within this region 350 .
In the case of a conducting liner, as mentioned above, the antennas need to be connected to a section of the liner that is electrically insulated from the rest of the liner and the metallic vessel wall. It is possible that a gap can be used in the section close to the gasifier, with an insulating region in between sections of the launching structure. Alternatively, sections of the electrically conducting liner can be used as loop antennas, with two separate coax lines feeding the loop antenna.
The plasma can be in region 350 of strong RF fields, if the objective is to provide additional heating to the plasma.
Microwave heating may also be used for augmented heating at the plasma region, which is very absorbing at these frequencies. The goal would be to illuminate most of the plasma, but the plasma size is small compared to the wavelength. Thus, the microwave heating can be used to augment or stabilize the plasma discharge, by appropriately phasing the launching structure so that there is a strong peaking of the microwave radiation in the area of the plasma. The goal of combining the plasma discharge and the microwave heating is to stabilize the discharge, heat the surrounding area of the plasma (in order to decrease the number density of the plasma discharge, or E/N), and decrease electrode erosion by providing some of the needed heating. Since the power supplies for microwave sources in this frequency range are inexpensive, and may be less expensive and more efficient than those needed to generate and or maintain the DC plasma, exchanging DC arc power for microwave power may also decrease operating and capital costs.
The microwave radiation can be steered by using phase arrays, that is, launching structures with appropriate phasing. This approach offers additional operational possibilities for gasifiers, as the location of the heated area can be adjusted, as long as there is absorbing material in the region of interest. Typically, the region of interest may be the solids, slag or the plasma.
It is also possible to use the microwave energy to heat directly the slag surface. Better ingestion of the solids occurs by decreased viscosity of the slag. This decreased viscosity is a result of increased temperature at the surface, enabled by the use of plasma heating (radiation). Additionally, or alternatively, microwave energy, which will be absorbed in a relatively thin layer on the surface of the slag, also serve to decrease its viscosity. Thus, temperature of the slag can be adjusted by use of microwave heating, and the heated zone on the surface of the slag adjusted by moving the region 350 of strong electric fields in the gasifier volume.
Alternatively or additionally, the microwave radiation can be used to directly heat the solids as they are introduced into the chamber, or while they are sitting on top of the slag before they are ingested by the slag. Soot is relatively absorbing, especially in the higher frequency of interest. The frequencies of interest are from 100 MHz, which corresponds to a wavelength of about 3 m, or half-wavelength of 1.5 m, to 10 GHz, which corresponds to a wavelength and half-wavelength of 3 and 1.5 cm, respectively. At the lower frequencies, the chamber may function as a microwave cavity, and use different modes, with peaks and valleys of the electric field determined by the mode structure. At higher frequencies, steering of the microwave can be achieved through phasing of the multiple launching structures.
The launching structures can be waveguides, as shown in FIG. 3A or can be antennas, as shown in FIG. 3B , or a combination of the two.
The microwave heating can be used in conjunction with plasma heating, as described above. In other embodiments, it can be used in lieu of plasma heating. When it is used instead of plasma heating, it can be combined with joule heating, where multiple electrodes are immersed in the molten material and heating is through Joule dissipation by currents flowing in the liquid. In order to achieve best heating of the slag without the plasma, it is useful to adjust the properties of the slag, mainly the absorption. If the slag is too conducting, the microwaves reflect. It is the goal of the invention to operate with modes away from fundamental. When the absorption is high, the gasifier chamber does not operate as a resonator. As opposed to the plasma heating, that has a relatively narrow power window (as the current increases, in general, the voltage decreases, and the arc power can not be controlled over a wide range), microwave heating can be adjusted easily. Either pulse-width modulation, or with more sophisticated power supplies, by changing the CW power, can be used to adjust the microwave heating power.
In the case of multiple waveguides/antennas, a single power supply can be used, with power splitters. The relative frequency between the multiple launchers can be adjusted using simple elements, such as stub tuners.
In other embodiments, plasma heating can be used during a portion of the time, plasma heating/microwave heating can be used during a different portion of the time, or microwave heating can be used during a third portion of the time. In other words, microwave heating and plasma heating can be used independently or simultaneously in some embodiments. When used at the same time, plasma heating and microwave heating can be used so that the microwave heating stabilizes/augments the plasma heating, or the microwave heating is used to heat the solids or the slag. Microwave heating is not sensitive to the operating pressure of the gasifier. Microwave heating of the plasma discharge allows stable plasma operation at higher pressures than possible when it is not used.
In the case of combined plasma heating and microwave heating, the microwaves can be launched from the inside of a hollow electrode, such as the one shown in FIG. 2B . As noted above, graphite is a good electrical conductor, and efficient transport of the microwave to the plasma region in either coaxial graphite conductors, or graphite waveguides.
Several embodiments are disclosed. Those of the art will recognize that the present disclosure is not to be limited in scope by the specific embodiments described herein. Indeed, other various embodiments of and modifications to the present disclosure, in addition to those described herein, will be apparent to those of ordinary skill in the art from the foregoing description and accompanying drawings. Thus, such other embodiments and modifications are intended to fall within the scope of the present disclosure. Further, although the present disclosure has been described herein in the context of a particular implementation in a particular environment for a particular purpose, those of ordinary skill in the art will recognize that its usefulness is not limited thereto and that the present disclosure may be beneficially implemented in any number of environments for any number of purposes. Accordingly, the claims set forth below should be construed in view of the full breadth and spirit of the present disclosure as described herein.
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The problems of the prior art are overcome by the apparatus and method disclosed herein. The reactor vessel of a plasma gasifier is operated at high pressure. To compensate for the negative effects of high pressure, various modifications to the plasma gasifier are disclosed. For example, by moving the slag, more material is exposed to the plasma, allowing better and more complete processing thereof. In some embodiments, magnetic fields are used to cause movement of the slag and molten metal within the vessel. An additional embodiment is to add microwave heating of the slag and/or the incoming material. Microwave heating can also be used as an alternative to plasma heating in a high pressure gasification system.
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This application is a continuation of application Ser. No. 919,862, filed June 28, 1978, now abandoned.
BACKGROUND OF THE INVENTION
Multi-color patterned area rugs, wall rugs and other pile face materials have met with increasing commercial success, in the United States in the past few years. Traditionally such products are associated with various weaving processes using predyed yarns. Generally, skilled operators are required for these processes, productivity is low, and the products are expensive. In the tufting industry products of this kind are currently manufactured by means of the manually operated tufting gun, and in recent times by single and double needle control broadloom tufting machines. With single needle machines, although productivity is low and the products are expensive, a few companies have been able to make a commercial success of the operation. With double needle machines, productivity is high, but, in relation to the investment, the productivity traditionally associated with broadloom tufting is low. Even so, in the context of area rugs, these machines are capable of producing a limited variety of styles, at rates exceeding the capacity of the market for them. For these reasons these machines have not realized the future predicted for them.
Within the past fifteen years or so a very large carpet printing industry have grown up within the tufting industry. The carpet printing industry is geared, largely to broadloom manufacture and is not especially suitable for the pattern flexibility, variety of carpet textures and pattern sizes traditionally associated with high quality area rugs. Moreover, the capital investment incurred by these printing machines can only be generated by the enormous productivity of the broadloom industry.
There are numerous methods used for dye printing piled sheet materials, such as carpets, towels, animal furs and the like. These printing methods include flat screen printing, rotary screen printing, raised pattern roller printing, and "deep dye" printing and the Militron process.
The flat screen methods involve the use of screens which contact the surface of the sheet material. The dye pastes are applied to the top surfaces of the screens and forced through holes in the screens by magnetic squeegies, sponges or by suction from behind the sheet material. The screens are impenetrable in some areas and penetrable in the pattern areas where it is desired that dye pass to the sheet material.
The rotary screen is an adaptation of the flat screen, where the screen is formed in the shape of a cylinder. Roller processes involve the use of cylinders with patterned dye area raised out of the cylinder. The cylinders pick up dye on the faces of the raised dye area and transfer the dye to the sheet material, according to the pattern of the dye area, by rolling over the sheet material as the material moves along its length through the machinery.
The screen and roller processes are capable of printing low pile materials such as materials having pile in a quantity of about 8-14 oz./sq. yd., but they usually lack the ability to produce satisfactory results on heavier, high pile materials, as there is insufficient dye material passing through the screens and insufficient force exerted on the dye material to satisfactorily penetrate heavier weights of pile facing.
In the screen and roller dyeing processes, a separate screen or roller is required for each different color. This makes multi-color processes somewhat expensive, both because of duplication and because of mechanization and precision needed to index the separate color patterns. Another disadvantage of these processes is that they are limited in their pattern size, thus requiring several pattern components to form a single large sized pattern as might be associated with an area rug.
The "deep dye" process offers a method of applying all the colors of a pattern to the sheet material simultaneously. In this system, the printing stencil, comprising partitioning built up on a plate so as to form trough-like pattern elements into which various colors of dye solution is fed, is pressed mechanically upwardly against the downwardly facing pile of the sheet material. The equipment for performing the deep dye process is expensive to manufacture and to operate.
The Militron process is one uniquely capable of printing broadloom carpeting and area rugs. The process is based on the simultaneous injection of several colors of dye solution from a matrix of fine nozzles. Those nozzles in the matrix, which fall within the particular element of the pattern to be printed, are controlled so that they all pass the same color of dye solution together. The device is computer controlled, and the pattern is readily changed. The machine involves high capital investment and is not generally available; it is also, as far as known, limited to a comparatively narrow range of carpet pile textures.
SUMMARY OF THE INVENTION
The present invention comprises a method of printing sheet matrials which alleviates many of the aforementioned difficulties as they apply to area rug printing associated with screen, roller and other types of dye printing apparatus. The invention also comprises a novel pattern stencil and print substrate handling platform used in the printing method. The process works successfully on both low and high pile face materials. Multi-color printing can be accomplished in one application, without bleeding, by using a single pattern stencil, thus circumventing the need to use a stencil for each color application as applied in "silk" screen printing processes. Also the pattern stencil can be built to the size of the material to be printed thus eliminating the need and indexing complications of having to use several stencils to build up the pattern.
The pattern stencil of the present invention comprises a plurality of divider walls suspended within a frame. These walls define the individual color areas of the pattern. The walls of the stencil assembly are suspended in the open space within the frame and are supported by a wire matrix extending from the frame.
Typically area rugs are made in sizes of six by nine feet and nine by twelve feet, and for printing them, the pattern stencils of the present invention are made commensurate with these sizes. The printing platform and rack of the present invention would also have to be commensurate in size, so that each rug size would require commensurate printing apparatus. Other, larger or smaller rug sizes can also be printed and these too would require commensurate printing apparatus. Alternatively a large stencil can be build comprising two or more small rug patterns set side by side thus permitting printing of two or more small rugs at one time. Additionally in printing large area rugs--6'×9' and up--the distance across the stencil are too great for the reach of the operators handling the print paste dispensing guns; to overcome this difficulty and also to optimize the conditions of application, a fly-bridge is provided for each printing apparatus. The fly-bridge comprises a motorized platform bridging the stencil and mounted on wheels which run on tracks laid down on the floor on both sides of the printing apparatus. Swivel seats, which also can be easily moved transversely along the length of the fly-bridge on rails, are furnished for the operators so that they can move freely to any position over the platform. The operators can also drive the fly-bridge back and forth along the length of the stencil and are thus able to position themselves with little expenditure of effort over any desired locality of the stencil. While seated on the fly-bridge the operators can also control operation of the entire printing apparatus
In application, the stencil is suspended horizontally by mechanical means, by which it can, as needed, be raised and lowered over a printing platform. The platform is rack mounted so that it can be moved transversely along the rack to three basic positions: the loading position, the printing position and the unloading position. In the loading position, the platform is fully withdrawn from under the stencil, thus permitting the unprinted rug to be precisely mounted on the platform with its pile face up. The accurate fitting of the rug on the platform is achieved by aligning the edges of the rug with the edges of the platform or with marks on the platform surface. The platform is then moved along the rack to the printing position where the rug is vertically aligned beneath the stencil. Precise fitting of the rug on the platform during loading is thus the means of properly positioning the rug beneath the stencil for accurately printing the rug. The stencil is lowered on to the rug during printing and afterwards raised again, and the platform, now carrying the printed rug, is moved further along the rack to the unloading position where the rug is removed. The empty platform is now returned to the loading position in readiness for another printing cycle. When the platform moves from the loading position to the printing position, it passes under a fixed or rotary doctor blade, which fluffs up the pile face of the rug, and removes whatever pile disorientation may have taken place in handling and loading the rug. Also, whenever the stencil is raised and before the platform can be moved transversely, into or out of the printing position, a canopy extends automatically beneath the stencil, between the stencil and the rug on the printing platform, to shield the rug from possible print paste drippings from the raised stencil.
The process performed by the printing assembly of the present invention includes the steps of moving the sheet material mounted in printing index on a movable platform into the printing zone, lowering the stencil onto the sheet material where the walls of the stencil penetrate between individual face piles of material and make edge contact with the sheet material backing, thus preventing paste from bleeding between areas of different color and also insuring printing of all the face piles by not incurring matting down of fibers under the stencil elements. The print paste is applied to the material by holding a dispensing nozzle in the vicinity of the sheet material below the height of the walls of the stencil and by dispensing the desired color of dye liquor onto the piles located in the area between adjacent walls. After printing, by the present invented process, has been completed, the stencil is raised off the sheet material and the canopy is immediately moved into position above the platform area between the sheet material and the stencil in order to catch any drippings of excess print paste from the stencil.
Therefore, it is an object of this invention to provide an uncomplicated dye printing process requiring only one printing stencil for multi-color printing.
Another object of this invention is to provide a dye printing process which will work successfully on both low and high pile sheet material.
A further object of this invention is to provide an economical method of expediently producing intricately printed multi-color piled sheet material.
These and other objects of the invention will become apparent from reference to the following description, attached drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a stencil of the present invention standing on its edge.
FIG. 2 is a perspective view of one stencil element of the stencil of FIG. 1.
FIG. 3 is a perspective view of a stencil of FIG. 1 but displaying a different design pattern.
FIG. 4 is an exploded perspective view of the printing apparatus of the invented printing system including the printing platform, stencil and fly-bridge.
FIG. 5 is an isolated view showing a stencil wall of the invented stencil assembly positioned on the sheet material.
FIGS. 6 and 7 are schematic diagrams of the electrical control circuit of the invention.
DETAILED DESCRIPTION
Referring in more detail to the drawings in which like components have like numerals throughout the several views, FIG. 1 shows a stencil assembly which includes a stencil 9 as used in the present invention. The stencil 9 includes a rectangular frame 10 having four sides 13, 14, 15, 16. The frame 10 encircles an empty space which shall be referred to as the pattern space 11. A number of various shaped stencil elements 18 are arranged in the pattern space 11 within the rectangular frame 10 in such a manner as to collectively define, in conjunction with the stencil frame 10 and the pattern space 11, a desired coordinated design pattern.
As illustrated in FIG. 2, each stencil element 18 comprises a plurality of divider walls 20 connected together and defining an encircled space 21. The encircled space 21 is part of the previously mentioned empty pattern space 11. The sections of empty pattern space 11 which are not definable as encircled spaces 21 shall be referred to as unencircled pattern space 11. The stencil elements 18 are supported inside the frame 10 by wire elements 19 running between opposite sides 13,15 and 14,16 of the frame 10 in a crossing matrix configuration. The wire elements 19 are spaced apart and serve to support the stencil elements 18 and to hold the stencil elements 18 in their correct positions relative to other stencil elements 18 and to the frame 10. Depending on the intricacy of the design, it may be necessary in some circumstances to put a double row of wire elements 19 in some places, one above the other. If only one row of wire 19 is used, it is desirable that the wire be located below the center of the divider walls 20 in order to obtain the best vertical stability. The invention, however, is not to be limited by this recommendation.
The wire elements 19 are pulled tight so that sagging of the stencil elements 18 will be minimized within the pattern space 11. The border walls 20 and stencil elements 18 are maintained in their proper positions in the frame by being fastened to the wires in a manner that prevents the stencil elements from moving along the wires. This can be done, for example, by tacking the wire directly to the stencil with soldering or like means, or by soldering a knot on the wire on each side of the wall 20. Where two perpendicular wires 19 cross one another, they can be tacked together.
As shown in FIG. 3, it is not always necessary that the divider walls 20 be formed into individual stencil elements 18. It is also the teaching of the present invention to interconnect the divider walls 20 with one another and with the sides 13,14,15,16 of the stencil frame 10. In this way, the pattern space 11 is, likewise, divided up into a series of encircled spaces 21. Wire elements 19 are again used to support the walls 20 as they span the pattern space 11.
The lower edges 22 (see FIGS. 2, 4 and 5) of the walls 20 are located in a common plane parallel to the plane defined by the stencil frame 10. The divider walls 20 extend perpendicular to this same common plane.
FIG. 4 illustrates the printing apparatus associated with the present invention. The printing apparatus comprises a platform 24 movably mounted on an elongated stationary rack 26 including three parallel rails 27, 28, 29. A rug 23 is shown as placed on the top surface of the platform 24. The platform 24 displays indexing or positioning marks 32 on its top surface and has wheels (not shown) mounted on its underside which run along the upper edges of the rails 27, 28, 29 of the rack 26. Chains 30, 31 encircle the rack 26 lengthwise and connect at opposite ends of the platform 24. At each end of the stationary rack 26, the chains 30, 31 pass over sprockets 33, 34. One set of sprockets are driving sprockets 33 operated by an electric platform motor 35.
One end of the rack 26 shall be referred to as the platform loading zone A and the opposite end of the rack shall be referred to as the platform unloading zone C. The printing zone B of the platform is located toward the unloading end C. Four mechanically coordinated motorized jacks 37a, 37b, 37c (not shown), 37d, having screw elements 38 are located in the printing zone B of the apparatus and define a rectangular area slightly wider than the platform 24. Each jack 37 is oriented so that the screw element 38 extends perpendicular to the platform 24. The four motorized screw jacks 37a, 37b, 37c, 37d are all operated simultaneously by the same jack operating motor 36 in order that movement of the four jacks can be coordinated. Two jacks 37a, 37b are connected by rotatable shaft 41a. Two jacks 37c, 37d are connected by rotatable shaft 41b. The shafts 41a, 41b, when rotated operate the screw elements 38 of the respective jacks 37. A driven pulley 57a is attached to an extension of shaft 41a and a driven pulley 57b is attached to an extension of shaft 41b. Two drive pulleys 58a, 58b are attached to the shaft of jack motor 36 and each set of drive pulleys and driven pulleys 57a, 58a and 57b, 58b, respectively, is connected by a timing belt 59a, 59b surrounding the two pulleys. Through this arrangement, the four jacks are operated in mechanized coordination. Four canopy stands 40 are positioned about the printing zone B with one stand 40 located near each of the jacks 37. The four canopy stands 40 support a canopy mechanism which comprises a canopy 42 attached to two canopy supporting chains 43, 44, each of which is carried by and extends about four sprockets 45, 46, 47, 48. The driving sprockets 45 are simultaneously driven by an electric canopy motor 51. The canopy supporting chains 43, 44 are located so as to encircle the rack 26 perpendicular to the rack rails 27, 28, 29 with the upper portion of the canopy supporting chain being higher than the level of the platform 24. To give strength to canopy 42 and prevent it from sagging, rigid tubing (not shown) is extended between and connected to the two supporting chains 43, 44 and attached to the canopy. A doctor blade 49 is mounted across the two canopy stands 40 nearest to the loading zone A and on the side of the canopy stand facing the loading zone. The blade 49 is parallel to the plane of the rug 23 and platform 24 and is adjustable in height along the stands 40 and relative to the rug 23. This doctor blade 49 is, in the present embodiment, a steel angle, one flange 50 of which extends downwardly into contact with the fibers 25 of the rug 23.
The printing method proceeds as follows: A stencil 9 having elements as previously described, is assembled to represent the desired design pattern and is made as large or small as necessary to fit the size of the rug 23, or like material, to be printed. A stencil bracket 39 is fastened to each corner of the stencil 9. Each bracket 39 is formed so that it can reach over the canopy supporting chain 43 or 44 and sit on top of the screw element 38 of its respective jack 37. The brackets 39 avoid contact with the chains 43, 44 even when the jacks 37 are lowered to position the stencil 9 on the platform 24. The stencil 9 is then placed in position in the printing zone B with each of the four brackets 39 at the corners of the stencil resting on one of the jack screws 38. The screws 38 are fully extended so as to hold the stencil high above the rack 26. The canopy 42 is in its extended position above the rack 26 and below the stencil 9. The rug 23 (see FIG. 4) is placed on the platform 24 in the loading zone A with carpet pile face 25 facing up from the platform 24. The rug 23 is accurately positioned on the platform 24 by an appropriate indexing system. For example, in the disclosed embodiment, the rug 23 is aligned with indexing marks 32 on the platform to insure proper positioning on the platform.
The electric motor 35 is activated and the platform 24 and rug 23 are pulled by chains 30, 31 from the loading zone A into printing position under the stencil in the printing zone B. The platform 24, with the rug 23 accurately positioned on the platform, is stopped in the printing zone B at a printing position where the rug is in proper vertical alignment with the stencil 9. Since the printing position of the platform 24 is automatically controled, as later described, and since the stencil 9 moves in a fixed vertical plane, the proper vertical alignment between rug 23 and stencil 9 is achieved by accurately placing the indexing marks 32 on the platform relative to the fixed vertical alignment of the stencil over the platform when the platform is in the printing position, and then aligning each rug on the indexing marks 32 each time a rug is placed on the platform. As the rug 23 enters the printing zone B, doctor blade 49 engages the face pile 25 with the extending flange 50 and fluffs up the piles as they pass by and makes them stand vertically so as to facilitate proper positioning of the divider walls 20 between the piles.
Once the platform 24 and rug 23 have been moved into position in the printing zone B, the canopy motor 51 is switched on and the canopy 42 is retracted to its position underneath the rack 26. The stencil 9 is lowered onto the rug 23 so that the walls 20 pass beneath the individual piles 25 until finally, the lower edges 22 of the divider walls 20 make contact with the rug backing 52 (see FIG. 5). The individual piles 25 are segregated to either one side or the other of the divider wall 20 so as to create a well defined separation between piles of adjacent encircled areas 21. The great majority of piles 25 will take up positions on one side or the other of the divider walls 20, but it is expected that some of the piles 25 may become trapped below the walls 25. The lowering (and subsequent lifting) of the stencil 9, in the disclosed embodiment, is accomplished by the retraction (and extension) of the four jacks 37. The four stencil brackets 39 are rigidly connected to the stencil 9, but are not connected to and only rest on the jack screws 38, so that the jacks 37 continue to retract, leaving the stencil resting on the rug 23.
After the stencil 9 has been properly positioned on the rug 23, print paste is applied to the rug pile face 25 according to the color scheme of the design pattern. Each different encircled space 21 and the unencircled pattern space 11 may receive a different color or treating agent, or may be left uncolored. The print paste, in the preferred method, is applied by spray dispensers 53 (see FIG. 5) which are hand held by operators positioned on a movable flybridge 56 suspended above the platform area. The nozzle end 54 of the spray dispenser 53 is held below the upper edge 55 of the divider wall 20 and moved about between adjacent divider walls 20. In this way, the print paste meant for pile face fibers 25 on one side of a divider wall 20 will not flow over to those on the other side. The term "print paste" of the present invention is meant to be a generally inclusive term encompassing dyes, resists and other treating agents of varying colors and viscosities.
Once the print paste has been fully applied, the stencil 9 is lifted from the rug 23 and canopy 42 is immediately moved back into place between the carpet and stencil to catch any drippings which may fall from the stencil 9. The platform 24 now carrying the printed rug 23 is moved further along the rack 26 by the motor 35 and chains 30, 31 to the unloading zone C. Here, the rug 23 is removed from the platform 24 and the platform is returned to the loading zone A by reversing the directional mode of the motor 35.
The circuitry controlling the movement of the platform 24, canopy 42 and stencil 9 of the present invention is shown in FIGS. 6 and 7. FIG. 7 shows the platform motor 35, canopy motor 51, and jack operating motor 36 which shall hereinafter be referred to as stencil motor 36 for ease of understanding. As will be obvious to those skilled in the art from inspection of FIG. 7, the motors 35, 51, and 36 of the preferred embodiment are driven by a three-phase 230 volt source indicated by the three lines noted as 79. As may further be seen from FIG. 7, platform motor 35 may be operated in one direction by closing a set of three contacts shown as PMF5, and the other direction by closing a set of contacts PMR5. Likewise, canopy motors 57 may be run in a first direction by contacts CMF5 and in a reverse direction by contacts CMR5. Also stencil motor 36 may be operated in a first direction by contacts SMF5 and in the opposite direction by SMR5.
The control logic circuitry of the present invention is shown in FIG. 6. It is to be noted that the circuitry includes a number of relays whose coils are designated as R1, R2, R3, R4, R5, R6, CMF, CMR, SMF, SMR, PMF, and PMR. The designations for the relay coils shown in FIG. 6 have been selected to aid in understanding their function. Coils R1-R6 activate relays which are internal to the control system shown in FIG. 6. Relay coil PMF corresponds to "platform motor forward" and PMR corresponds to "platform motor reverse". Likewise coils CMF and CMR correspond to coils controlling the forward and reverse movement of the canopy motor 51, respectively, and coils SMF and SMR control the stencil motor 36.
In order to understand the operation of the control circuitry it must be understood that contacts PMF5 shown in FIGS. 7 are closed upon the excitation of coil PMF shown in FIG. 6. Similarly contacts PMR5 shown in FIG. 7 are closed by the excitation of coil PMR shown in FIG. 6. Likewise contacts CMF5 are closed by excitation of coil CMF; contacts CMR5 are closed by excitation of coil CMR; contacts SMF5 are closed by excitation of coil SMF; and contacts SMR5 are closed by excitation of coil SMR.
It should be further understood that contacts C1A and C1B are closed by excitation of coil R1 as shown in FIG. 6 and in a similar manner contact C2 is closed by excitation of coil R2. It can therefore be seen that in FIG. 6, contacts denoted as CX where X is an integer are closed by excitation of a coil RX where X is the same integer. Also contacts noted as PMFX are closed by coil PMF; contacts noted as PMRX are closed by excitation of coil PMR; contacts noted as CMFX are operated by excitation of coil CMF; contacts noted as CMRX are operated by excitation of coil CMR; contacts noted as SMFX and SMRX are operated by excitation of coils SMF and SMR respectively.
A control circuit shown in FIG. 6 also includes seven limit switches which are activated by the mechanical movements of the platform 24, canopy 42, and stencil 9. All limit switches with the exception of switch 65 are two pole single throw switches. Switches 60a and 60b are mechanically activated when the platform 24 is in its loading position in the loading zone A. Switches 61a and 61b are mechanically activated when the platform 24 is at its printing position in printing zone B and switches 62a and 62b are mechanically activated when the platform 24 reaches its unloading position in unloading zone C. Similarly switch 65 is operated when the stencil 9 is in its up position and switches 66a and 66b are operated when the stencil is in its down position. Switches 67a and 67b are mechanically activated when the canopy 42 is in its extended position above the rack 26 and switches 68a and 68b are mechanically activated when the canopy is in its retracted position below the rack 26.
The arrangement of the control circuitry shown in FIG. 6 is such that its operation may be conveniently explained by defining three cycles. The first cycle is initiated when the platform 24 is in its loading position with a rug 23 loaded thereon. Therefore switch 60a is closed and switch 60b is open at the beginning of the first cycle. Depression of start button 75 completes a circuit through lines 80 and excites coil R1. The excitation of coil R1 closes contacts C1 thus completing a circuit between points 81 and 82 which completes a circuit through switches 66a and 60a to line 85 thus exciting coil R2. The excitation of coil R2 closes contact C2 completing a circuit between points 86 and 82. As will be obvious to those of ordinary skill in the art, the closing of contact C2 will latch coil R2 when switch 60a opens in response to the platform moving from its loading position and contact C1a opens when start switch 75 is released thereby maintaining the excited state of coil R2 until some other interruption to its holding current occurs.
The closing of contact C2 also completes a circuit between point 86 and point 87 which provides excitation to coil R3 through switch 61a and line 88. The excitation of coil R3 closes contact C3 and completes a circuit through switch 62a to point 89, along line 90 to line 91 and thus exciting coil PMF.
The excitation of coil PMF closes contact PMF5 (shown in FIG. 7) thus operating platform motor 35 and causing forward movement of the platform 24 from its loading position towards its printing position. Recall that since contact C2 latches coil R2 thus assuring prolonged excitation of coil R3, contact C3 will remain closed and thus maintain holding current on coil PMF until switch 61a opens causing coil R3 to become deenergized. When the platform reaches its printing position, switches 61a and 61b are mechanically tripped so as to be opened and closed respectively. The opening of switch 61a deenergizes coil R3, thus opening contact C3 and terminating the energized state of coil PMF. This stops operation of platform motor 35. The closing of switch 61b completes a circuit from point 87 to line 92 on to point 95 thus exciting coil CMF. The excitation of coil CMF closes contacts CMF5 (shown in FIG. 7) causing canopy motor 36 to become activated and begin retracting the canopy 42. Furthermore the excitation of coil CMF opens normally closed contacts CMF1 thus preventing excitation of coil CMR. The system remains in this state until the canopy 42 has been retracted to the point where it mechanically triggers limit switches 68a and 68b. When the canopy reaches its fully retracted position, switches 68a and 68b are opened and closed respectively. The opening of switch 68a opens the circuit between points 92 and 95 and thus deenergizes coil CMF. The closing of switch 68b completes a circuit between points 92 and 96 thus energizing coil SMF.
The excitation of coil SMF closes contacts SMF5 (shown in FIG. 7) thus lowering the four jacks 37 and lowering the stencil 9. Also the excitation of coil SMF opens normally closed contacts SMF1 preventing excitation of coil SMR. When the stencil reaches its printing position, it mechanically opens limit switch 66a and closes limit switch 66b. The opening of switch 66a terminates the connection between line 70 and point 86, thus deenergizing coil R2, which causes contact C2 to open and therefore maintains coils R2, R3 CMF and SMF in their unexcited states. This completes the first cycle of operations and the control circuit is in a stable state.
Once printing of the rug 23 has been completed, depression of start switch 75 will begin the second cycle of operation of the control circuit. The depression of start switch 75 again energizes coil R1 thus closing all contacts associated therewith. However, limit switch 66a is open, and therefore the closure of contacts C1a in response to the excitation of coil R1 will not energize coil R2. However the excitation of coil R1 closes contacts C1c. As may be seen from FIG. 6, the closure of contacts C1c completes a circuit through switch 66b (which is closed due to the down position of the stencil) and switch 62a to line 97 and thus energizes coil R4. The excitation of coil R4 closes contact C4 thus completing a circuit between point 89 and point 98 and thereby latching coil R4. As may be seen from the foregoing, the latching of coil R4 in response to the closure of contact C1c at the beginning of the second cycle of the control circuit operation is similar to the latching of coil R2 in response to the closure of contacts C1a at the beginning of the first cycle of the control circuit operation.
Closure of contact C4 also completes a circuit between points 89 and points 99 to line 100 thus exciting coil SMR. The excitation of coil SMR opens normally closed contacts SMR1 preventing excitation of coil SMF and furthermore closes contacts SMR5 (shown in FIG. 7) thus causing stencil motor 36 to begin raising of the stencil by raising of the four jacks 37. The control circuit remains in this state until the stencil 9 reaches its uppermost position closing limit sswitch 65. The closure of limit switch 65 completes a circuit along line 101 which excites coil R6. The excitation of coil R6 both closes contacts C6b and opens normally closed contacts C6a. The opening of contacts C6a deenergizes coil SMR and the closure of contacts C6b completes a circuit between point 99 and point 102 through switch 67a which allows excitation of coil CMR. The excitation of coil CMR opens normally closed contacts CMR1 thus preventing excitation of coil CMF and furthermore closes contacts CMR5 (shown in FIG. 7) thus causing canopy motor 51 to begin retraction of the canopy 42. The circuitry remains in this state until the canopy reaches its extended position thus mechanically opening limit switch 67a and closing limit switch 67b. The opening of switch 67a deenergizes coil CMR and the closing of switch 67b energizes coil R5. The excitation of coil R5 closes contact C5 completing a circuit from point 89 along line 90 through contact C5 to line 91 thus energizing coil PMF. The excitation of coil PMF opens normally closed contacts PMF1 preventing excitation of coil PMR and also closes contacts PMF5 (as shown in FIG. 7) causing platform motor 35 to move the platform 24 from its printing position to its unloading position. The control circuit remains in this state until the platform reaches its unloading position thus mechanically opening limit switch 62a and closing limit switch 62b. The opening of switch 62a deenergizes coil R4, thus opening contacts C4 and preventing excitation of coils SMR, CMR, and R5. The loss of holding current on coil R5 opens contact C5 terminating holding current to coil PMF and thus terminating operation of platform motor 35. The control circuit is now in a stable state and has completed its second cycle of operation. As will be apparent from the foregoing description, the stencil 9 is in its upper position, the canopy 42 is in its extended position and the platform 24 is at its unloading position.
In the third cycle of operation of the control circuitry it is only necessary to move the platform from its unloading position in unloading zone C all the way back to its loading position in unloading zone A. Depression of start button 75 energizes coil R1 thus closing contact C1b. The simultaneous closure of contacts C1a and C1c, also effected by depression of button 75, will not energize any of the other relay coils since limit switch 60a is open and 60b is closed due to the stencil 9 being in its upper position and limit switch 62a is open and 62b is closed due to the platform 24 being in its unloading position. Depression of start button 75 also energizes coil R6 through limit switch 65 which is closed as a result of the stencil 9 being in its upper position. Excitation of coil R6 closes contacts C6c. The closure of contact C1b completes a circuit through contacts C6c through switches 60b and 62b along lines 105 and 106 to coil PMR. The excitation of coil PMR closes contacts PMR5 (shown in FIG. 7) causing platform motor 35 to begin retracting the platform from its unloading position back to its loading positon. The excitaton of coil PMR also opens normally closed contacts PMR1 preventing excition of coil PMF. Furthermore excitation of coil PMR closes contacts PMR2 thus completing a circuit between point 107 and line 106. The closure of contacts PMR2 will provide a circuit for the holding current on coil PMR when limit switch 62b is opened by to the platform moving from its unloading position back toward its loading position. The control circuitry will remain in this state until the platform arrives at its loading position thus mechanically opening switch 60b and terminating holding current to coil PMR. This completes the third cycle of operation of the control circuitry and the printing apparatus is now in the same state as was described at the beginning of the first cycle.
While this invention has been described in detail with particular reference to preferred embodiments thereof, it will be understood that variations and modifications can be effected within the spirit and scope of the invention as described hereinbefore and as defined in the appended claims.
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A dye printing system for multi-color patterning or pile face sheet materials, such as tufted carpet, includes a stencil, in which the pattern elements are formed by divider walls extending perpendicularly to the plane of the sheet material. The stencil is lowered into contact with the pile face of the sheet material and its divider walls penetrate between the face pilings and rest on the base of the material, and isolate neighboring areas of pile face material from one another, so that print paste can be applied to the pilings within a pattern element without bleeding into neighboring pattern elements. Mechanical means raise and lower the stencil on to the pile face sheet material, and a dye liquor drip catching canopy is passed between the sheet material and the stencil whenever the stencil is raised to protect the sheet material from possible drip contamination. The sheet material is loaded on a rack-mounted platform, moved with the platform to the printing position beneath the stencil, and after the printing step, moved with the platform to an unloading position. A flybridge is suspended over the stencil, so that operators can position themselves conveniently and quickly at any position over the stencil to apply the dye liquor.
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BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a coupling device for transferring viscous fluids, from one bottle to another, and relates more particularly, to an improvement in such a coupling device whereby the device is made to couple with the connected bottles in a streamline and readily detachable manner. It should be understood that by “viscous fluids” it is meant that a myriad of substances are addresses by this application under this term whereby each having the characteristic of a slow moving fluid, examples of which are as follows: ketsup, barbecue, sauces, glazings, toppings such as, chocolate fudge or butterscotch, salad dressings, liquid food groups such as, honey, syrup, sauces, mustard and cocktail sauces, no food products such as shampoo, cream rinse, gels, lotions, hand cream, motor oil, brake fluid, antifreeze, automotive care products such as waxes, etc., cleaning products such as liquid detergent and spot removers, liquid soap.
The problem which exists in salvaging slow flowing material, such as catsup or oil, in the partially or almost completely used container is that the time it takes to drip from the nearly expended container to the one in which the food material is to be collected is quite a lengthy period. In addition, it is desirable to use a device which acts only between the interior surfaces of the containers thereby eliminating the movement of food material, for example, from around the threaded neck areas of the containers.
Coupling devices for draining one bottle of viscous fluid into another are known. Such devices are disclosed, for example, in the following patents.
U.S. Pat. No. 3,877,499 issued to Fulster on Apr. 15, 1995.
U.S. Pat. No. 3,963,063 issued to Pacarella on Jun. 15, 1976.
U.S. Pat. No. 3,620,267 issued to Seabolm on Nov. 16, 1971.
Such coupling devices are useful in the prevention of waste of the food material within the partially or almost fully used container. However, as is apparent from the above listed patents, coupling devices for transferring viscous fluids, such as found in a partially filled ketsup bottle, are known. But, one problem associated with such devices is apparent from U.S. Pat. No. 3,877,499. The device disclosed therein is seated outside the neck of the lowermost bottle which can become problematic in that the food material which normally builds up around the neck of the bottle, may come into contact with the transfer device as it is placed down over the neck of the bottle. In addition, as it drains, flowing material from the upper draining bottle might seep between the interface of the lower bottle neck and the connection device.
Accordingly, it is an object of the invention to provide a fluid transfer device which is capable of being readily inserted into two containers for gravity feeding of viscous fluid between one container and the other.
It is yet a further object of the invention to provide a fluid transfer device of the aforementioned type which acts only between the interior surfaces of the container
It is yet a further object of the invention to provide a fluid transfer device of the aforementioned type which uses no threaded connections.
It is still a further object of the invention to provide a fluid transfer device of the aforementioned type wherein the device is capable of being made in a single unitary piece.
SUMMARY OF THE INVENTION
The invention resides in fluid transfer device having an inverted funnel at its top and a conically downwardly tapered funnel at its bottom with a collecting portion formed about generally its midspan. The upper inverted funnel has a longitudinal slot formed therewithin and an opening is formed in the collecting portion allowing fluid to pass between the upper container and the lowermost container and the slot allows the upper inverted funnel to be circumferentially compressed against the interior surface of a container so as to act as a fluid conduit therebetween.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing aspects and other features of the present invention are explained in the following description, taken in connection with the accompanying drawings, wherein:
FIG. 1 a is a first perspective view of the fluid transfer device shown in its connecting mode between two containers.
FIG. 1 b is a perspective view of the fluid transfer device shown in FIG. 1 without the two containers.
FIG. 2 is a second perspective view of the fluid transfer device shown at a second angle.
FIG. 3 is a vertical section through the device of FIGS. 1-2.
FIG. 4 is a top plan view of the device shown in FIG. 3 .
FIG. 5 is a bottom view of the device shown in FIG. 4 .
FIG. 6 is a view taken along line 6 — 6 in FIG. 3 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1 a it should be seen that a device indicated generally as numeral 2 is shown in the preferred embodiment. The device 2 is adapted to be readily connected between an inverted container 4 and an upright container 6 . The inverted container may contain food material, such as ketsup, or other like viscous material which requires time in which to move downwardly through the device 2 and into the upright container 6 where it is collected for further use. With time, the material in the container 6 will be used to the point where the foodstuff in the container 6 will become so limited that it will itself need to be inverted over and allowed to drip into another container disposed below it.
Referring now to FIGS. 1 b - 6 , it should be seen that the fluid transfer device 2 has a top inverted funnel portion 10 and a lower downwardly tapered funnel portion 12 connected with one another through a collecting portion 14 interposed therebetween.
The collecting portion 14 is integrally formed with the top inverted funnel portion 10 and includes a circumferentially disposed annular base plate 16 having a through opening 18 formed therein which communicates with each of the upper and lower tapered funnel portions 10 and 12 . In the preferred embodiment, the upper and lower funnel portions 10 and 12 are made from like materials, such as, polypropylene, and the lower flange portion 12 has an integrally formed top annular flange 12 ′ which is uniformly connected to the undersurface of the collecting portion 14 by an ultrasonic weld connection to give the device 2 a generally integral form.
The annularly disposed base plate has a sidewall 20 which extends upwardly from the base plate 16 and is preferably radially angled outwardly from the central axis CA at an angle A′ equaling approximately 20° thereto. The angular disposition of the sidewall 20 is further effective in collecting the material dripping from the upper container 4 into the collecting portion 14 .
It is a further feature of the invention to provide a fluid transfer device of the type disclosed herein which is capable of fluidic connection with the upper inverted container 4 and the lower upright collecting container 6 without the need of a threaded connection or other intricate connecting structure.
Accordingly, it should be seen that the inverted upper funnel portion 10 and the lower downwardly tapered funnel portion 12 each has a means 22 and 24 , respectively, for quick connect insertion into a respective one of the containers 4 and 6 . In the case of the upper tapered funnel portion 12 , the means 22 includes a slot 23 having a median width of about 0.375 inch formed therein extending longitudinally parallel to the central axis CA of the device. The slot 23 allows the upper funnel portion 12 to be radially compliant so as to be releasably attached to the upper container 4 . In this way, the device 2 is connectable to the upper container 4 such that upon insertion of the upper funnel portion 12 of the fluid transfer device 2 into the upper container 4 by axial movement through the opening in the container 4 , the upper funnel portion 12 is caused to be circumferentially compressed and act against the interior surface of the container so as to act as a fluid conduit therebetween.
The slot 23 further extends with the upper funnel portion 10 longitudinally with the axis CA so as to communicate with the central opening 18 in the base plate 16 of the collecting portion. As seen in FIG. 4, the slot 23 further extends through the base plate 16 radially outwardly from the central axis CA so as to allow material which may flow through the slot 23 from the upper funnel portion 10 and collect in the collection portion 14 , to pass through the base plate 16 and down into the lower funnel portion 12 and then desirably, into the upright lower collecting container 6 . To enhance the flow of fluid from the collecting portion 14 into the opening 18 , opposed rectangular slots 19 , 19 are formed in the base of the upper funnel portion 10 . The slots 19 , 19 have a horizontal or long dimension equal to about 0.575 inch and a height or short dimension equal to about 0.155 inch.
The lower downwardly tapered funnel portion 12 includes the means 24 for quick connect insertion into the collecting container 6 . This means is defined by the downwardly tapered configuration of the lower inverted funnel portion 12 which is correspondingly sized and shaped to be wedged into the opened top of the lower container 6 . To assist in this function, the outer surface 38 of the lower tapered funnel portion 12 has four longitudinally extending ribs 35 , 35 which are integrally formed therewith and extend radially outwardly of the central axis CA Each of the ribs 35 , 35 is generally circular in shape and has a diameter of about 0.065 inch. In this way, each of the inverted funnel portion 10 and the lower funnel portion 12 is capable of circumferentially holding and securing a releasable connection between the involved one of the two containers 4 and 6 . At the base of the lower funnel portion 12 is provided a plurality of arc-shaped cutouts 37 , 37 which are provided to better increase the flow of fluid material from the lower funnel portion 12 and into the collecting container 6 and to also allow the lower funnel portion to be fit within smaller necked containers. Each of the arc-shaped cutouts has a width of about 0.235 inch and extends axially into the lower funnel portion a length equal to about 0.360 inch.
The device 2 is formed from a semi-rigid plastic material, such as polypropylene or the like and is molded. In the preferred embodiment of the invention, the polypropylene material used is injection molding grade FDA approved polypropylene with a flexural modulus of 152,00 psi and a tensile strength yield of 4030 psi, and is sold under name Epsilon Polypropylene E-5135C by Epsilon Products Co., P.O. Box 432, Post Road and Blueball Ave., Marcus Hook Pa. 19051.
Also, while not limited to the following dimensions, the device in one embodiment may have the dimensions which correspond, for example, with an application for use in catsup bottles. The reference letters below are those corresponding to those shown in FIG. 3 and are in inches.
A=0.55
B=2.25
C=2.25
D=1.0
E=0.650
F=1.0
G=2.0
H=0.070
From the foregoing, an improved fluidic transfer device has been described by way of the preferred embodiment. However numerous modifications and substitutions may be had without departing from the spirit of the invention. For example, while it is disclosed that the sidewall of the collecting portion is angled somewhat outwardly from the central axis, it is nevertheless within the purview of the invention to provide a sidewall which extends parallel to the central axis CA of the device rather than being angled outwardly. Also, the device 2 could be integrally molded as a single unitary piece.
Accordingly, the invention has been described by way of illustration rather than limitation.
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The invention resides in fluid transfer device having an inverted funnel at its top and a conically downwardly tapered funnel at its bottom with a collecting portion formed about generally its midspan. The upper inverted funnel has a longitudinal slot formed therewithin and an opening is formed in the collecting portion allowing fluid to pass between the upper container and the lowermost container and the slot allows the upper inverted funnel to be circumferentially compressed against the interior surface of a container so as to act as a fluid conduit therebetween.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an electron-emitting device and its application particularly to making flat television screens.
2. The Prior Art
At present, a certain number of electron-emitting devices are known, which are either hot cathodes where the electron emission is facilitated by thermal agitation or cathodes operating on the photoemission principle, or also sources of electrons created in a plasma discharge, or also by field emission tips, these tips being supplied directly by a electric power supply.
In numerous applications, there is an interest in point cold sources with a controlled amount of emitted electrons.
Known devices do not make it possible to obtain these results.
SUMMARY OF THE INVENTION
The present invention provides a simple device making it possible, on the one hand, to control the electron emission and, on the other hand, to cause this electron emission to be able to be performed sequentially and variably.
The device according to the invention essentially consists of a electric power supply connected to the two plates of a capacitor supplying, by one of these plates, at least one field emission tip and an extraction grid placed close to the top of this tip, said grid itself being connected to the other plate of the capacitor by a variable voltage generating device.
The invention also covers as an interesting application, that of such a device for making flat television screens.
According to this application, several devices according to the invention are connected together in series facing a fluorescent screen placed to receive the flow of electrons emitted by these devices.
BRIEF DESCRIPTION OF THE DRAWINGS
The interest and scope of the invention will come out more clearly from the following description given with reference to the accompanying drawings in which:
FIG. 1 is a diagrammatic view of a device according to the invention; and
FIG. 2 is a diagram showing the application of several of these devices to making a flat television screen.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to these figures, the device according to the invention (FIG. 1) comprises an electric power supply 5 with a programmable direct voltage, connected to the two plates of a capacitor 1.
Plate 1a of this capacitor 1 is connected to the base of at least one field emission tip 2 whose top is located close to orifice 3a of a plate, hereafter called grid 3. This grid itself is connected to the other plate 1b of capacitor 1 by variable voltage generator 4.
The device that has just been described functions as follows.
It operates cyclically, each cycle breaking down into two parts of equal or different duration. During the first part, generator 4 is brought to a zero or sufficiently low potential to prevent electron emission by tip 2. Electric power supply 5 provides an electric charge to capacitor 1.
During the second part, supply to the capacitor is interrupted by any means known in the art and generator 4 is brought to a sufficient potential to allow discharge of capacitor 1 through 2, thus providing the desired flow of electrons emitted through orifice 3a of grid 3. Once this flow is obtained, capacitor 1 is again supplied and the cycle described above is resumed.
Thus it can be seen that the device according to the invention not only makes it possible to obtain a given amount of electrons but also to control the frequency at which this amount is obtained, this frequency itself being a function of the supply frequency of capacitor 1.
These properties then allow all types of applications in which it is desired to have a sequential flow of electrons of controlled intensity. Actually it suffices to have in rows and columns several devices of the type of that just described opposite a fluorescent screen like that illustrated in FIG. 2. In this figure can be seen a fluorescent flat screen 6 directly connected to electric power supply 5 by fixed voltage generator 7, the set of devices according to the invention A, B, C, D . . . N being connected together and in series, on the one hand, by a single line 9 and, on the other hand, by electronic devices 8 making it possible to isolate the charges of different capacitors 1. Moreover, voltage generator 4 is connected to grid 3 connected in series and to the devices 8 themselves connected in series.
Such an arrangement functions cyclically, each cycle being made up of two periods.
During the first period, electric power supply 5 supplies to capacitor 1 of device A the electric charge which is supposed to go into the capacitor of device N. This charge is then transferred into the capacitor of device B through one of electronic devices 8, then electric power supply 5 supplies to the capacitor of device A the electric charge corresponding to the capacitor of device N-1. The charges of capacitors B and A are then transferred in the same way to the capacitors of devices C and B and so on until the complete charging of the capacitors of the set of all the devices to device N. During all this first period, voltage generator 4 is put at zero or sufficiently low potential to prevent electron emission.
During the second period of the cycle, supply of the arrangement by electric power supply 5 is interrupted by means known in the art. Voltage generator 4 is then brought to a sufficient potential to allow simultaneous discharge of all the capacitors of devices A to N. The impact of the electrons emitted by each of tips 2 of each device A and N forms on screen 6, brought to a positive potential by voltage generator 7, an image whose intensity of each point depends on the charge accumulated on each capacitor. Once all the capacitors have been discharged, the cycle resumes as described above.
A number of the advantages obtained by the device according to the invention and in particular are as follows.
Regardless of the number of devices placed in rows or columns, their supply requires only a minimum number of connecting wires since each arrangement corresponds to a connection in series (connections 8 and 9 for each unit).
Further, the grids are all connected together, which simplifies the production of a television screen.
The potential applied to the grids can be high (several hundred volts) thus simplifying the switching problems, the frequency being able to be only 25 to 30 Hz.
Because of a high voltage that can be applied to the grids, the electrons can be extracted more easily and it is not necessary to have tip materials with low work function. It is thus possible to use materials less expensive than those usually used and the production of tips is less critical on the plate unit supporting them.
This new system make the television screen less sensitive to contamination of the tips and increases their life.
In the standard column line addressing, the light intensity is achieved by varying the voltage or current which is difficult to control. But by applying the device of the invention, the amount of the charge emitted creates the light intensity levels. These charges are thus perfectly controlled.
Finally, since any electronic equipment can be integrated on a tip support plate, it is possible to achieve screens by juxtaposing smaller unit modules of some square centimeters in surface, each of these modules being able to be connected to others, for example, by the back face of the circuit. There is no control electronic equipment on the edges of the screen which prevents them from being juxtaposed.
Further, it will be noted that to obtain color, it will suffice to use the tips existing on each of the assembled devices, making a screen by means of alternating red, green and blue bands. The bands of each color will then be connected together when the image of a given color is created, the corresponding band or its support being brought to a positive potential to accelerate the electrons, while the other two bands (or their supports) will be brought to a lower potential or a negative potential.
Of course, this invention was described only by way of pure explanatory example in no way limiting and any useful modification can be made thereto without going outside its scope.
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A flat television screen, comprising several electron-emitting devices, each essentially consisting of an electric power supply connected to two plates of a capacitor supplying by one of these plates at least one field emission and an extraction grid placed close to the top of the field emission, the grid itself being connected to the other plate of the capacitor by a variable voltage generating device, these devices being connected together facing a fluorescent screen placed to receive a flow of electrons emitted by the field emission of each of the devices.
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BACKGROUND OF THE INVENTION
Field of the Invention
[0001] This invention relates to oil well cleaning apparatus, and more particularly, to a reamer tool which can be used for scraping and removing paraffin, scale, ice, barium cement, salt, calcium and other accumulations from the inside surfaces of oil well tubing and casing. The tool can easily be adapted for use with a snubbing unit, cable rig, coiled tubing, cable, or electric wireline in an oil or gas well. The reamer tool may be operated in cooperation with a wire line typically fitted with a swivel joint, and with a load applicator such as one or more spanner jars, for alternately applying a repetitive impact load to the tool and sequentially repositioning the tool for further load application.
[0002] The problem of restricted flow of hydrocarbons in oil wells due to the accumulation of paraffin and other deposits on the inside wall of the tubing is one of great concern in the oil field. Paraffin accumulation sometimes occurs in a relatively short period of time and can form a tough, semi-solid deposit which severely restricts the flow of fluid in the tubing. Accumulation thickness and character vary with the type and quantity of oil and hydrocarbon fluid produced, and frequently causes severe stress in pumping apparatus and equipment, with resulting equipment failure or low operating efficiency. Typically, the accumulation of paraffin deposits in oil well production tubing occurs at a point where the hydrostatic pressures and temperatures create favorable conditions for precipitation of solid paraffin from the oil. Other deposits such as rust, scale, salt, calcium cement, barium and ice must frequently be removed from production tubing and casing, particularly in corrosive environments, and in the case of ice, in regions characterized by prolonged low temperature.
[0003] Paraffin and other deposit accumulations in production tubing are frequently removed by using expensive and sometimes complicated scraping tools which may be attached to the sucker rods deployed in the well This technique is time-consuming and expensive since the sucker rod string must first be removed, the paraffin scraper tool or tools then installed on the sucker rods, the rods and accompanying scraping tools reinserted in the well, the scraping operation completed, and the tools finally removed. Such a procedure can be prohibitively expensive in some wells and impractical in others, and the tools sometimes break and become jammed in the tubing. Furthermore, the accumulation of paraffin and asphalt in the tubing sometimes becomes too thick for removal by application of such equipment, and the tubing string must then be pulled out of the well and “burned” in order to remove the accumulated deposits. This procedure is extremely time-consuming and expensive, and is normally used only as a last resort when conventional tools cannot be used effectively. Further, while tools which have become inadvertently stuck or jammed in the well bore or casing can be jarred loose and removed easily and inexpensively in most cases, sometimes it is necessary to apply rotational force to the jammed tool in order to dislodge and remove the the tool from the well bore or casing.
[0004] Another technique frequently used to remove accumulated deposits from well tubing includes pulling and disconnecting a sufficient number of sucker rods to facilitate insertion of a “hook and washer” type cleaning tool to the point of deposit accumulation, and subsequently pulling the tool out of the tubing to scrape the deposit loose. This technique is also time-consuming, and is relatively inefficient and expensive.
[0005] Accordingly, an object of this invention is to provide a reamer tool which can be used to remove deposits and accumulations of paraffin, asphalt, scale, ice, salt, calcium, barium, cement and other materials from the inside surfaces of oil well tubing and casing.
[0006] Another object of the invention is to provide a reamer tool which can be lowered into a well tubing or casing and repetitively loaded to clear the tubing and casing.
[0007] Yet another object of this invention is to provide a casing and tubing reamer tool which is capable of cleaning deposits in well tubing and casing, which reamer includes a housing and a threaded shaft slidably displaceable in the housing, such that sliding of the shaft in the housing rotates the housing.
[0008] A still further object of this invention is to provide a reamer tool which is capable of cleaning deposits in well tubing and casing, which reamer tool includes a housing capable of suspension in the well tubing or casing; a shaft slidably mounted in the housing; shaft threads provided on the shaft; a lock nut threadibly mounted on the shaft for removably engaging the housing; and a reset spring provided in the housing between the housing and the end of the shaft, such that displacement of the shaft in the housing causes the lock nut to engage the housing, and the lock nut rotates on the shaft threads and rotates the housing such that the housing rotates in the well bore or casing and removes paraffin, scale, ice, salt, calcium, cement, barium or other solid blockages from the well bore or casing.
[0009] Yet another object of the invention is to provide a reamer tool for insertion in oil field casing and tubing, which reamer tool is capable of being adapted to run fishing tools in addition to removing accumulations of paraffin, scale, ice, cement, salt, calcium, barium and other material from the tubing and casing of oil and gas wells.
[0010] Another object of this invention is to provide a reamer tool which can be easily adapted to and used on virtually any type of conventional oil or gas service application, including snubbing units and cable rigs, coiled tubing, drill string, cable, or electric wireline.
[0011] Yet another object of this invention is to provide a reamer tool which can be adapted with a cutlip guide to facilitate maneuvering tubing, cable, electric wireline or other objects to the center of well casing, or adapted with an overshot to facilitate dislodging and removing immobilized or inadvertently released downhole tools from the well bore or casing.
[0012] A still further object of this invention is to provide a reamer tool which can be used to penetrate tight segments of a well bore and is capable of extension through downhole valves for clearing the valves.
SUMMARY OF THE INVENTION
[0013] These and other objects of the invention are provided in a reamer tool which is capable of removing paraffin, scale, ice, salt, calcium, cement, barium and other accumulations from the inside surfaces of oil well pump tubing and casing and can easily be adapted for use with coiled tubing, cable or electric wireline, which reamer tool may include a housing for suspension in the well tubing or casing; a shaft slidably mounted in the housing; shaft threads provided on the shaft; a lock nut threadibly mounted on the shaft for removably engaging the housing; and a reset spring provided in the housing between the housing and the end of the shaft, such that displacement of the shaft in the housing causes the lock nut to engage the housing, rotate on the shaft threads and rotate the housing such that the housing rotates in the well bore or casing and removes paraffin, scale, ice, salt, calcium cement, barium or other solid blockages from the well bore or casing. The reamer tool can be fitted with an overshot to facilitate dislodging and removing downhole tools or other immobilized or inadvertently released objects from the well bore or casing, or with a cutlip guide to facilitate maneuvering downhole objects to the center of the well bore or casing, as needed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The invention will be better understood by reference to the accompanying drawings, wherein:
[0015] [0015]FIG. 1 is a perspective, partially exploded view of an illustrative embodiment of the reamer tool of this invention;
[0016] [0016]FIG. 2 is a side view of the reamer tool illustrated in FIG. 1, with the shaft partially extended from the housing;
[0017] [0017]FIG. 3 is a sectional view taken along lines 3 - 3 in FIG. 1, more particularly illustrating the reamer tool with the shaft in retracted configuration in the housing;
[0018] [0018]FIG. 4 is a sectional view, also taken along 3 - 3 in FIG. 1, of the reamer tool, more particularly illustrating the shaft partially extended from the housing;
[0019] [0019]FIG. 5 is an exploded, perspective view, partially in section, of the reamer tool;
[0020] [0020]FIG. 6 is a front or rear view of the lock nut component of the reamer tool;
[0021] [0021]FIG. 7 is a longitudinal sectional view of the lock nut illustrated in FIG. 6;
[0022] [0022]FIG. 8 is a longitudinal sectional view of another illustrative embodiment of the reamer tool of this invention;
[0023] [0023]FIG. 9 is a bottom view of the lock nut illustrated in FIG. 6;
[0024] [0024]FIG. 10 is a longitudinal sectional view of a blade base component of the reamer tool of this invention, in an illustrative application of the reamer tool; and
[0025] [0025]FIG. 11 is a side view of the reamer tool, with the blade base of FIG. 10 mounted on the reamer tool.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] Referring initially to FIGS. 1, 2 and 5 of the drawings, an illustrative embodiment of the reamer tool of this invention is generally illustrated by reference numeral 1 . The reamer tool 1 typically includes an elongated housing 19 having a top housing section 2 , a middle housing section 3 and a bottom housing section 4 , which are removably attached to each other, respectively, by means of cooperating threads, as hereinafter described. Removal of the top housing section 2 from the middle housing section 3 and the middle housing section 3 from the bottom housing section 4 , respectively, is typically achieved by applying a wrench (not illustrated) to wrench flats 13 , to unscrew the respective housing sections and disassemble the reamer 1 . Typically, as illustrated in FIG. 1, top housing internal threads 5 of the top housing section 2 receive upper external threads 9 of the middle housing section 3 , and lower external threads 9 a of the middle housing section 3 receive interior bottom housing threads 11 (FIG. 5) of the bottom housing section 4 in assembly of the housing 19 . The top housing section 2 is typically additionally secured to the middle housing section 3 by means of housing set screws 14 , which are threaded in respective top housing set screw apertures 15 , as illustrated in FIG. 5. Similarly, the middle housing section 3 is typically further secured to the bottom housing section 4 by means of additional set screws 14 , which are threaded in respective bottom housing set screw apertures 17 . The top housing section 2 is further typically provided with a top housing collar 7 , which is capped by a top housing fishing flange 8 , provided with a top housing flange aperture 36 that opens the top housing section 2 , as illustrated in FIG. 5. Similarly, the middle housing section 3 is provided with a middle housing aperture 37 at the top thereof, and is further provided with a middle housing shoulder 21 for receiving the bottom edge of the top housing section 2 .
[0027] Referring next to FIGS. 3 - 5 of the drawings, a shaft 25 , provided with course, double-lead shaft threads 29 and an upper, polished shaft segment 25 a, is inserted in the top housing flange aperture 36 (FIG. 5) of the top housing fishing flange 8 . As particularly illustrated in FIGS. 3 and 4 , the polished shaft segment 25 a of the shaft 25 projects through the top housing flange aperture 36 (FIG. 5), through the top housing collar 7 and into the top housing cavity 12 in the interior of the top housing section 2 , and through the middle housing aperture 37 into the middle housing cavity 18 of the middle housing section 3 , as illustrated in FIG. 3. The shaft 25 further extends into a spring cavity 6 of the bottom housing section 4 , as illustrated in FIG. 3. The shaft 25 is further provided with connector threads 26 at the upper end thereof for cooperating with a wire line apparatus (not illustrated), and is provided with a connector flange 27 , located immediately beneath the connector threads 26 . As illustrated in FIG. 5, the opposite end of the shaft 25 is fitted with shaft threads 34 , in order to accommodate a circular shaft nut 30 , provided with central interior nut threads 31 . It will be appreciated by those skilled in the art that the shaft threads 34 are typically provided on the shaft 25 in the same direction as the shaft threads 29 , and the shaft nut 30 is threaded to fit on the shaft threads 34 . One or more set screws 14 may be threaded through respective shaft nut set screw apertures 30 a to engage the shaft threads 34 (FIG. 5) of the shaft 25 and further secure the shaft nut 30 on the shaft threads 34 . Alternatively, it is understood that the shaft nut 30 can be characterized by a conventional, self-locking, plastic-coated nut which is adapted for mounting on the shaft 25 according to the knowledge of those skilled in the art. The shaft 25 is maintained in essentially vertical configuration inside the housing 19 by means of the top housing collar 7 . As illustrated in FIGS. 3 and 4, a thrust washer 22 is typically provided in the top housing cavity 12 , against the top housing collar 7 , and encircles the shaft 25 . A lock nut 38 , provided with a pair of downwardly-extending lock nut lugs 39 , is fitted with internal lock nut threads 40 , as illustrated in FIG. 7, and is situated in the top housing cavity 12 for threadible cooperation with the shaft threads 29 of the shaft 25 . The lock nut 38 is free to rotatably traverse the shaft threads 29 on the shaft 25 inside the top housing cavity 12 , responsive to movement of the shaft 25 between a fully extended configuration from the housing 19 , as illustrated in FIG. 4, and the retracted position in the housing 19 , shown in FIG. 3. A lock nut lug seat 42 is provided in the top housing cavity 12 at the top end of the middle housing section 3 , and is fitted with at least two lug seat slots 43 , which are typically shaped to define lug seat bevels 44 , as more particularly illustrated in FIG. 5. The lug seat slots 43 are designed to receive the respective, downwardly-extending lock nut lugs 39 of the lock nut 38 when the lock nut 38 is seated on the lock nut lug seat 42 , as the shaft 25 is forced downwardly through top housing collar 7 , the top housing cavity 12 and the middle housing cavity 18 by operation of a downward load applied to the shaft 25 . The lug seat slots 43 may be slightly deeper than the length of the lock nut lugs 39 , in order to allow the lock nut 38 to contact the lock nut lug seat 42 . As illustrated in FIGS. 3 - 5 of the drawings, the depth of retraction or closing of the shaft 25 inside the housing 19 is limited by the shaft fishing flange 28 , provided on the shaft 25 , as illustrated. The shaft fishing flange 28 is typically formed integrally with the shaft 25 for maximum strength. As further illustrated in FIGS. 3 and 4, a wiper ring 32 and an o-ring 33 , seated in respective grooves provided in the top housing collar 7 of the top housing section 2 , encircle the polished shaft segment 25 a of the shaft 25 for wiping and sealing, respectively, the polished shaft segment 25 a as the shaft 25 reciprocates in the top housing collar 7 , which wiper ring 32 maintains the polished shaft segment 25 a free from dirt and other contaminants and thus, prevents locking or sticking of the shaft 25 in the top housing collar 7 .
[0028] Referring next to FIGS. 3 - 5 of the drawings, the bottom housing section 4 of the housing 19 is characterized by an internal spring cavity 6 , which communicates with a typically smaller-diameter bottom sucker rod receptacle 4 a, provided with interior receptacle threads 4 b. A coiled reset spring 16 is fitted in the spring cavity 6 , and rests against an annular spring shoulder 6 a of the bottom housing 4 , between the spring cavity 6 and the sucker rod receptacle 4 a. As illustrated in FIGS. 3 and 4, the shaft nut 30 , provided on the bottom end of the shaft 25 , impinges against the reset spring 16 , and the reset spring 16 is compressed between the shaft nut 30 and the spring shoulder 6 a when the shaft 25 is disposed in the retracted configuration in the housing 19 as illustrated in FIG. 3. Conversely, the reset spring 16 is in the extended configuration in the spring cavity 6 when the shaft 25 is in the fully extended configuration from the housing 19 , as illustrated in FIG. 4, the purpose of which reset spring 16 will be hereinafter described. In one application of the reamer 1 , the sucker rod receptacle 4 a is capable of receiving the threaded male element (not illustrated) on the upper end of a sucker rod (not illustrated) in the well bore or tubing for loosening the sucker rod in the event that the sucker rod inadvertently becomes immobilized in the tubing, as hereinafter described.
[0029] Referring next to FIGS. 10 and 11 of the drawings, a blade base 45 , such as that described in my U.S. Pat. No. 4,452,307, can be mounted on the bottom housing section 4 of the reamer tool 1 to facilitate cleaning paraffin, scale, ice, salt, calcium, cement, barium or other material from a length or section of tubing or casing (not illustrated), as hereinafter described. The blade base 45 is tapered and, as illustrated in FIG. 10, includes a threaded base nipple 48 that threadibly engages the receptacle threads 4 b (FIG. 3) of the bottom housing section 4 , in the sucker rod receptacle 4 a thereof. Multiple set screws 14 threaded into respective set screw apertures (not illustrated) provided in the bottom housing 4 are typically caused to engage the base nipple 48 and further secure the blade base 45 on the bottom housing section 4 . As illustrated in FIG. 11, the blade base 45 is typically provided with multiple, parallel longitudinal blade slots 46 , each of which receives and mounts a corresponding blade 47 which is typically heat-treated for maximum hardness and strength and configured to define a blade head 49 that mates with a base blade support 6 at the lower, tapered end of the blade base 45 . The blades 47 are typically removably mounted in the respective blade slots 46 by means of multiple blade bolts (not illustrated).
[0030] Referring again to the drawings, in typical operation, a reamer tool 1 having a shaft 25 fitted with left-handed shaft threads 29 , is utilized to clean a length or section of tubing or casing (not illustrated), as follows. One or more spanner jars (not illustrated) are threadibly connected to the connector threads 26 of the shaft 25 , and a wire line (not illustrated) having a conventional swivel joint (not illustrated) is attached to the opposite end of the spanner jar string. The reamer tool 1 is then lifted by means of the wire line into position for insertion in the tubing or casing such that the weight of the housing 19 , in combination with the upward biasing effect of the reset spring 16 against the shaft 25 , facilitates fill extension of the shaft 25 from the housing 19 , as illustrated in FIG. 4. At this point the lock nut 38 , supported on the shaft 25 by means of the shaft threads 29 , is initially in the uppermost position in the top housing cavity 12 , against the thrust washer 22 . The lock nut 38 then rotates on the shaft 25 as it downwardly traverses the shaft threads 29 by pull of gravity, until the lock nut lugs 39 of the lock nut 38 engage the lock nut lug seats 42 of the housing 19 . The reamer tool 1 , spanner jar or jars, and wire line are then lowered into the casing or tubing string until the reamer tool 1 is prevented from further penetration by an accumulation or deposit of paraffin, scale, ice, salt, calcium, cement, barium or other material in the casing or tubing string. At this point, the wire line and spanner jar assembly are lifted in conventional fashion until the spanner jars are raised to maximum position above the reamer tool 1 , after which the spanner jars are allowed to drop and impact on the connector flange 27 of the shaft 25 . This impact initially causes the shaft 25 to downwardly traverse the top housing cavity 12 of the top housing section 2 and non-rotatably extend downwardly through the lock nut 38 , whereupon the lock nut 38 , engaging the middle housing section 3 at the lock nut lug seats 42 , rotatably traverses the shaft threads 29 of the downwardly-moving and non-rotating shaft 25 . This clockwise rotation of the lock nut 38 on the shaft threads 29 effects clockwise rotation of the housing 19 and attached blade base 45 with the lock nut 38 on the non-rotating and downwardly-moving shaft 25 , when a shaft 25 and lock nut 38 having cooperating left-hand threads are used in the reamer 1 . This rotating action of the housing 19 and blade base 45 , imparted by the rotating lock nut 38 , effects removal of the deposits which are adjacent to the blades 47 due to the rotation of the blade base 45 and blades 47 . After the initial impact between the spanner jar or jars and the connector flange 27 of the shaft 25 , the spanner jar assembly is again lifted by means of the wire line, and is again caused to impact on the connector flange 27 , thus effecting additional rotation of the reamer tool 1 and additional contact between the blades 47 and the accumulated deposits to effect additional removal of the deposits. This repetitive 1 and dropping of the spanner jar or jars to achieve impact between the spanner jar system and the connector flange 27 on the shaft 25 is continued until the shaft fishing flange 28 contacts the top housing fishing flange 8 , as illustrated in FIG. 3 of the drawings. When this configuration of the reamer tool 1 is realized, the wire line is again placed in tension and the spanner jar or jars are lifted. Accordingly, the shaft 25 is again displaced from its retracted position in the top housing section 2 and the middle housing section 3 , as the lock nut lugs 39 disengage the lug seat slots 43 and the lock nut 38 is displaced upwardly with the shaft 25 in the top housing cavity 12 . Upward movement of the shaft 25 in the top housing cavity 12 and through the top housing collar 7 is assisted by the reset spring 16 , which impinges against the shaft nut 30 and tends to reset the original position of the shaft 25 and the lock nut 38 in the top housing cavity 12 . It will be appreciated from a consideration of FIGS. 3 and 4 of the drawings that when the shaft 25 is extended from the housing 19 as illustrated in FIG. 4, the lock nut 38 is initially and transiently raised against the thrust washer 22 inside the top housing collar 7 and then rotates as it downwardly traverses the shaft threads 29 by pull of gravity. At that point, the lock nut lugs 39 of the lock nut 38 engage the lock nut lug seats 42 of the housing 19 prior to non-rotating, downward movement of the shaft 25 through the top housing cavity 12 and the lock nut 38 , as heretofore described. Any rotation of the shaft 25 with respect to the wire line is handled by means of the swivel joint, which attaches the wire line to the spanner jar system, in order to prevent the wire line from twisting.
[0031] It is understood that a shaft 25 having right-handed shaft threads 29 and a cooperating lock nut 38 can be installed in the reamer tool 1 to replace the shaft 25 and lock nut 38 having left-handed threads, as heretofore described. This replacement causes the housing 19 to rotate in a counter-clockwise direction when the reamer tool 1 is operated as described above.
[0032] It will be further understood that the reamer tool 1 of this invention can also function as a fishing tool runner by removing the blade base 45 from the bottom housing section 4 to expose the sucker rod receptacle 4 a to receive an “overshot” having a male fitting adapted for threadible cooperation with the sucker rod receptacle 4 a. A wire line and fishing tool (not illustrated) can be suspended from the overshot to effect fishing operations, and the rotational motion of the reamer tool 1 responsive to hammer jar impact can be used to free immobilized tubing, casing, tools and the like, in the hole. It is also understood that a conventional bailer (not illustrated) can be attached to the sucker rod receptacle 4 a to facilitate cutting salt, calcium, cement, barium, paraffin, ice, scale or other accumulations and removing the accumulations from the well bore in a single operation.
[0033] It will be appreciated by those skilled in the art that the reamer tool 1 of this invention can perform many of the functions which otherwise require high-cost equipment, at a fraction of the cost and time. The reamer tool 1 is capable of cutting and removing virtually any type of accumulation or deposit in an oil well tubing and casing, including salt, calcium, cement, barium, hard paraffin, ice plugs, scale and asphalt, in non-exclusive particular. Additionally, by fitting a conventional bailer (not illustrated) on the reamer tool 1 , as heretofore described, both the cutting and bailing functions of the reamer tool 1 can be performed at the same time, thus significantly decreasing the time required for the cutting and excavating operations. By fitting the reamer tool 1 with the blade base 45 (FIG. 11), the reamer tool 1 can be used to penetrate tight segments or areas in tubing string or well casing. A cutlip guide (not illustrated) can be fitted on the bottom end of the reamer tool 1 for maneuvering downhole tools or other objects to the center of the well bore or casing by operation of the reamer tool 1 . The reamer tool 1 can be adapted to and used on virtually any type of ice application, including coiled tubing, snubbing units, cable rigs and electric wirelines, in non-exclusive particular, and can further be used to clear downhole valves clogged with deposit accumulations.
[0034] Referring next to FIG. 8 of the drawings, in another embodiment of the reamer tool, generally illustrated by reference numeral 62 , the lock nut 38 has multiple lock nut lugs 39 which are upwardly-extending from the lock nut 38 in the top housing cavity 12 . Accordingly, multiple, congruent lock nut lug seats 42 , each having a lug seat bevel 44 (FIG. 5) and separated by lug seat slots 43 (FIG. 5), extend downwardly from the top housing section 2 , into the top housing cavity 12 and above the upwardly-extending lock nut lugs 39 of the lock nut 38 . A thrust washer 22 is typically seated on a washer seat 3 a inside the top housing cavity 12 . Accordingly, the lock nut 38 , engaging the shaftthreads 29 of the shaft 25 , is situated to travel downwardly through the top housing cavity 12 with the shaft 25 upon application of a repetitive impact load to the connector flange 27 of the shaft 25 , until the lock nut 38 engages the thrust washer 22 . Upon subsequent upward pressure applied to the shaft 25 by operation of the wire line (not illustrated, attached to the connector threads 26 of the shaft 25 ), the shaft 25 , assisted by the compressed reset spring 16 , initially moves upwardly with respect to the housing 19 , through the middle housing cavity 18 , top housing cavity 12 and top housing collar 7 . The lock nut 38 travels upwardly with the shaft 25 through the top housing cavity 12 , until the lock nut lugs 39 of the lock nut 38 register with and are seated in the respective lock nut lug seats 42 of the top housing section 2 . Continued upward and non-rotating movement of the shaft 25 through the top housing collar 7 causes the shaft threads 29 to progressively engage and rotate the interior lock nut threads 40 (FIG. 7) of the lock nut 38 and facilitate rotation of the lock nut 38 on the shaft 25 and consequently, rotation of the housing 19 . Accordingly, the reamer tool 62 can be used to dislodge and remove a sucker rod (not illustrated) threadibly attached to the reamer tool 62 at the sucker rod receptacle 4 a of the bottom housing section 4 of the housing 19 , for example. After full extension of the shaft 25 from the housing 19 , the spanner jar assembly (not illustrated) is again lifted by means of the wire line, and is again caused to impact on the connector flange 27 , thus effecting additional rotation of the housing 19 upon removal of the inpact load from the connector flange 27 , as needed.
[0035] Referring again to FIGS. 3, 4 and 8 of the drawings, the pitch of the shaft threads 29 is ½ inch under circumstances where the shaft threads 29 are doublelead threads. The term “double-lead” is used to characterize shaft threads 29 which begin at points on the shaft 25 which are 180 degrees apart. The double-lead shaft threads 29 serve to more efficiently permit the lock nut 38 to freely rotate inside the top housing cavity 12 when the shaft 25 is displaced in the reamer housing 19 and the lock nut lugs 39 engage the lug seat slots 43 , to rotate the reamer housing 19 . It is understood that the shaft threads 29 of the shaft 25 and the lock nut threads 40 of the lock nut 38 can be either right-handed or left-handed, depending on the desired direction of rotation of the reamer housing 19 during application of the reamer tool 1 . For example, when the shaft threads 29 of the shaft 25 and the lock nut threads 40 of the lock nut 38 are right-handed, the reamer housing 19 of the reamer tool 1 illustrated in FIGS. 3 and 4 rotates in the counterclockwise direction upon downward movement of the shaft 25 in the reamer housing 19 , whereas the reamer housing 19 of the reamer tool 62 illustrated in FIG. 8 rotates in the clockwise direction upon upward movement of the shaft 25 in the reamer housing 19 . Conversely, when the shaft threads 29 of the shaft 25 and the lock nut threads 40 of the lock nut 38 are left-handed, the reamer housing 19 of the reamer 1 illustrated in FIGS. 3 and 4 rotates in the clockwise direction upon downward movement of the shaft 25 in the reamer housing 19 , whereas the reamer housing 19 of the reamer tool 62 illustrated in FIG. 8 rotates in the counterclockwise direction upon upward movement of the shaft 25 in the reamer housing 19 . Therefore, depending upon the desired application, the reamer housing 19 of the reamer tool 1 illustrated in FIGS. 3 and 4 can be adapted to rotate downwardly in the clockwise direction or downwardly in the counterclockwise direction, depending upon whether the shaft threads 29 are left-handed or right-handed, respectively, whereas the reamer housing 19 of the reamer tool 62 illustrated in FIG. 8 can be adapted to rotate upwardly in the clockwise direction or upwardly in the counterclockwise direction, depending upon whether the shaft threads 29 are right-handed or left-handed, respectively.
[0036] While the preferred embodiments of the invention have been described above, it will be recognized and understood that various modifications can be made in the invention and the appended claims are intended to cover all such modifications which may fall within the spirit and scope of the invention.
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A reamer tool which is capable of removing paraffin scale, ice, salt, calcium, cement, barium and other accumulations from the inside surfaces of oil well pump tubing and casing, which reamer tool may include a housing for suspension in the well tubing or casing; a shaft slidably mounted in the housing for attachment to an impact device; shaft threads provided on the shaft; a lock nut threadibly mounted on the shaft for removably engaging the housing; and a reset spring provided in the housing between the housing and the end of the shaft. Displacement of the shaft in the housing causes the lock nut to engage the housing, and the lock nut rotates on the shaft threads and rotates the housing such that the housing rotates in the well bore or casing and removes the solid blockages from the well bore or casing.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims benefit of U.S. Provisional Patent Application 60/242,726, filed Oct. 24, 2000, the disclosure of which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
The present invention relates to processes for etching silicon to form macroscopic cavities within the interior of a silicon wafer, each cavity having at least one opening connecting to the exterior surface of the wafer.
A number of references teach the electrolytic etching of silicon in acidic solutions. For example, German Patent No. 3,324,232 to Foll et al. teaches an etching process whereby a number of honeycomb pattern of open cells are formed in the surface of a silicon wafer, thereby increasing its effective surface area.
U.S. Pat. No. 5,544,772 to Soave et al. proposes the fabrication of microchannel plate devices by light-assisted electrochemical etching of n-type <100> silicon. The light-assisted electrochemical etching process described in the '772 patent is applied only to n-type silicon, and a light source is required to generate surface charges so that etching may proceed.
As described, for example, in Lehmann et al., Formation Mechanism and Properties of Electrochemically Etched Trenches in N-Type Silicon, J. Electrochemical Society, Vol. 1-7, No. 2, pp. 653-659 (1990) and in U.S. Pat. No. 4,874,484, light-assisted electrochemical etching of n-type silicon produces deep channels perpendicular to the surface of the silicon. If the silicon surface is provided with pits at preselected locations, the channels form at the pits and hence at the same preselected locations. As described in these references, and in numerous other references, it has long been believed that the mechanism responsible for such selective etching limited its application to n-type silicon.
U.S. Pat. No. 5,997,713 to Beetz, Jr. et al. disclosed the successful application of controlled deep-channel etching to p-type silicon. In processes disclosed in the '713 patent, the silicon surface is provided with pits at preselected locations with the result that channels are etched into the silicon body at the same preselected locations as the pits.
Propst et al., The Electrochemical Oxidation of Silicon and Formation of Porous Silicon in Acetonitrile, J. Electrochemical Society, Vol. 141, No. 4, pp. 1006-1013 (1994), discloses the formation of deep channels at random locations in a p-type silicon body using electrochemical etching with a non-aqueous, anhydrous electrolyte. This reference does not disclose processes for etching channels at preselected locations. Moreover, this reference emphasizes that the use of aqueous electrolytes results in formation of highly branched, porous structures rather than trenches, cavities or other non-branched deep structures. Similar teachings are found in Rieger et al., Microfabrication of Silicon by Photo Etching, The Electrochemical Society Proceedings, Vol. 94-361 (1994). U.S. Pat. Nos. 5,348,627 and 5,431,776 to Propst et al. relate to this same work.
Despite these and other efforts in the art, substantial needs remain for further improvements in processes for forming buried cavities in silicon elements. It would be desirable to provide a process for forming cavities in p-type silicon at preselected locations. P-type silicon wafers are fabricated in large numbers for use in manufacture of conventional silicon semiconductor devices. Therefore, p-type wafers are readily available at low cost.
It would be particularly desirable to produce silicon elements having a number of macroscopic cavities beneath the surface of the silicon element wherein the cavities are covered by a layer of monocrystalline silicon near an exterior surface of the element. Structures having a monocrystalline region overhanging a cavity would be desirable in standard silicon device processing to produce active and passive microelectronic structures. It is not possible to produce such structures using a single-etching process by the state-of-the-art processing methods described above. While it is possible to make such overhung cavities by combinations of standard processing methods and wafer bonding, these approaches are less efficient than a single-etching process would be, because they require additional processing time, equipment and materials.
Applications such as high-speed radio frequency (RF) electronics, e.g., those used in cellular communications, require microelectronic devices having silicon layers that are electrically isolated from the bulk wafer substrate. It is desirable, but not possible in current practice, to produce such layers by removing material between the silicon layer and the bulk of the wafer in a single process. Moreover, it is desirable to produce thin layers of silicon oxide, as could be produced by etching macrocavities beneath a layer of crystalline silicon, then subjecting the remaining silicon to thermal treatment in an oxygenated environment. Such layers can be produced, at present, by SIMOX processing where oxygen atoms are injected individually beneath the surface of a silicon body, but the silicon body is subject to radiation damage that is intrinsic to the SIMOX process.
Other technologies, such as inkjet printing, slow-release drug delivery systems, and miniature reagent supply/storage reservoirs for “lab-on-a-chip” chemical analysis systems require a plurality of precisely placed reservoirs on a single chip. Under current techniques, such reservoirs are produced by etching wafers of diverse materials and bonding them to each other. It is desirable to produce such structures by a single process.
The processes used to etch voids in silicon heretofore have operated at relatively low etch rates, so that the dimensions of the voids increase at less than 1 μm per minute. It would be desirable to form cavities at a faster rate to reduce the cost of the process.
Moreover, processes which require anhydrous electrolytes incur additional costs due to the precautions that must be taken to eliminate water from the solvents and to isolate the process from moisture in the environment. These processes incur further costs associated with purchase and disposal of the required organic solvents. It would be desirable to eliminate these costs by providing an aqueous etching method.
SUMMARY OF THE INVENTION
A method according to a preferred aspect of the invention begins with providing a p-doped silicon element having front and back surfaces. The method further includes the steps of forming a plurality of pits at preselected locations on the front surface of the element and subjecting the pitted silicon element to electrochemical etching. In the electrochemical etching procedure, the front surface of the element and a counter-electrode are maintained in contact with an electrolyte while maintaining the silicon element at a positive potential with respect to the counter-electrode. A patterned electrode provides electrical contact at the back surface of the element within discrete regions which are aligned with the pits of the front surface. The element is etched preferentially at the pits to form cavities beneath the wafer surface. The silicon body is maintained at a positive potential relative to the counter-electrode, and the electrochemical cell is operated at a constant current density throughout the etching process. Preferably, the current density is maintained at a value on the order of twenty times as large as the current densities typically used to etch p-type silicon. More preferably, the current density is maintained at a value between 0.05 and 0.9 amps/cm 2 , most preferably at a value of about 0.4 amps/cm 2 . As cell impedance decreases, the voltage is allowed to decrease so that the current density is maintained near a constant value.
The term “p-doped silicon” as used in this disclosure refers to silicon having an appreciable quantity of p-type dopants such as B, Al and Ga, which tend to form positively charged sites, commonly referred to as holes in the silicon crystal lattice. Desirably, the silicon element contains at least about 10 14 and more preferably at least about 10 15 atoms of p-type dopants per cubic centimeter. The silicon element therefore has an appreciable number of holes in the silicon crystal lattice. The p-type material may optionally include some n-type dopants as well as the p-type dopants, and its electrical characteristics may be p-type, n-type or compensated. Most typically, the material is doped only with p-type dopants, or with an excess of p-type dopants over n-type dopants, and hence exhibits p-type electrical conductivity with holes as the majority carriers.
This aspect of the present invention incorporates the discovery that when a p-doped silicon body is provided with pits at preselected locations in its exposed surface, electrochemical etching will proceed at these preselected locations. Most preferably, the silicon element is substantially monocrystalline silicon, such as a wafer of the type commonly used in a semi-conductor fabrication or a portion cut from such a wafer. Desirably, the exposed surface of the silicon element is a <100> surface of the crystal.
According to a particularly preferred aspect of the invention, the electrolyte is an aqueous electrolyte which includes fluoride ions and a surfactant. The aqueous electrolyte desirably has a pH of about 1 to about 4, more desirably about 2 to about 4 and most desirably about 3 to about 4. Most desirably, the electrolyte includes an acid other than hydrofluouric and a fluoride salt as a source of fluoride ions. Whether the fluoride ions are added as HF or as salt, the resulting electrolyte contains some HF. The aqueous electrolyte desirably has an HF concentration at least 0.25 M and more desirably between about 0.25 M and 10 M. HF concentrations of about 1.5 M to about 2 M are most preferred. Inorganic acids and salts are preferred. For example, the electrolyte may include HCl and NH 4 F. This preferred aspect of the present invention incorporates the realization that the teachings of the art, to the effect that etching of the p-type silicon with an aqueous electrolyte will result only in a branched microporous structure, are incorrect.
The most preferred processes do not require either the expense of anhydrous processing or the expense and hazards associated with handling and storing liquid HF as a starting reagent.
Methods according to the foregoing aspect of the present invention can be used to fabricate structures with numerous macrocavities buried within p-type silicon elements. The cavities can be placed at any desired locations on the silicon element. Etching p-doped monocrystalline silicon according to the preferred processes of the invention produces macroscopic cavities buried within the body with a uniform layer of crystalline silicon overlying the macrocavity. The thickness of the layer can be controlled by the initial diameter of the pits etched into the front surface of the silicon element. The use of particularly preferred etching processes produces monocrystalline silicon bodies wherein at least a major portion of the volume below the layer of crystalline silicon has been etched away, effectively isolating the silicon layer from the rest of the silicon body. An etching process according to the present invention may also be used to fabricate a silicon body having a single macrocavity with an overhanging layer of crystalline silicon, with the macrocavity occupying a major portion of the planar area beneath the surface of the silicon body.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1-4 are fragmentary diagrammatic sectional views of a silicon element at progressively later stages of treatment in a manufacturing process according to an embodiment of the present invention.
FIG. 5 is a microphotographic sectional view at 125× magnification of a silicon element etched according to an embodiment of the invention.
DETAILED DESCRIPTION
A preferred process, according to one aspect of the present invention, for fabricating a microchannel plate from a p-type silicon wafer begins with providing a p-type silicon element such as a substantially monocrystalline p-doped silicon wafer 10 having a front surface 12 and a rear surface 22 . Front surface 12 is oxidized or nitrided to form a front surface layer 16 . A pattern is transferred into front surface layer 16 using standard photolithographic techniques. The pattern may consist of any desired arrangement of circular or other shaped holes or apertures 18 . The pattern of holes, for example, may be a square array of 30 μm diameter circular holes arranged on 300 μm centers. The number and location of holes may be determined by the number and size of the desired macrocavities. Silicon elements with as few as one cavity may be produced. The pattern of holes is transferred to the silicon oxide/nitride surface by coating the surface with a photoresist (not shown), properly curing the photoresist, and then exposing the photoresist-covered surface with an appropriate light source that has passed through a photolithographic mask containing the desired pattern of openings. The photoresist is then developed, and the oxide or nitride layer is then etched using either wet or dry etching techniques to expose the underlying silicon substrate. The photoresist mask may then be removed. The silicon substrate is then etched in a separate step to form depressions or pits 20 in the silicon exposed by the opening 18 in layer 16 . Pits 20 serve as preferential etch sites during the electrochemical etching process. A preferred method for making these depressions is to anisotropically etch the silicon in a solution of potassium hydroxide to produce an array of pyramidal pits in the <100> silicon surface having the same periodicity as the pattern on the photolithographic mask. The silicon oxide/nitride layer 16 may then be removed. Preferably, the resulting pits have relatively large, open ends at the front surface 12 and relatively small ends pointing into the silicon element toward the rear surface 22 .
A patterned electrode is provided to establish electrical contact with discrete regions of back surface 22 . Preferably, at least some of these regions are aligned with at least some of the pits 20 in front surface 12 . Preferably, patterned electrode 32 is formed on the back surface of the wafer 10 . More preferably, back surface 22 is oxidized or nitrided to form back surface layer 26 , and openings 28 are created within the oxide/nitride layer, exposing back surface 22 within discrete regions of back surface layer 26 . The same photolithographic techniques may be used to create a pattern of openings in back surface layer 26 as were used to create openings in front surface layer 16 . Preferably, the pattern consists of openings 28 which are aligned with openings 18 in front surface layer 16 . The pattern may be transferred and the exposed oxide/nitride areas etched as described above. In contrast to the method of preparing front surface layer 16 , it is preferred that back surface layer 16 not be subjected to an anisotropic etch. The back side of the wafer 10 is then implanted with boron to produce a heavily doped region near back surface 22 of wafer 10 . Following boron implantation, metal is deposited onto back surface layer 26 to form the patterned electrode 32 . This metallization step may comprise evaporating aluminum metal onto back surface layer 26 and openings 28 and providing a consolidating heat treatment at temperatures of about 400° C. to about 480° C. to form a good low-resistance contact with wafer 10 at regions 28 . 24 The wafer 10 is then placed into an electrochemical cell with front surface 12 facing into the cell cavity. The ratio of the exposed surface area of the silicon wafer 10 to the exposed surface area of the counter-electrode 34 may be from about 0.2 to about 100. The cell has a platinum cathode or counter-electrode 34 , and silicon wafer 10 serves as the anode. The cell is filled with an aqueous electrolyte 36 containing fluoride and desirably having a pH of about 1 to about 7, more desirably between about 3 and about 4. The fluoride concentration desirably is about 0.25 to about 5 M. The electrolyte may consist essentially of HF and water, and a surfactant. More preferably, the electrolyte includes an acid other than HF and a fluoride salt, with or without a surfactant. Inorganic acids and salts are preferred. The preferred inorganic acids include HCl, H 2 SO 4 and H 3 PO 4 , whereas the preferred inorganic fluoride salts include NH 4 F and flouroborate salts such as NH 4 BF 4 , and HBF 4 . The surfactant may be anionic, cationic or nonionic. Suitable surfactants include ethanol, formaldehyde and the material sold under the trademark Triton X-100. The surfactant is added in an amount effective to promote wetting of the silicon surface by the electrolyte. Aqueous electrolytes and etchants disclosed in commonly assigned U.S. Pat. No. 5,997,713, the disclosure of which is incorporated by reference, are suitable for use in preferred processes of the present invention.
The wafer 10 is biased to a positive voltage relative to counter-electrode 34 . The cell is operated at initial voltages in excess of 5 volts up to as much as 25 volts. The cell is operated in a current-controlled mode so that as the cell impedance decreases, the voltage also decreases so as to maintain the electrochemical current density near a constant value. Preferably, the cell is initially biased to produce an electrochemical current density on the order of 20 times larger than the current densities typically employed in ordinary anodic etching of p-type silicon as practiced, for example, in commonly owned U.S. Pat. No. 5,997,713. More preferably, the current density is maintained at a value between 0.05 and 0.9 amps/cm 2 based on the area of the exposed silicon surface without considering any increase in surface area due to the presence of pits or cavities. Most preferably, the current density is maintained at a value of about 0.4 amps/cm 2 . Under the preferred conditions, the electrochemical cell operates at higher voltages than are normally employed to etch p-type silicon. The largest voltage drop occurs at the silicon-electrolyte interface, so that electrons entering the silicon during removal of a silicon atom from the surface of the cavity are injected into the body of the silicon element with an excess kinetic energy. These energized electrons then produce impact ionization that locally accelerates the etching process.
Under the preferred operating conditions, a nearly isotropic etching proceeds from the tip of etch pit 20 in contact with the etchant 36 . The etch front propagates parallel to the front surface 12 , causing lateral expansion of the cavity, e.g., from sidewall location 46 a to sidewall location 46 , and towards the back surface 22 causing extension of the cavity, e.g., from back wall location 44 a to back wall location 44 . Expansion toward front surface 12 is negligible, resulting in formation of an overhanging layer 42 of monocrystalline silicon. These movements of the etch front appear to occur because the regions from which current can originate are limited to those regions where electrode 32 contacts back surface 22 . The electrons are swept to these contact points by the applied electric field, preventing the etch front from propagating toward front surface 12 . The use of a patterned electrode 32 also induces a higher operating voltage for a given current density relative to the voltage required for a wafer having an electrode in contact with the entire back surface 22 . As the cavity enlarges, the voltage on the cell decreases due to the increasing surface area being etched.
Etching processes according to preferred embodiments of the invention lead to the etching effects shown in FIG. 5 which shows the front surface 52 of the silicon element, the overhanging layer of monocrystalline silicon 62 , macroscopic cavities 60 and wafer back side 54 . Back wall 64 and side walls 66 of cavities 60 are also shown. The openings in front surface 52 , similar to openings 20 in front surface 12 shown in FIG. 4, are not visible in the cross-section of FIG. 5 .
The thickness of overhanging silicon layer 62 is substantially uniform across the planar area occupied by macrocavities 60 . The thickness of overhanging layer 62 may be controlled by the initial depth of pit 20 , which will be approximately the same as the diameter of the opening 18 . This effect appears to be determined by the geometry of the silicon crystal. When the exposed surface of the silicon element is a <100> surface of the crystal, the caustic anisotropic etch produces a pit that has a sloping wall along the <111> plane, i.e., 54 degrees off the vertical plane relative to the exposed surface, and is, therefore, approximately as deep as opening 18 is wide. Since etching proceeds most rapidly along the <100> plane, the etching front moves parallel to front surface 12 , resulting in an overhanging layer 62 that has a thickness roughly equivalent to the initial depth of pit 20 .
Under preferred embodiments of the etching process, the extent of the lateral expansion of the macrocavities is self-limiting. The final thickness of sidewall 66 between adjacent cavities 60 is about two to three times the diameter of the opening for the illustrative sample presented herein. The ratio of wall thickness to the diameter of the opening in the front surface of the silicon body can be controlled by altering the resistivity of the silicon element, higher resistivity resulting in a greater final thickness of sidewall 66 . The back wall 64 of cavity 60 continues to move toward back surface 54 after lateral expansion ceases. The lateral extent of the cavities is limited by the spacing of the openings in front surface 52 and the thickness of sidewalls 66 .
The self-limiting nature of the lateral expansion creates sidewalls that effectively isolate adjacent macrocavities from each other. The resulting macrocavity is physically isolated from the adjacent cavities and communicates with the exterior of the silicon element only through the initial opening etched in the front surface 52 . The pyramidal shape of back walls 64 apparently is controlled by the geometry of the crystal as discussed with regard to pits 20 .
In another preferred aspect of the invention, a single pit is etched into front surface 12 of silicon body 10 . Electrode 32 is provided to establish electrical contact within a discrete region of back surface 22 , preferably aligned with the pit formed in front surface 12 . The etching process proceeds as described herein, resulting in a silicon body 10 having a single macrocavity with an overhanging layer of crystalline silicon. Operating conditions of current density and duration, and the resistivity of silicon body 10 , are selected to control the extent of etching. These conditions may be adjusted to produce a silicon body in which the macrocavity occupies a major portion of the planar area beneath the front surface 12 .
According to other preferred aspects of the invention, the electrolyte may be a non-aqueous electrolyte such as anhydrous acetonitrile with tetrabutylammonium perchlorate and hydrogen fluoride. Other non-aqueous electrolytes such as dimethylformamide, dimethylsulfoxide, diethylene glycol, propylene carbonate, methylene chloride and the like may be employed. Sources of fluoride ions other than HF may also be employed in the non-aqueous electrolyte. Tetrabutyl ammonium perchlorite may be added to increase the electrical conductivity of the electrolyte. Other additives may be employed for the same purpose. Several non-limiting examples of non-aqueous electrolytes that are suitable for use with the present invention are disclosed in commonly assigned U.S. Pat. No. 5,997,713. When using a non-aqueous electrolyte, it is important to keep the residual amount of water in the solution low, i.e., at less than 100 ppm. Preferably, initial current densities in accordance with the present invention will be on the order of 20 times as great as those disclosed in the examples of U.S. Pat. No. 5,987,713.
The etching processes discussed above are light-insensitive. The processes do not depend upon the presence of light for operation, and can be conducted in essentially any lighting conditions, including the complete absence of light or normal room lighting. Although some holes may be formed in the p-doped silicon by incident light, such holes are insignificant in comparison to the number of holes present as a result of p-doping.
The following non-non-limiting example describes the conditions under which the etching effects shown in FIG. 5 were produced:
A 200 mm diameter silicon wafer was patterned with 30 micron openings on 300 micron centers using conventional semiconductor processing techniques.
The patterned silicon was then subjected to an isotropic KOH etch to produce a pyramidally-shaped depression in the silicon surface. The masking layer on the front surface of the wafer was then removed. A pattern of 30 micron openings on 300 micron centers was patterned on the back surface of the wafer, also using conventional semiconductor processing techniques, with the pattern array aligned to the pattern on the front side of the wafer. The back side of the wafer was then implanted with boron in the patterned area, and the wafer back side was metallized and given a consolidating heat treatment at about 400° C. The wafer was placed in an electrochemical cell containing the following electrolytes and operating at the specified voltages and current density. The silicon wafer was biased to a positive potential relative to a platinum wire cathode.
1.
Electrolyte
NH 4 F (40 wt % aqueous solution)
700 ml
HCl (36.5 wt % aqueous solution)
300 ml
H 2 O
2100 ml
2.
Cell Operating Conditions
Initial: 18 mA at 25 V
Final: 18 mA, 1 V
Duration: 4 hours
Typical etch rates under these conditions are 100 to 150 microns per hour.
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 to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.
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A silicon element having macrocavities beneath its exterior surface is fabricated by electrochemical etching of a p-type silicon wafer. Etching at a high current density results in the formation of deep macrocavities overhung by a layer of crystalline silicon. The process works with both aqueous and non-aqueous electrolytes.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is related to drilling and mining processes and, more particularly, but not by way of limitation, to a mining system incorporating hydraulic, borehole mining techniques particularly adapted for the recovery of coal from relatively thin coal seams.
2. History of Related Art
The recovery of coal from coal seams has been the subject of technical development for centuries. Among the more conventional mining techniques, hydraulic mining systems have found certain industry acceptance. Hydraulic mining typically utilizes high pressure water jets to disintegrate material existing in strata or seams generally disposed overhead of the water jets. The dislodged material is permitted to fall to the floor of the mining area and is transported to the mining surface via gravity and/or water in a flume or slurry pipeline. Along these lines, certain developments in Russia included a series of hydro monitors capable of extracting a strip of coal 3 feet wide and 30 to 40 feet in depth within a matter of minutes. The units were designed to be conveyed on a track to the advancing coal face for extracting the coal. The coal would flow downwardly and be transported to the surface via a flume. Similar techniques to this have found commercial acceptance in China, Canada, and Poland, but with only limited attempts in the United States.
Although not as widely accepted in the United States, hydraulic mining methods have been the subject of numerous U.S. patents. U.S. Pat. No. 3,203,736 to Anderson describes a hydraulic method of mining coal employing hydraulic jets of water of unusually small diameter to cut the coal. Such techniques would be particularly applicable to steeply dipping coal seams. Likewise, U.S. Pat. No. 4,536,052 Huffman describes a hydraulic mining method permitting coal removal from a steeply dipping coal seam by utilizing a vertical well drilled at the lowest point of the proposed excavation. Another slant borehole is drilled at the bottom of the coal seam to intersect with the vertical well. High pressure water jets are then used to disintegrate the coal in a methodical fashion with the resulting slurry flowing along the slant borehole into the vertical well. Once in the well, this coal slurry could be pumped to the surface of the mine. While effective in steeply dipping coal seams where gravity would allow the slurry to flow to the vertical well, other techniques would be necessary for more horizontal mining systems. Additionally, U.S. Pat. No. 4,878,712 to Wang teaches the use of water jets to remove horizontal slices of coal within a seam. Through the sequential mining of layers in this manner from top to bottom, the entire seam of coal can be extracted and the mine roof subsides onto the floor without need for artificial roof support.
Another technique for extracting minerals from subterranean deposits is the above referenced borehole mining. Such techniques create minimal disturbance at the mining surface while water jets are used to cut or erode the pay zone and create a slurry down hole. A sump is created below the pay zone to collect the produced cuttings and slurry, which is transported to the surface via a jet or slurry pump. A wide variety of minerals, primarily soft rock formations, may also be mined utilizing this technique. A more recent borehole mining technique is described in U.S. Pat. No. 3,155,177 to Fly wherein a process for under reaming a vertical well and a hydrocarbon reservoir is shown. The technique illustrated therein utilizes electric motors to convert the apparatus from drilling to under reaming.
More conventional techniques are seen in U.S. Pat. Nos. 4,077,671 and 4,077,481 to Bunnelle which describe methods of and apparatus for drilling and slurry mining with the same tool. A related borehole mining technique is shown in U.S. Pat. No. 3,797,590 to Archibald which teaches the concept of completely drilling the vertical well through the portion of the strata to be mined. Separate lines are used for water jet cutting and slurry removal. A progressive cavity pump is used to transport slurry to the surface. In the later improvement (U.S. Pat. No. 4,401,345) the cutting tool is moved independently from the pumping unit. Later developments are shown in U.S. Pat. No. 4,296,970 which describes the use of various types of rock crushers at the inlet of the jet pump. A feed screw on the bottom of the drill string is used to meter the flow of slurry into the orifice of a venturi in association with the rock crusher. In a subsequent development (U.S. Pat. No. 4,718,728), it is suggested to use a tri-cone bit assembly on the end of the tool to reduce the particle size to allow slurry transport. In U.S. Pat. No. 5,197,783 an extensible arm assembly is incorporated to allow the water jet cutting mechanism to extend outwardly from the borehole mining tool to provide more effective cutting in the water filled cavity.
Complementing some mining techniques is the J. H. Fletcher & Co. Model LHD-13 long hole drill unit. This unit consists of a drilling system disposed upon a four wheeled tender car having a drill boom and carriage. Roof jacks are also included and the system is generally used to install in-mine methane drainage boreholes in advance of gassy coal mines.
The above described mining techniques present methods of and apparatus for mineral excavation for sites with specific geological characteristics. In the main such characteristics include steeply dipping coal seams and/or gravity to facilitate transport of the coal to the surface. Transport of the coal, however, is not the only design problem. The distance between the cutting face and the water jet unit increases as material is eroded away. Cutting effectiveness therefore decreases until the unit is moved. These specific design points have been referred to above and are areas of continued technical development. This is particularly true due to the fact that in borehole mining, cutting effectiveness of the water jets also decreases as the cavity becomes larger in size. When the cavity reaches a point that cutting effectiveness diminishes, either another vertical well must be installed to initiate another cavity or the cutting unit needs to be moved closer to the coal face. Also, when a cavity is created in unconsolidated material, subsidence may be created and the cavity may collapse. Borehole mining is, therefore, referred to as a selective mining technique and may not always be suitable for low cost extraction on a large scale basis. Borehole mining is also generally constrained by the ability to remove material from the sump as described above. It would be an advantage therefore to overcome the problems of the prior art by providing a system for horizontal remote mining capable of addressing low cost and effective mineral excavation while effectively utilizing cutting techniques that are consistent with material removal methods therewith.
The present invention provides such an advance over the prior art by utilizing a continuously advancing horizontal remote mining unit that may be disposed within a coal seam close to the face of the coal being eroded. In this manner, a horizontal remote mining unit may develop a horizontal in-seam excavation with improved cutting and slurry removal effectiveness.
SUMMARY OF THE INVENTION
The present invention relates to horizontal mining methods for thin seam coal deposits and requisite mining systems therefor. More particularly, the present invention relates to a horizontal remote mining unit comprising a water jet cutting head, down hole crusher, jet pump, and guidance system for orchestrating select excavation of a borehole or tunnel. The terms "tunnel" and "borehole" will be used interchangeably hereafter when referring to the methods of and apparatus for the present invention. The unit will be assembled on the end of a drill string comprised of multiple compartments accommodating various water pressures and functions in association with the remote excavation process. Selective tubing may also be utilized to facilitate movement of air and ventilation of the borehole in the event an accumulation of methane gas or the like is encountered. A high pressure water line may also be used to deliver water pressures between 1000 psi and 5000 psi and volumes of 50 to 500 gpm, in accordance with the principles of the present invention.
Another aspect of the above described invention would generate a series of boreholes spaced to allow relatively small pillars between tunnels for creating roof support. Such a method and system could eliminate and/or reduce the need for a conventional roof support systems typical of long wall or room and pillar mining.
In another aspect, the present invention enhances water jet effectiveness under water or in air by keeping the water jet nozzle close to the cutting face at all times. This is accomplished by advancing the water jets via a horizontal drill unit in conjunction with or independent of a hydraulically driven down hole crawler. In certain applications, materials other than coal may be excavated.
In yet another aspect, the above described invention includes a down hole guidance system to maintain alignment of the excavation parallel with the previous borehole and avoid intersection therewith while assisting and maintaining the borehole within the confines of the coal seam. The final borehole diameter would be tailored to the thickness of the coal seam with the borehole drilled as long as practical with an objective length of 1,000 feet. In this manner, rapid penetration rates may be utilized with water jetting systems. In one embodiment, the present invention includes a mechanically assisted cutter head. Coal excavated therewith would be transported to the well head with a jet pump through reverse circulation back through the discharge pipeline. The jet pump would be incorporated in the downhole end of the discharge pipeline to assist in removal of produced coal. The jet pump in conjunction with reverse circulation would allow the use of acceptable water flow rates, pressure and velocity in order to maintain the produced coal and suspension for routing to the well bore or to the mining surface. In one embodiment, the coal would be conveyed to the surface via a belt line or slurry pipeline, with additional coal de-watering and processing conducted on the surface for final coal processing before delivery and sale.
In a further aspect, the present invention comprises a method of horizontal borehole mining of relatively thin seam coal deposits. The method includes the steps of defining an area for horizontal borehole mining and excavating access tunnels therealong and/or therearound. A borehole mining unit is positioned in the access tunnel and generally horizontal boreholes are execavated therefrom. The boreholes are spaced to form roof support webs therebetween. The coal is excavated by a waterjet cutting head and discharged therefrom by a jet pump positioned near the cutting head. In one embodiment the access tunnels are boreholes extending transversely thereacross.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the method and apparatus of the present invention may be had by reference to the following Detailed Description when taken in conjunction with the accompanying Drawings wherein:
FIG. 1 is a side elevational, cross sectional, diagrammatical view of one embodiment of a mining system utilizing the principles of the present invention.
FIG. 2A and 2B are front elevational, diagrammatical, cross sectional views of excavation configurations utilizing the system of FIG. 1 and taken along lines 2--2 thereof;
FIG. 3 is a side elevational, cross sectional, diagrammatical view of one embodiment of the system of FIG. 1;
FIG. 4 is a top plan, cross sectional, diagrammatical view of the system of FIG. 1;
FIGS. 5A and 5B are front elevational, diagrammatical, cross sectional views of pipeline configurations for the system of FIG. 1;
FIG. 6 is a side elevational, cross sectional, diagrammatical view of an alternative embodiment of the system of FIG. 1; and
FIG. 7 is a top plan, diagrammatic view of a defined area for the horizontal mining operations of the present invention; and
FIG. 8 is an enlarged top plan, diagrammatic view of a portion of the access tunnel 18A.
DETAILED DESCRIPTION
Referring first to FIG. 1, there is shown a side elevational, cross sectional, diagrammatical view of one embodiment of a mining system utilizing the principles of the present invention. System 10 is shown disposed in a tunnel 12 of a coal seam 14 located beneath layers of earth 16. A vertical shaft 18 connects an above ground dewatering and coal recovery plant 20 on surface 21 to the tunnel 12 which terminates at cutting face 13. Coal 22 is mined from face 13 of seam 14 partially dried at separator/pump 32, and carried to the surface 21 by a network of devices described below. It should be noted that FIG. 1 is only a general schematic. There may be numerous tunnels 12 developed throughout the coal seam 14. There may be limited shafts 18 and access tunnels 18A (described below). The wellhead will be the term that is used to describe the start of each borehole tunnel 12 along the access tunnel 18A. The devices of the present invention thus provide means for mining coal 22 that is not available to conventional mining techniques, because conventional underground and surface highwall coal mining techniques are generally not cost effective for extraction of thin (e.g. less than 36" in diameter) coal seams. The present invention allows the economic extraction of such thin coal seams that could be used on a flat or moderately pitched coal seam. As described below, the system 10 uses water jet nozzles or water jet assisted mechanical techniques to erode the coal face. A down hole crusher 180 is integrated with a jet pump 183, wherein the crusher prevents clogging of coal from the inlet of the jet pump. Coal is then transported to the wellhead via a plastic coal slurry discharge pipeline 28. Packer 33 is an inflatable (with compressed air, water, or other liquid/gas medium) rubber element that enables the downhole portion of tunnel 12 to be isolated from the pumps, drill unit, and manpower working area. Isolation of the working face allows a differential pressure to be created which may facilitate removal of coal 22 out of the borehole. These aspects and others will now be set forth with the degree of specificity deemed necessary for those skilled in the art.
Referring still to FIG. 1, the system 10 includes a hydraulic cutting head 24, such as a water jet assembly mounted upon a moveable frame or crawler 26. the crawler 26 allows the cutting head 24 to advance into seam 14 at the end of a drill string 25 which includes the discharge pipeline 28, high pressure waterline 160, and jet pump pipeline 188. A discharge pipeline 28 is also mounted to the crawler 26 for carrying removed coal 22 and liquid back through tunnel 12 to a collection trough 30, wherein the coal 22 may be collected and returned to the surface 21.
The present invention thus presents a horizontal remote mining system utilizing waterjet drilling. Waterjets without the aid of mechanical cutting devices are very useful for drilling into coal. This is because of the relative ease with which water can cut coal, in contrast to other, harder rocks. It is well known that in coal, the ability of the waterjet to cut at a considerable distance from the nozzle and to drill holes of relatively large diameter is enhanced because of the unique structure of the coal. Waterjets take advantage of the face and butt cleats and its weakness in tension. The result is that water jets can cut and move large volumes of coal with little effort. Furthermore, tailoring the cutting pressures may allow the selective extraction of coal and not roof or floor strata. Cutting pressures between 1000 and 5000 psi are currently projected. However, it has been shown through other borehole mining operations that water jets may produce oversized pieces of material. This issue requires a downhole crusher to effectively convey produced material out of the borehole. The water jet nozzles could be positioned offset from the cutting head axis. The cutting head would be connected to a downhole swivel and allow rotation of the cutting head downhole and eliminate rotation of the drill string. Dual compartment drill strings have also been used for both cutting and coal transportation out of a borehole. The primary problem encountered in certain of those studies was removing cuttings. For this reason, augers have been tested to convey the coal out of the borehole. Additionally, systems have been developed by others for specialized applications, including (1) drilling small diameter boreholes in advance of mining for exploration and methane drainage and (2)retro jets to assist drill rods in penetrating small diameter boreholes. For these reasons, the present invention utilizes the advantages of many of these types of systems and new innovations in a system 10 specifically adapted for remote penetration through a horizontal coal seam 14.
Referring now to FIGS. 2A and 2B, there are shown front elevational, diagrammatical, cross-sectional views of excavation configurations. The views are taken along lines 2--2 shown in FIG. 1. What is shown in FIG. 2A is a series of circle shaped excavations 100 formed in a coal seam 14 of earth section 16. The excavations 100 are each separated by webs 110 of coal that are left to provide roof support. The discharge pipeline 28 is also shown for reference purposes.
FIG. 2B illustrates an alternative embodiment of an excavation configuration depicting pie shaped excavations 120 formed in coal seam 14 of earth section 16. A "pie" shaped excavation 120 would not likely allow rotation of the entire cutting head 24 but would facilitate coal removal from the borehole. A shield, described below, would be used in conjunction with a protruding pipe in both round and pie shaped tunnels 12 to prevent inadvertent advancement of the horizontal remote mining unit 10 into the face faster than it is cut. A web 140 is again left for structural reasons. This figure also illustrates the discharge pipeline 28 disposed in lower sections 148 of excavation 120. In this particular embodiment, water 150 may be incorporated for lubricating, floating or otherwise facilitating the movement of a frame such as the crawler 26 of FIG. 1.
Referring now to FIG. 3, there is shown a side elevational, cross sectional, partial, diagrammatical view of one embodiment of the system 10 of FIG. 1. High pressure water is routed to the cutting head via a high pressure water hose 160. The cutting head 24 comprises a high pressure water jet nozzle assembly 161 protected by a shield 162. High pressure steel pipes 165 emanate out of a nozzle head 167 to distribute high pressure water to the water jet nozzles 170 distributed across the cutting face. The coal face is cut by the rotating water jets which may be assembled in a configuration slightly offset from the axis of the cutting head to induce torque. The cutting head 24 may be connected to a swivel in nozzle head 167. Alternatively, a rigid drill string may be rotated by the drill unit. The cut coal 22 falls to the floor and is directed into a down hole crusher 180 where oversized pieces are reduced to a manageable size. Suction is created by a jet pump 183 which conveys coal into the discharge pipeline 28. A guidance system 185 may be provided to provide survey data to allow directional control of the borehole and avoid intersection of adjacent boreholes. The cutting head 24 continues to advance horizontally into the coal face through the progression of the down hole crawler 26 that pulls the discharge pipeline 28 operated in conjunction with a long hole directional drill that would push the down hole tools. Not shown for clarity are the side portions of the crawler 26, as seen in FIG. 5A and 5B, that will preferably be formed to curve up on each side of system 10. Attached to these sides of the crawler will be flexible stainless steel straps to secure system 10.
Still referring to FIG. 3, several operational aspects are herewith addressed. The downhole crushers are preferably hydraulically driven to break up oversized cuttings of coal 22 to prevent blockage of the jet pump inlet. The jet pump 183 is a device in which a jet of fluid (in this case, water) is used to move more fluid. The principle is fluid dynamics. The jet pump preferably has no moving parts. The water jet creates a differential pressure at the inlet by directing a high pressure stream of water through an eductor which is connected to the downhole crusher 180 at the inlet and to the discharge pipeline 28 at the outlet. Water and coal production are drawn into the crusher 180 and accelerated into the discharge pipe 28 by the high velocity water stream. It is projected that each crusher 180 may require 5-100 gpm @ 100-500 psi. The jet pump(s) 183 may require 100-1000 gpm @ 100-500 psi.
Referring now to FIG. 4, there is shown a top plan, cross sectional, diagrammatical view of one embodiment of the system of FIG. 1. It may be seen that the cutting head 24 is positioned in front of a pair of downhole crushers 180 configured in flow communication with jet pumps 183. Both jet pumps 183 are fed by a common water line 188 and then feed a common discharge pipeline 28. High pressure water hose 160 is shown delivering water to the water jet nozzle assembly 161 protected by shield 162. The nozzle head 167 preferably integrates a swivel assembly to allow the high pressure water hose 160 to remain stationary and rotate the cutting head 24 as appropriate.
Referring now to FIGS. 5A and 5B, there are shown elevational views of a diagrammatical type of the drill string 25 and pipeline configurations taken from the front or beginning, of the tunnel 12 looking therein. This view is also taken in cross-section illustrating the coal seam 14 and earth 16. For purposes of clarity in this diagrammatical representation, many of the other elements of the system 10 are not shown. What is shown is a cross sectional view of the pipelines, hoses, and crawler 26 that will be used for the system 10. FIG. 5A shows that each of the lines can be installed separately and independently. The largest diameter pipe is the discharge pipeline 28. The discharge pipeline transports produced coal from the cutting face to the wellbore in slurry form. The jet pump water line 188 provides water at sufficient flow and pressure to activate the jet pumps 183 to induce a suction on the downhole crusher 180 (both shown in FIG. 4) at the cutting face 13. The high pressure water line 160 provides water to the water jet nozzles 170 (FIG. 3) to erode the coal from the face 13. System 10 preferably includes intake line 179 and return line 181 comprising ventilation lines for basic ventilation at the face 13 during development of the tunnel 12. Fresh air is forced down the intake line 179 and sweeps and dilutes any gas accumulation and is routed out of the borehole through the return ventilation line 181.
Referring now to FIG. 6, there is shown a side elevational, cross sectional diagrammatical view of an alternative embodiment of the system 10 of FIG. 1. In this view, a pilot borehole 200 is formed by a water jet downhole motor 202. A bent housing 204 is shown connected to a steering tool 206 extending in seam 14. In one embodiment, water jet cutting head 24 is mounted on a crusher 180, and the bent housing 204 is rotationally mounted to the crusher 180 on a bearing means 207. A water jetcutting head 24 is schematically shown eroding face 13 of seam 14. The eroded coal 22 is then flushed by water into the crusher 180, which is connected to a jet pump 183. Crawler 26 advances the system 10 forward to keep close to the eroding face 13. The water and coal 22 forms a slurry which is carried out the tunnel 12 by return pipe 28.
Still referring to FIG. 6, the borehole 200 is directionally drilled and required to maintain the borehole within the coal seam. However, cutting pressures may be able to be monitored to cut coal and not rock. This design would build on previous efforts by University of Missouri and University of Queensland by including a steering tool, reaming device, and address coal removal through a jet pump, coal crusher and reverse circulation. The borehole 200 is directionally drilled with small diameter, downhole motor 202 in conjunction with bent housing 204 and existing drilling technology used in conventional directionally drilled horizontal boreholes. Steering of the pilot borehole would be accomplished with a real time measurement while drilling ("MWD") steering tool 206 located in the drill string behind the small diameter water jetting tool 202. The water jetcutting head 24 would be installed behind the steering tool 206 and enlarge the pilot borehole 200 to the final borehole design for tunnel 12. The pilot borehole 200 drilled to initiate tunnel 12 could be enlarged to create a final excavated area of approximately 10 ft. 2 . The pilot borehole 200 may be directionally drilled and the reaming by water jet cutting head 24 may be controlled to avoid intersection with the adjacent tunnels shown in FIGS. 2A and 2b. The drill string will include a separate external high pressure hydraulic hose for the high pressure (e.g. 5000-10,000 psi) water required for coal cutting and a 6"-8" pipe for coal transport. Using this approach, the system 10 could achieve a coal cutting and removal rate of 40 tph for a single unit operation. This rate is greater than coal removal through many conventional and reverse circulation systems. Conventional circulation of most wells consists of pumping drilling fluid through the drill string and circulating the cuttings up the annulus to the surface. Typically, additives are mixed in the drilling fluid to create a more viscous and higher density drilling fluid to enable the drill cuttings to stay in suspension.
It is known that larger size excavations make it difficult to maintain the required fluid velocity (e.g. 10 fps) to keep cuttings in suspension. As shown in Table 1, calculations were made to estimate the required pump rates to circulate various size cuttings. Conventional circulation will not be practical at these flow rates. Furthermore, a build-up of cuttings in the annulus will cause the rods to stick and potential loss of downhole equipment.
TABLE 1______________________________________Conventional Circulation ParametersChip Size Slurry Velocity Circ. Rate Horsepower Oper. Cost(inches) (fps) (gpm) (HP) ($/day)______________________________________1.00 20 40,000 12,000 10,8000.50 10 20,000 6,000 5,4000.25 5 10,000 3,000 2,7000.10 2.5 5,000 1,500 1,3500.01 0.25 500 750 135______________________________________
Reverse Circulation
Coal transported through reverse circulation allows water to be pumped through the annulus and move produced coal back through the drill pipe which offers several advantages as follows:
Pumping pressures, rates, and resulting horsepower requirements are lower.
The chances of sticking the drill string and excavating tool are greatly reduced.
The flow characteristics of the return path can be carefully controlled.
Water can be used as a transport medium.
During unexpected shut-down periods the circulating fluid is contained in the excavated area and the excavated material is contained in the drill pipe.
Cuttings are observed at the well head much more rapidly to verify necessary corrections to stay in the coal seam.
The primary disadvantages of a reverse circulation process are:
The borehole walls must contain a positive circulating pressure, and a highly fractured or permeable coal seam may allow the positive pressure to leak into the formation.
A packer or pressure seal must be maintained on the wellhead and allow the discharge pipeline to continue to advance into the tunnel.
The excavating material must be routed through the crusher and jet pump into the discharge pipeline at an acceptable mass flow rate.
Preliminary calculations were conducted to determine the required circulation rates to transport the coal slurry through reverse circulation. The results are shown in Table 2.
TABLE 2__________________________________________________________________________Circulation Rates for Reverse Circulation5" ID 6" ID 8" IDER CR vf CP CR vf CP CR vf CP(tph) (gpm) (fps) (psi) (gpm) (fps) (psi) (gpm) (fps) (psi)__________________________________________________________________________20 450 7 90 450 5 60 800 5 6040 930 15 200 930 10 130 800 6 80__________________________________________________________________________ ER -- Excavation rate CR -- Circulation rate vf -- Fluid velocity inside the drill string CP -- Circulating pressure
Table 2 indicates that at targeted production rate (40 tons per hour), the water flow in the annulus would need to be ˜1000 gpm @ 130 psi for a 6" ID pipeline. This flow rate would move coal production from the water jet cutting head into the discharge pipeline in a slurry to the wellhead. These calculations were based on a particle size of 8 mesh to 1/4". Therefore, a discharge pipeline with an internal diameter of at least 6 inches is projected to be required to limit the circulating pressure against the borehole perimeter.
Other calculations have also been made relative to the operation of the system 10. Various diameters and configurations of tunnels 12 have been analyzed to determine the general excavation, size, and penetration rates required per tunnel to achieve reasonable productivity rates for low cost production of coal. For example, Table 3 details tons of coal contained in a 100 foot segment of the tunnel 12 of a given diameter or configuration. These calculations are provided for reference purposes.
TABLE 3______________________________________Tons of Coal for Various Borehole ConfigurationsBorehole Configuration Area (ft.sup.2) tons per 100'______________________________________12" diameter "φ" (circle) 0.79 3.224" φ (circle) 3.14 12.636" φ (circle FIG. 2A) 7.07 28.32' × 6' φ (ellipse) 9.42 37.736" φ ("pie" FIG. 2B) 10.21 40.8______________________________________
Referring now to FIGS. 1, 3, 4 and 6 in combination, certain components of the system 10 will be discussed for reference purposes. Many borehole excavating tools are commercially available as described in printed publications. Referring first, then, to the cutting head 24, several hydraulic mining systems are shown in U.S. Patents. For example, U.S. Pat. Nos. 1,851,565, 3,155,177 and 4,401,345 disclose hydraulic mining systems employing cutting water jets. Individual elements of the cutting head 24 are also shown in U.S. Pat. No. 3,203,736 which depicts a small diameter water jet to be used to cut coal. Improvements in modern design include flow straighteners and carbide orifices. The shield 162 is preferably a steel plate fabricated with holes cut according to the configuration of the nozzle assembly 161. As described above, the nozzle head 167 would include a swivel which allows rotation of the cutting head as generally described by StoneAge Waterjet Engineering in 1996 Catalog as a SG Rotary Coupling.
As referred to above, the hydraulic downhole crusher 180 reduces the produced coal and rock to a manageable size prior to discharge into the pipeline. Crushers of this general type are described in U.S. Pat. No. 4,296,970 and Flow Industries, Inc. in its catalog as Model SBE-12. Other variations of downhole crushers are described by Flow Industries, Inc. as Models SSE-8, DSE-12, and DSE-18.
As referred to above, the jet pump 183 is integral to operation of the system 10. The jet pump 183 preferably has no moving parts and is adapted to handle coal slurries without difficulty. Such pumps are generally described in U.S. Pat. Nos. 3,155,177 and 4,077,671 and other borehole mining related patents. The jet pump is readily available from industry. Several vendors, including Fox Valve Development Corporation, Pemberthy, Inc., and Schutte & Koerting, provide such pumps.
As referred to above, packer 33 may be required to create a higher differential pressure where system 10 operates relative to the wellhead where the longhole drill and pumps are located. As shown in Table 2, higher downhole pressures will improve reverse circulation production rates. The rubber packer is commonly used in the oil and gas and environmental industries for downhole testing, hydraulic fracturing, zone isolation, etc. and available in various sizes and configurations from Aardvark, Corp. and Tam International, Inc.
As referred to above, control of the drill string and down hole tools may be accomplished from the wellhead through the use of a longhole directional drill. However, it is deemed preferable to push or pull the entire drill string 25 from either end. Therefore the use of a downhole crawler 26 allows pulling of the drill string 25 to advance the cutting head 24 continuously into the coal face 13 as coal 22 is eroded from said face.
During the development of the excavation, or tunnel 12, this down hole crawler 26 would hold the downhole cutting head 24, jet pump 183, crusher 180, and front segment of the discharge pipeline 28. The crawler 26 could use a moving steel track 26A that would be hydraulically driven.
As referred to above, a steering tool 206 may be used. Field experimentation will indicate the level of sophistication that will be required for guidance of the horizontal remote miner of system 10. The basic survey tool is a camera type that takes a picture of a compass at a moment in time. These survey tools are relatively inexpensive and permissible for use in underground coal mines. For example, the Sperry Sun Single Shot and CBC Wellnav Pee Wee are two single shot survey tools that provide inclination, azimuth, and tool orientation. Efficient guidance of the horizontal remote miner may require a cabled tool that would provide continuous reading of surveys or a measurement while drilling ("MWD") survey tool that is wireless and transmits a signal through the formation, drill pipe, or drilling fluid to a receiver on the well head. The term wellhead is referred to herein as that region located at the longhole drill where the borehole 12 initiated. These tools are commonly used in conventional oil and gas industry operations and are available through Halliburton, Schlumberger, Baker Hughes, GeoServices and the like.
As also referred to above, the discharge pipeline 28 is integral to the coal recovery process. The discharge pipeline 28 is preferably lightweight, medium or high density polyethylene pipe of the type commonly used for distribution and transportation of natural gas, liquids and slurry. Likewise, the jet pump water line 188 will likely be of similar construction, including lightweight medium or high density polyethylene pipe. The proposed technique of system 10 requires limited thrust, only to advance the drill string 25 and cutting unit, for penetration. Therefore, lightweight pipe may be used for the drill string 25. Long lengths (e.g., 40-100 feet each) as practical, could be fused to minimize the coupling of joints which slow penetration. The pipe OD may be 6, 8, or 10 inches. Connections between the fused joints may be made with gripper couplings or fused as appropriate. Threaded joints may be used but would require another material such as fiberglass or PVC plastic pipe. The ventilation lines may on the other hand be rubber hose or lightweight medium or high density polyethylene pipe.
Referring now to FIG. 7, there is shown a top plan, diagrammatic view of a defined area 300 for the horizontal mining operations of the present invention. Area 300 may comprise a mineral deposit of relatively thin proportions, perhaps on the order of 1 to 4 feet in thickness. Minerals such as coal in seams only 1 to 4 feet thick can be difficult to mine in an economical fashion with conventional technology. For that reason, the present invention affords a marked improvement over the prior art.
Referring still to FIG. 7, defined area 300 herein shown comprises a region approximately 1 mile by 1.5 miles in size. This area is preferably only a portion of a larger mineral deposit for which mining is desired. Access tunnels 18A are thus formed therethrough for defining smaller excavation regions 302, 304, 306, 308, 310, 312, 314 and 316, each approximately one mile long and 1000 feet wide. Boreholes 12 are representatively shown formed in region 310 transversely therethrough by the crawler 26 and the remainder of system 10 of the present invention. The access tunnels may be on the order of 15 to 20 feet wide and 3-6 feet high.
Referring now to FIG. 8, there is shown an enlarged, diagrammatic top plan view of an area of access tunnel 18A. Said tunnel is shown to be formed with a plurality of coal pillars 320 and 322. The coal pillars 320 and 322 are formed during conventional room and pillar excavation of access tunnel 18A. Pillars 320 have spaces 324 therebetween. Pillars 322 are connected by stoppings 330 constructed therebetween to form a generally solid wall capable of directing and isolating the flow of air for ventilation of boreholes 12. Fresh air 340 is illustrated passing along pillars 320 while return air 342 passes along pillars 322. The wellheads or initiation of boreholes 12 are illustrated as starting from fresh air 340 along access tunnel 18A. The ends of boreholes 12 are illustrated as terminating into access tunnel 18A where return air 342 is routed.
In operation, the system 10 described above may be used to mine coal 22 from coal seams 14 that have heretofore not been economically producible. This may be appreciated by the fact that water jets have already demonstrated the ability for rapid cutting of a coal face. For example, previous surface drilled borehole mining projects have achieved coal cutting rates in excess of 40 tons per hour. However, the ability to: (i) sustain this cutting rate as the cavity is enlarged and (ii) match coal transportation rates out of the hole with coal cutting rates, has not been demonstrated. The present invention addresses these issues by creating a system 10 that uses limited manpower, decreases overall roof support requirements, and may be capable of remote actuation, guidance and control. Cutting head 24 is thus mounted on crawler 26 as described above to permit continuous advancement into the coal seam 14 as the water jets cut coal 22. The crawler 26 is preferably hydraulically driven to pull the drill string that consists of pipes 28, 188, 179 and 181 into the tunnel 12. Another approach is also contemplated by the present invention wherein a drill unit located at the start of the borehole at the wellhead will push the drill string into the excavation. For example, a longhole permissible drill of the type typically used for installation of horizontal methane drainage boreholes could be used. The drill would grip the drill string (primarily 28) and, if rigid, push it into the hole. Such a drill unit would also provide the flexibility of periodic directional drilling of small diameter exploration boreholes along the panel in advance of the horizontal remote mining unit. Either approach would require equipment to be sized to handle the horizontal pushing or pulling of approximately 40,000 pounds which is the anticipated weight of the drill string full of slurry at total depth (e.g. 1000 feet), including the system 10.
Finally, during operation of the system 10 and prior to the installation of a joint of the plastic pipe described above, high pressure water to the cutting head 24 would be stopped to allow the coal slurry in the discharge pipeline 28 to be removed out of the tunnel 12. This step would minimize potential settling of the coal 22 out of the slurry during the adding of sections to the discharge drill pipe 28. Other operational features include the volume of water in the tunnel 12. Although it is unlikely that the entire excavation may be filled with water, there may be a possibility of gas production. Therefore, the drill string 25 includes the ventilation lines described above to remove potential accumulations of methane or other gases. The use of this ventilation system will be determined by site specific geologic and reservoir conditions and by federal regulatory authorities (e.g. Mine Safety and Health Administration "MSHA"). Additionally, a compressed air system for ventilation of the tunnel 12 may be used. An air compressor (not shown) may be installed on the surface 21 and a pipeline system (not shown) may route air to each horizontal remove mining tunnels 12. FIGS. 5A and 5B do show a flexible intake hose 179 will provide fresh air to the cutting face 13. The intake air will dilute any gas to a safe level and will be removed from the excavation through the flexible return hose 181. Each of the hoses may be approximately 2 inches in diameter in order to deliver acceptable air flow, as currently configured.
Although a preferred embodiment of the method and apparatus of the present invention has been illustrated in the accompanying Drawings and described in the foregoing Detailed Description, it will be understood that the invention is not limited to the embodiment disclosed, but is capable of numerous rearrangements, modifications and substitutions without departing from the spirit of the invention as set forth and defined by the following claims.
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A horizontal remote mining system comprising a water jet cutting head, down hole crusher, jet pump, and guidance system for orchestrating select excavation of a horizontal borehole. The system is assembled on the end of a drill string comprised of multiple compartments accommodating various water pressures and functions in association with the remote excavation process. Selective tubing is also utilized to facilitate movement of air and ventilation of the borehole. In this manner, relatively thin coal seams can be economically mined.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority of the German patent application 103 39 618.7 filed Aug. 28, 2003 which is incorporated by reference herein.
FIELD OF THE INVENTION
The invention concerns an illumination apparatus for an optical observation device, in particular a stereomicroscope or a stereo surgical microscope.
BACKGROUND OF THE INVENTION
Light-emitting diodes (LEDs) that emit colored light have now become so bright that they are used, for example, for traffic signal systems and in the rear lights of vehicles.
For a microscope illumination system, white light is principally desirable. White-light-emitting LEDs already exist. These are not, however, bright enough for this application. A plurality of light-emitting diodes arranged next to one another and emitting red, green, and blue light can be used to generate white light.
DE 37 34 691 C2 presents a solution making possible a variety of illumination types and an intensity control capability with the aid of this type of red-green-blue arrangement of many small LEDs. A bright-field, dark-field, or oblique illumination can be produced by selective local activation of the individual LEDs. The overall intensity of the illumination can be regulated by the fact that either all or fewer LEDs are in operation, or on the other hand only those LEDs that result in a specific configuration. The individual LEDs are not, however, individually controllable; they can only be switched on and off.
To achieve uniformly homogeneous coverage of the illumination aperture, a frosted disk must be introduced in the immediate vicinity of the LED light source.
A further embodiment according to this existing art provides that white light can be generated with a red, green, and blue planar LED light source and a system of dichroic splitters. This illumination apparatus offers a high light intensity, but is relatively bulky. Because of the long optical paths, the light must be collimated using additional lenses. A further disadvantage is the high alignment accuracy of the dichroic mirrors required to ensure good and constant color accuracy.
The disadvantages of tungsten lamps, halogen lamps, etc., as used hitherto for microscopes, are principally high thermal dissipation, high power consumption and short service life, little robustness, large space requirement, and heavy weight (cf. DE 37 34 691 C2, col. 1, lines 7–12).
DE 19 13 711 A presents a solution for uniform light distribution and intensity regulation of a single conventional light source (Planck radiator) by means of fiber bundles. For that purpose, a fiber bundle having a single entrance and exit surface is placed after the conventional light source with diaphragm. No positional allocation of the fibers with respect to the entrance and exit surface exists.
This offers the advantage that the inhomogeneous intensity distribution of the light source image is homogenized at the end of the fiber, and a continuous intensity regulation is produced at the end of the fiber by way of the diaphragm at the fiber entrance.
SUMMARY OF THE INVENTION
The basis of the present invention is not primarily the need for a uniform light distribution, but rather the combination and associated increase in intensity of the light from a variety of light sources, with no increase in space requirement and without the aforementioned disadvantages of conventional light sources.
It is presently the case in the existing art that a colored-light-emitting LED possesses a higher luminance than a white-light-emitting LED. Combining the light of three color LEDs makes the luminance difference as compared with a single white-light-emitting LED that much greater.
According to the present invention, therefore, at least one red-, one green-, and one blue-light-emitting LED are arranged physically next to one another. The light that emerges is fed respectively into a multi-arm light-guiding fiber bundle, each light guide arm being illuminated by one colored-light-emitting LED. The light guide arms are combined into one common light guide, and the individual light fibers are optimally mixed. The result is a light coupler. For effective light yield, it is preferable to use, instead of normal light guides, ones with hot-melted ends.
With the aid of these fiber-optic components, the light-emitting diodes can now also be arranged remotely from the microscope. This yields the advantage that the microscope body can be made small and light. A further advantage is the elimination of the need to place a frosted disk immediately in front of the optical system as a diffuser, since the scattering function of the frosted disk is taken over by the light-guiding fibers.
The colored light emerges in mixed fashion at the end near the microscope and is usable in toto as white light, and is moreover very much brighter than presently available LED light from white-light-emitting LEDs.
The white mixed light need not necessarily be assembled from red, green, and blue LED light; this can also be done using yellow and blue LED light.
It is a presently common procedure to mix white light from red, blue, and green light; the invention is, however, expressly not limited to that procedure. It is thus also possible, for example, to assemble white light from blue and yellow light; cf. in this context Siemens Magazin Forschung und Innovation/Leuchtdioden, New World 4/2000, p. 39.
The light coupler can also comprise a light-guiding rod system. If the light-guiding rods are correspondingly short, this yields the advantage of a compact design.
Numerical aperture adaptation can be achieved by way of a cross-section changer having different entrance and exit areas.
The spectrum of the illuminating light can furthermore be freely selected by electrical brightness regulation of the individual light-emitting diodes; no filters are necessary. It would be possible, for example, temporarily to use only the red-light-emitting LED to produce a returned light (red reflection) in ophthalmology, or only the green-light-emitting LED for red-free observation. “Blue light hazard” can be reduced by reducing the emission of the blue-light-emitting LED.
Tissue-specific changes can moreover be selectively depicted with this kind of false-color illumination. Better contrast can also thereby be obtained. This is done for diagnostic purposes, but also to ensure an illumination that damages tissue as little as possible.
The possibility furthermore exists of generating, with this spectrally selective illumination, only the particular light that contributes to the requisite imaging configuration of the microscope or to the spectral sensitivity of the observer's eye. If the LEDs cannot be electrically regulated without a change in color, controllable filters that damp the relevant color component as necessary could be selectably placed after them.
According to a refinement, a further fiber bundle can also be provided for feedback purposes. This fiber bundle receives, at the distal end of the fiber bundle (i.e. at the end located opposite the light source), the light reflected from the specimen and conveys it to a sensor that detects the light color and brightness. This information can thus be made available for evaluation, or used for control purposes. For example, any desired spectra can be preselected using a computer, and then compared with the measured ones. Deviations are compensated for by discrete activation and regulation of the respective color LEDs. This allows the generation of any desired illumination spectra deviating from the Planck radiation spectrum.
According to a further embodiment of the illumination apparatus according to the present invention, provision is made for acquiring false-color images using a camera, and storing them in the computer. At a later time, as desired, these can be reflected into or overlaid onto the currently active image in one or both stereomicroscope beam paths using a display.
Reference is also made to a simultaneously submitted application of the Applicant in which one or more white-light-emitting LEDs are integrated into the surgical microscope or into the illuminating optical system of the microscope. The teachings of the two applications are intended to be combinable.
Further embodiments of the invention are described in the Figures and in the dependent claims. The Parts List is a constituent of the disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained in more detail, in symbolic and exemplary fashion, with reference to the Figures. Identical reference characters denote identical components; reference characters with different indices indicate identically functioning or similar components. In the drawings, schematically in each case:
FIG. 1 shows an arrangement of three planar LED light sources that, using dichroic mirrors, combine red, green, and blue light into white mixed light in accordance with the existing art;
FIG. 2 shows an illumination apparatus according to the present invention for an optical observation device, e.g. a microscope, having three LEDs that blend red, green and blue LED into white mixed light using a light guide with coupler;
FIG. 3 shows an arrangement according to FIG. 2 that has only a yellow- and a blue-light-emitting LED and a corresponding light guide with coupler;
FIG. 4 shows the arrangement of FIG. 2 having an additional light guide arm, a measurement sensor, and a signal processing unit; and
FIG. 5 shows the arrangement of a complex LED illumination apparatus according to the present invention having a computer as well as the capability for reflection into the observation beam paths of the optical observation device by means of a display.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1 , the light of a red, a green, and a blue planar LED light source is mixed into white light, in known fashion, using dichroic splitters.
The illumination apparatus depicted in FIG. 2 encompasses at least one red-light-emitting LED 1 a , one green-light-emitting LED 1 b , and one blue-light-emitting LED 1 c , which respectively emit red light 11 a , green light 11 b , and blue light 11 c . This red-green-blue arrangement constitutes LED arrangement 1 . Each of the light-emitting diodes 1 a , 1 b , 1 c has associated with it one respective input of a total of three light guide arms 2 a , 2 b , 2 c . The three light guide arms 2 a , 2 b , 2 c come together and thus constitute a light guide with coupler 2 that has a single output. Here white mixed light 15 travels through an illuminating optical system 3 onto a mirror 4 , by which it is directed through a main objective 5 of an optical observation device 10 . Viewer 7 then sees the illuminated specimen 6 through observation beam path 20 a.
The arrangement shown in FIG. 3 is in principle the same as in FIG. 2 , but here white illuminating light 15 is assembled from two light-emitting diodes: 1 d that emits, for example, yellow light 1 d , and 1 e that emits, for example, blue light 11 c . A three-armed light guide with coupler 2 is no longer necessary for this, a two-armed one instead being sufficient.
It is noted that LEDs 1 a through 1 e may be laser diodes or other semiconductor light sources.
FIG. 4 shows that an additional light guide arm 2 d conveys specimen light 21 , reflected from specimen 6 and transported by it, via an optical system 9 to a measurement sensor 8 . Measurement sensor 8 in turn forwards its measured data to a signal processing unit 12 . The latter, in a freely preselectable or automatic regulation process, controls light-emitting diodes 1 a , 1 b , 1 c and/or also corresponding filters 14 a , 14 b , 14 c in terms of a desired spectrum.
FIG. 5 shows the arrangement of FIG. 4 supplemented by a computer 13 and a camera 16 . Camera 16 , using a deflection element 18 a , takes from left observation beam path 20 a of the stereoscopic optical observation device 10 an image that it conveys to computer 13 . Computer 13 can retrieve stored data or images, optionally in false-color depiction, from its memory unit. These data and/or images from computer 13 are reflected via a display 17 and a deflection element 18 b into right observation beam path 20 b or right eyepiece 19 b . In principle, stereoscopic reflection into both observation beam paths 20 a , 20 b is also possible.
Parts List
1 , 1 ′ LED arrangement
1 a Red-light-emitting LED
1 b Green-light-emitting LED
1 c Blue-light-emitting LED
1 d Yellow-light-emitting LED
1 e Blue-light-emitting LED
2 Light guide with coupler
2 a–d Light guide arms
3 Illuminating optical system
4 Mirror
5 Main objective
6 Specimen
7 Observer's eye
8 Measurement sensor
9 Optical system
10 Optical observation device
11 a Red light
11 b Green light
11 c Blue light
11 d Yellow light
12 Signal processing unit
13 Computer
14 a–c Filter
15 White mixed light
16 Camera
17 Display
18 a, b Deflection elements
19 a Left eyepiece
19 b Right eyepiece
20 a, b Observation beam path
21 Specimen light
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The invention concerns an illumination apparatus for an optical observation device ( 10 ), in particular a stereomicroscope or a stereo surgical microscope. A multi-armed light guide with coupler ( 2 ) mixes colored light emitted by light-emitting diodes ( 1 a–c ) to yield white mixed light ( 15 ).
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BACKGROUND
The invention relates to a command controller and a prefetch buffer, and in particular, to a command controller and a prefetch buffer for accessing a serial flash in an embedded system.
Embedded systems typically comprise flash memory such as serial flash or parallel flash for storing data and code. An embedded system requires a plurality of pins (address pins, data pins, and control pins) to access a parallel flash. Fewer pins are required to access a serial flash. For example, an embedded system only requires four pins (an enabling pin CE, a clock pin SCLK, a data input pin SI, and a data output pin SO) to access the serial flash. Additional commands and addresses, however, must be issued each time the serial flash is accessed. If the embedded systems access the serial flash too frequently, large number of additional commands and addresses will be issued and the performance of the embedded system may be decreased. Additionally, the serial flash is controlled by vendor specific instructions, which vary between manufacturers, resulting in compatibility problems.
SUMMARY
An object of the invention is to provide a command controller applied in an embedded system. The embedded system comprises a processor, a plurality of access devices and a serial flash. The processor and the plurality of access devices send various commands to read data from or write data to the serial flash. The command controller comprises a direct reader and a command interpreter. The direct reader processes a first command to generate a first instruction according to a trapping input wherein the first command can be from the processor or any access device and the first instruction is shifted to the serial flash for reading data in the serial flash. The command interpreter interprets a second command to generate a second instruction according to the trapping input wherein the second command is from the processor and the second instruction is shifted to the serial flash for reading data from or writing data to the serial flash.
Another object of the invention is to provide a prefetch module applied in an embedded system. The embedded system comprises a processor, a plurality of access devices and a serial flash. The processor and the plurality of access devices send various commands to read data from or write data to the serial flash. The prefetch module comprises a command interpreter and a prefetch buffer. The command interpreter interprets a second command to generate a second instruction wherein the second command is from the processor and the second instruction is shifted to the serial flash for reading data from or writing data to the serial flash. The prefetch buffer temporarily stores a predetermined amount of data before data being read from or written to the serial flash.
A further object of the invention is to provide an embedded system. The embedded system comprises a serial flash, a processor, a plurality of access devices, and a command controller. The processor and the plurality of access devices send various commands. The command controller processes the various commands to generate and send various instructions to the serial flash to read data from or write data to the serial flash.
A further object of the invention is to provide an embedded system. The embedded system comprises a serial flash, a processor, a plurality of access devices, and a prefetch buffer. The processor and the plurality of access devices send various commands to read data from or write data to the serial flash. The prefetch buffer temporarily stores a predetermined amount of data before data being read from or written to the flash.
A further object of the invention is to provide a method of controlling a command controller applied in an embedded system. The method comprises: processing a first command from a processor to generate a first instruction according to a trapping input and shifting the first instruction to the serial flash for reading data; and interpreting a second command from the processor or any access device to generate a second instruction according to the trapping input and shifting the second instruction to the serial flash for reading or writing data.
Yet another object is to provide a method of controlling a prefetch buffer applied in an embedded system. The method comprises: continually storing data in the prefetch buffer until the prefetch buffer is full, and transmitting data from/to the serial flash.
DESCRIPTION OF THE DRAWINGS
The following detailed description, given by way of example and not intended to limit the invention solely to the embodiments described herein, will best be understood in conjunction with the accompanying drawings, in which:
FIG. 1 shows a block diagram of an embedded system according to an embodiment of the invention;
FIG. 2A shows a block diagram of the serial flash interface;
FIG. 2B is a flow chart of access command interpreting process;
FIG. 3A shows a block diagram of the command controller;
FIG. 3B shows another block diagram of the command controller;
FIG. 4A shows a schematic diagram of the command register in FIG. 2 ;
FIGS. 4B˜4E show schematic diagrams of a series of instructions, data, and address sent to the serial flash 110 different operations of the command controller;
FIG. 5 is a flow chart of a prefetch buffer reading control method applied to an embedded system;
FIG. 6 is a flow chart of a prefetch buffer writing control method applied to an embedded system.
DESCRIPTION OF THE INVENTION
A detailed description of the invention is provided in the following. Please refer to FIG. 1 . FIG. 1 shows a block diagram of an embedded system 100 according to one embodiment of the invention. The embedded system 100 comprises a serial flash 110 , a processor 120 , a flash DMA engine 130 , an access device 140 , a serial flash request arbiter 150 , a serial flash interface 160 , a prefetch buffer controller 170 and a prefetch buffer 180 . The processor 120 , flash DMA engine 130 , and access device 140 can access the serial flash 110 . For example, the processor 120 can read/write the serial flash 110 and the flash DMA engine 130 can move data in the serial flash 110 to a DRAM (not shown). If there are more than two elements requesting access to the serial flash 110 at the same time, the serial flash request arbiter 150 chooses one element to send a command through the bus BUS_ 2 to access the serial flash 110 . Additionally, the command can be issued by the processor 120 directly through the bus BUS_ 1 without going through bus BUS_ 2 . The prefetch buffer controller 180 is utilized to collect and translate several single read access requests to the burst read access for reducing total access time. A detailed description of reducing access time through the prefetch buffer controller 180 will be described later and access to the serial flash is provided in the following.
Please refer to FIG. 2A . FIG. 2A shows a block diagram of the serial flash interface 160 . The serial flash interface 160 comprises a command controller 210 , a write data register 220 , an address register 230 , a command register 240 , an instruction register 250 and a parallel-serial shift register 260 . The command controller 210 interprets the flash command (access command COM access from bus BUS_ 1 or direct command COM write /COM read from bus BUS_ 2 ) to the flash instruction with the help of the plurality of registers and trapping input TRAPin. Finally the parallel-serial shift register 260 converts the instruction from a parallel form to a serial form and shifts the instruction to the serial flash 110 (in FIG. 1 ). A detailed description of access command interpreting process is provided in the following.
Please refer to FIG. 2B . FIG. 2B is a flow chart of access command interpreting process. Steps of the process are given in the following.
Step 20 : The processor 120 sets the plurality of registers 220 - 250 through the bus BUS_ 1 initially. Step 22 : The access command COM access is issued from the processor 120 to the command controller 210 through the bus BUS_ 1 . Step 24 : A corresponding action (e.g. bulk erase, byte read, byte write . . . ) is determined according to the value of command register 240 , which is set in the previous step 20 . Step 26 : The command controller 210 performs interpretation to generate a series of instructions, data, and address. For example, in the case of byte write action, vendor-dependent instruction is generated first, data to be written and writing address are generated in turn. Please note that the vendor-dependent instruction is generated according to the instruction register 250 , data written to the serial flash 110 is temporarily stored in the write data register 220 , and the writing address is temporarily stored in the address register 230 .
Further discussion of the instruction register 250 is provided in the following. There are various kinds of instruction register implementation. Please note that the implementation of instruction register is only meant to serve as an example, and is not meant to be taken as a limitation. For example, if the space of instruction register is large enough to store the whole instruction sets of a specific serial flash vendor, the instruction register 250 does not need to be set (or initialized) each time of command interpreting process. Otherwise, the instruction register 250 needs to be reset (or re-initialized) each time of command interpreting process. Additionally, different serial flash vendor provides different instruction sets, thus, the instruction register 250 needs to further update its content if the vendor of serial flash changes. Similarly, if the space of the instruction register 250 is large enough to store a plurality of instruction sets corresponding to different serial flash vendor, the instruction register 250 can simply provide the instruction set of the current vendor according to the trapping input TRAP in rather than reset again.
Please refer to FIG. 3A . FIG. 3A shows a block diagram of the command controller 210 . The command controller 210 comprises a direct reader 320 , a command interpreter 310 , and a multiplexer (MUX) 330 . The direct reader 320 processes the read command COM read (from bus BUS_ 2 ) to generate an instruction INS temp — 2 according to the trapping input TRAP in . For example, if the trapping input TRAP in from the vendor is ST, then the direct reader 320 generates the interpreted instruction INS temp — 2 equal to “03h”. If the trapping input TRAP in from the vendor is ATMEL, then the direct reader 320 generates the interpreted instruction INS temp — 2 equal to “E8h”. The command interpreter 310 also interprets the access command COM access (from bus BUS_ 1 ) to generate another instruction INS temp — 1 according to the trapping input TRAP in . For example, in a read status access, if the trapping input TRAP in from the vendor is ST, then the command interpreter 310 generates the interpreted instruction INS temp — 1 equal to “05h”. If the trapping input TRAP in from the vendor is ATMEL, then the command interpreter 310 generates the interpreted instruction INS temp — 1 equal to “D7h”. The MUX 330 selects one instruction from the instructions INS temp — 1 and INS temp — 2 to be the interpreted instruction INS com . After the interpreted instruction is generated, the corresponding flash data REG data and the flash address REG add will be sent in turn.
In the case of access command COM access (through bus BUS_ 1 ), if the corresponding action handled by the command interpreter 310 is to perform reading (determined by the register value REG com ), the command interpreter 310 sends the interpreted instruction INS temp — 1 (according to the trapping input TRAP in and the register value REG ins ), and the reading address from register value REG add . Similarly, if the corresponding action is to perform writing (determined by the register value REG com ), the command interpreter 310 sends the interpreted instruction INS temp — 1 (according to the trapping input TRAP in and the register value REG ins ), the writing data from register value REG data , and the writing address from register value REG add .
In the case of read command COM read (through bus BUS_ 2 ), the corresponding action handled by the direct reader 320 is to perform reading. The direct reader 320 sends the interpreted instruction INS temp — 2 (according to the trapping input TRAP in and the register value REG ins ), and the reading address from register value REG add .
Please refer to FIG. 3B . FIG. 3B shows another block diagram of the command controller 210 . Compared with the previous one in FIG. 3A , the key difference is that the direct reader 320 is replaced by the reader/writer 420 . The reader/writer 420 not only can handle the read command COM read but also the write command COM write .
Please refer to FIGS. 4A˜4E . FIG. 4A shows a schematic diagram of the command register 240 in FIG. 2 . FIGS. 4B˜4E show schematic diagrams of a series of instructions, data, and addresses sent to the serial flash 110 in different operations (e.g. bulk erase, byte read, byte write . . . ) of the command controller 210 . The command register 240 comprises a byte read segment 411 , a byte write segment 412 , a bulk erase segment 413 , a WRSR (write status register) segment 414 , and a RDSR (read status register) segment 415 . For example, the size of each segment in the register 240 is equal to one bit. In FIG. 4B , a bulk erase instruction is generated after the bulk erase segment 413 is set by the processor 120 . The command interpreter 320 processes the bulk erase access command COM access to output the bulk erase instruction INS com according to the trapping input TRAP in . No other flash data REG data or flash address REG add is followed with the bulk erase instruction INS com and sent to the serial flash 110 . In FIG. 4C , a read status instruction is generated after the RDSR segment 415 is set by the processor 120 . The command interpreter 310 processes the RDSR command COM access to output RDSR instruction INS com according to trapping input TRAP in . No other flash data REG data or REG add is followed with the RDSR instruction INS com and sent to the serial flash 110 . After the RDSR command COM access is triggered and completed, the return status is available from the serial flash 110 . In FIG. 4D , a write status instruction is generated after the WRSR segment 414 is set by the processor 120 . The command interpreter 320 processes the WRSR command COM access to output WRSR instruction INS com according to the trapping input TRAP in . In FIG. 4E , a byte program instruction is generated after the byte write segment 412 is set by the processor 120 . The command interpreter 320 processes the byte write command COM access to output byte write instruction INS com according to the trapping input TRAP in . After the access command COM access is triggered, a series comprising instruction, address, data and handshaking is generated and sent to the serial flash 110 . Then the byte data can be written to the assigned address of the serial flash 110 .
From the description set forth above, it is clear that the command controller translates various commands to corresponding instructions, even though these instructions are based on different instruction sets provided by different serial flash vendors. Thus, compatibility issues can be solved. A detailed description of the prefetch buffer 170 (in FIG. 1 ) is provided below.
Please refer to FIG. 5 . FIG. 5 is a flow chart of a prefetch buffer reading control method applied to an embedded system. Steps of the method are given in the following.
Step 502 : The prefetch buffer is idle. Step 504 : A processor or any other access device issues a request to a serial flash request arbiter to read wanted data. Step 506 : The prefetch buffer controller determines if data in the prefetch buffer is the wanted data. If yes, proceed to step 508 ; Otherwise proceed to step 510 . Step 508 : The prefetch buffer controller returns data in the prefetch buffer to the processor or any other access and continues fetching until the prefetch buffer is full. Step 510 : The prefetch buffer controller determines if data is being fetched from a serial flash and if it is ready to be read by the processor or any other access device. If yes, proceed to step 512 ; Otherwise proceed to step 514 . Step 512 : Wait and determine whether data is ready. If yes, proceed to step 508 ; Otherwise proceed to step 514 . Step 514 : Abort previous command if present and issue a new request to a serial flash interface.
Please refer to FIG. 6 . FIG. 6 is a flow chart of a prefetch buffer writing control method applied to an embedded system. Steps of the method are given in the following.
Step 602 : A processor or any other access device issues a request to a serial flash request arbiter to write data to a serial flash. Step 604 : The processor or any other access device writes data to the prefetch buffer until full. Step 606 : The processor or any other access device sets a plurality of related parameters (e.g. a written address or a serial flash vendor). Step 608 : The processor or any other access device triggers a command controller to translate and send commands to the serial flash. Step 610 : The command controller polls a serial flash status. Step 612 : Determine if the serial flash is ready. If yes, proceed to step 614 ; Otherwise, proceed to step 612 . Step 614 : The command controller sends a write enable instruction to the serial flash. Step 616 : The command controller sends sequence of an interpreted instruction (OP code), a writing address, and data until the prefetch buffer is full.
Compared with the related art, the prefetch buffer of the present invention can translate several single access requests into a burst access. Hence access frequency decreases and performance is increased. Additionally, the command controller can translate various commands to corresponding instructions even though these instructions are provided by different instruction sets from different serial flash vendors.
While the invention has been described by way of example and in terms of the preferred embodiment, it is to be understood that the invention is not limited thereto. To the contrary, it is intended to cover various modifications and similar arrangements (as would be apparent to those skilled in the art). Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements.
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The invention relates to a command controller and a prefetch buffer, and in particular, to a command controller and a prefetch buffer for accessing a serial flash in an embedded system. An embedded system comprises a serial flash, a processor, a plurality of access devices, and a prefetch buffer. The processor and the plurality of access devices send various commands to read data from or write data to the serial flash. The prefetch buffer temporarily stores a predetermined amount of data before data being read from or written to the serial flash.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] None.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT.
[0002] Not applicable.
THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT.
[0003] Not applicable.
REFERENCE TO A “SEQUENCE LISTING,” A TABLE, OR A COMPUTER PROGRAM LISTING APPENDIX SUBMITTED ON A COMPACT DISC
[0004] Not applicable.
BACKGROUND OF THE INVENTION
[0005] 1. Field of the Invention
[0006] This invention concerns the field of fenestration products and, more specifically, to windows provided with internal Venetian blinds and operators therefor.
[0007] 2. Background of the Invention
[0008] In a prior art search directed to the subject invention, the following US Patents were noted: U.S. Pat. Nos. 6,401,790; 5,699,845; 5,497,820; 4,913,213; 4,611,648; 4,274,469; 3,366,159; and 2,878,667. In addition, UK Patent Application No. 2,252,349 was noted.
BRIEF SUMMARY OF THE INVENTION
[0009] The present invention is an inside operator for controlling a primary operator for controlling a Venetian type blind that is in an insulated glass unit comprising two spaced glass panes. The insulated glass unit is supported in a sash frame which is supported on a window frame for pivotal movement between an open position and a closed position, as is the case, for example, with casement type windows and awning type windows. The primary operator may be one that controls the tilt orientation of the Venetian type blind slats or one that controls the vertical position of the bottom of the blind so as to raise and lower the blind. The primary operator is carried in the sash frame. The primary operator is supported in a longitudinally extending slot for longitudinal movement therein and may be operably connected to a slat tilt mechanism so that longitudinal movement of the primary operator effects a corresponding change in the tilt orientation of the slats. Alternatively, the primary operator may be operably connected to a mechanism for raising and lowering the blind so that longitudinal movement of the primary operator raises or lowers the blind. From the inside of the window frame, access to the primary operator is limited and access often requires the removal of a screen or a storm window from the window frame.
[0010] The inside operator is carried in the window frame and is supported for longitudinal movement within a longitudinally extending slot. When the window sash is open, the inside operator does not engage the primary operator and longitudinal movement of the inside operator has no effect on the position of the primary operator provided in the window sash. When the window sash is closed, arms or prongs provided on the inside operator operably engage a boss portion of the primary operator so that, when the primary operator and the inside operator are aligned, longitudinal movement of the inside operator effects a corresponding longitudinal movement of the primary operator. When the window sash is closed and the operators are not aligned, longitudinal movement of the inside operator will bring the operators into alignment so that the prongs engage the boss and subsequent longitudinal movement of the inside operator effects a corresponding movement of the primary operator. In the case where the primary operator is operably connected to a slat tilt mechanism, longitudinal movement of the inside operator, when the window sash is closed and the inside operator and the primary operator are aligned, effects a corresponding change in the tilt orientation of the slats. In the case where the primary operator is operably connected to a mechanism for raising and lowering the blind, longitudinal movement of the inside operator, when the window sash is closed and the operators are aligned, raises or lowers the blind.
[0011] Accordingly, it is an object of the invention to provide an operator for controlling a Venetian type blind carried in a pivoting window sash, even when access to the sash is restricted, for example, by a screen or a storm window.
[0012] It is another object of the invention to provide an inside operator for controlling the longitudinal position of a primary operator which is operably connected to a tilt mechanism for controlling the tilt orientation of the slats of a Venetian type blind carried in a pivoting window sash.
[0013] It is another object of the invention to provide an inside operator for controlling the longitudinal position of a primary operator which is operably connected to a mechanism for raising or lowering a Venetian type blind carried in a pivoting window sash.
[0014] It is another object of the invention to provide an inside operator with arms or prongs that are operable to engage a boss provided on a primary operator so that longitudinal movement of the inside operator effects a corresponding longitudinal movement of the primary operator.
[0015] It is another object of the invention to provide an inside operator with arms that engage a boss on a primary operator when they are aligned wherein longitudinal movement of the inside operator when the boss and the arms are not aligned will bring the arms and the boss into alignment and engagement.
[0016] It is another object of the invention to provide an inside operator that can be moved longitudinally to control the tilt orientation of the slats of a Venetian type blind carried in a casement window sash without the need to remove a screen or other object that effectively closes the casement window frame.
[0017] It is another object of the invention to provide an inside operator that can be moved longitudinally to raise or lower a Venetian type blind carried in a pivoting window sash without the need to remove a screen or a storm window or another object that effectively closes the pivoting window frame.
[0018] These and many other objects and advantages of the invention will be understood by persons skilled in the art who study the following description and the accompanying drawings which, although thorough, are merely illustrative.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0019] FIG. 1 is an inside view of a casement type window unit including a Venetian type blind in between panes of glass in an insulated glass unit in the casement window sash.
[0020] FIG. 2 . is an upper perspective view of the casement window unit with the sash in an open position.
[0021] FIG. 3 is an inside view of the casement window unit shown in FIG. 1 with the slats of the Venetian type blind in an open tilt orientation.
[0022] FIG. 4 is a top view of an inside operator according to one example of the invention.
[0023] FIG. 5 is atop view of an inside operator aligned with a primary operator in a first position.
[0024] FIG. 6 is a top view of an inside operator aligned with a primary operator in a second position.
[0025] FIG. 7 is a top view of an inside operator not aligned with a primary operator.
[0026] FIG. 8 is a top view of an inside operator touching but not aligned with a primary operator.
[0027] FIG. 9 is a top view of an inside operator touching and nearly aligned with a primary operator.
[0028] FIG. 10 is a top view of an inside operator aligned with a primary operator.
[0029] FIG. 11 is an upper perspective view of a window unit with a pivoting window sash in an open position with an internal Venetian type blind with slats in an open tilt orientation.
[0030] FIG. 12 is an upper perspective view of a window unit with a pivoting window sash in an open position with an internal Venetian type blind with slats in a closed tilt orientation.
DETAILED DESCRIPTION OF THE INVENTION
[0031] In FIGS. 1 , 2 and 3 , a window unit of the pivoting casement type is indicated generally at 10 . The window 10 comprises a window frame 12 and a sash 14 mounted for pivotal movement about a vertical axis relative to the window frame 12 . The invention also can be embodied in a window unit having a sash 14 that pivots about a horizontal axis such as an awning type window (not shown). An insulated glass unit 16 is supported in the sash 14 and a Venetian type blind 18 is enclosed within the insulated glass unit 16 . A primary operator 20 is supported on the sash 14 .
[0032] The primary operator 20 comprises a housing 22 and a slider 24 mounted for longitudinal movement within the housing 22 . A raised boss 26 is provided on the slider 24 for facilitating finger control of longitudinal movement thereof. The slider 24 is operably connected to apparatus (not shown) inside of the insulated glass unit 16 in the sash 14 so that longitudinal movement of the slider 24 is translated into rotational movement of the slats in the blind 18 . One such apparatus is available from OEM Shades under the name TOPSLIDE INTERNAL GLASS BLIND SYSTEM. The apparatus is described by OEM Shades as follows: “A top mounted external magnet assembly controls the blind with a movable finger controlled slide device. The slide device moves the external magnet laterally left or right, which drives an internal magnet with which it is coupled. Moving the slide device left or right on the outer magnet assembly will tilt the blind.” Other apparatus for translating longitudinal movement of a slide device or slider into rotational movement of blind slats are now known and may be developed in the future and they are to be considered to be apparatus for translating longitudinal movement of a slider into rotational movement of blind slats for purposes of this invention. The slats of the shade 18 are open when the slider 24 is moved to the left, as in FIG. 3 , and the slats of the shade 18 are closed when the slider 24 is moved to the right, as in FIG. 1 .
[0033] Unlike some prior art designs, the window frame 12 includes a head frame insert 28 which has a bottom edge 30 that is positioned below the height of the primary operator 20 . An inside operator 32 is supported on the head frame insert 28 . The inside operator 32 comprises a housing 34 and a slider 36 mounted for longitudinal movement relative to the head frame insert 28 which is part of the window frame 12 . A boss 38 is provided on a front face 40 of the slider 36 . The front face 40 is seen in FIGS. 1 and 3 and faces the room in which the window unit 10 is supported. On a rear face 42 of the slider 36 there are first and second prongs or arms 44 and 46 .
[0034] The prongs 44 and 46 are shown in more detail in FIG. 4 . The prong 44 comprises a first end 48 supported on the slider 36 . The prong 44 further comprises a second, free end 50 . The prong 46 comprises a first end 52 which is supported on the slider 36 and further comprises a second, free end 54 . A contact surface 56 is provided near the free end 50 of the prong 44 and a contact surface 58 is provided near the free end 54 of the prong 46 . As explained below, the contact surfaces 56 and 58 are operable to selectively engage the boss 26 of the primary operator 20 so that longitudinal movement of the slider 36 of the inside operator 32 is translated into longitudinal movement of the slider 24 of the primary operator 20 when the sash 14 is closed.
[0035] In FIG. 5 , the inside operator 32 and the primary operator 20 are spaced apart a fixed distance as they would be when the sash 14 is closed. FIG. 5 shows the operators 20 and 32 in an aligned condition. The free ends 50 and 54 of the prongs 44 and 46 are positioned on either side of the boss 26 of the primary operator 20 . The contact surface 56 of the prong 44 is adjacent to a contact surface 60 on one side of the boss 26 and the contact surface 58 of the prong 46 is adjacent to a contact surface 62 on the other side of the boss 26 .
[0036] Longitudinal movement of the slider 36 of the inside operator 32 from the position shown in FIG. 5 to the right, for example, to the position shown in FIG. 6 , effects a corresponding longitudinal movement of the slider 24 ( FIG. 2 ) of the primary operator 20 to the right to the position shown in FIG. 6 . Longitudinal movement of the slider 36 is transmitted to the slider 24 in this case by co-action between the contact surface 56 of the prong 44 and contact surface 60 of the boss 26 . Thus, longitudinal movement of the slider 36 to the right causes corresponding longitudinal movement of the slider 24 of the primary operator 20 to the right.
[0037] Longitudinal movement of the slider 36 of the inside operator 32 from the position shown in FIG. 6 to the left, for example, to the position shown in FIG. 5 , effects a corresponding longitudinal movement of the slider 24 ( FIG. 2 ) of the primary operator 20 to the left to the position shown in FIG. 5 . In this case, longitudinal movement of the slider 36 is transmitted to the slider 24 by co-action between the contact surface 58 of the prong 46 and contact surface 62 of the boss 26 . Thus, longitudinal movement of the slider 36 to the left causes corresponding longitudinal movement of the slider 24 to the left. In FIGS. 5 and 6 , the primary operator 20 is aligned with the inside operator 32 and vice-versa.
[0038] The prongs 44 and 46 are yieldingly rigid. When not subjected to any force, the free end 50 is spaced a fixed distance X ( FIG. 4 ) from the slider 36 and the free end 54 is also spaced a fixed distance from the slider 36 . If a force is applied to the free end 50 in the direction of the slider 36 , the prong 44 will flex as indicated in dotted lines in FIG. 4 . When the prong 44 flexes this way, the distance between the slider 36 and the free end 50 is reduced, for example, to a distance X′. When the prong 44 is flexed, it is biased to return to its not flexed condition. This feature solves problems that can arise when the primary operator 20 and the inside operator 32 are not aligned and the sash 14 has been pivoted to the closed position, as discussed below.
[0039] In FIG. 7 , the operators 20 and 32 are spaced apart as they would be when the sash 14 is closed but the primary operator 20 and the inside operator 32 are not aligned. The prongs 44 and 46 are positioned to the right of the boss 26 and longitudinal movement of the slider 36 does not affect the longitudinal position of the primary operator.
[0040] In FIG. 8 , the operators 20 and 32 are spaced apart as they would be when the sash 14 is closed and the primary operator 20 and the inside operator 32 are not aligned. The slider 36 has been moved to the left from the position shown in FIG. 7 until a portion of the prong 44 is touching the right side of the boss 26 . The contact surface 56 of the prong 44 is not engaged with the contact surface 60 of the boss 26 .
[0041] In FIG. 9 , the operators 20 and 32 are spaced apart as they would be when the sash 14 is closed and the primary operator 20 and the inside operator 32 are not aligned. The inside operator 32 has been moved to the left from the position shown in FIG. 9 so that co-action between the prong 44 and the boss has caused the prong 44 to flex and the free end 50 of the prong 44 is in contact with an upper contact surface 64 of the boss 26 . The prong 44 is prevented from assuming a not flexed condition although the prong 44 is biased to return to a not flexed condition. The contact surface 56 of the prong 44 is not adjacent to or in contact with the contact surface 60 of the boss 26 and the contact surface 58 of the prong 46 is not adjacent to or in contact with the side contact surface 62 of the boss 26 .
[0042] As the inside operator 36 is moved longitudinally to the left from the position shown in FIG. 7 through the positions shown in FIGS. 8 . and 9 , the boss 26 co-acts with a contact surface 66 on the housing 22 of the primary operator 20 preventing the primary operator 20 from moving longitudinally to the left beyond the position shown in FIGS. 7 through 10 . When the slider 36 reaches the position shown in FIG. 10 , the inside operator 32 and the primary operator 20 are aligned. In the FIG. 10 condition, the free end of the prong 44 enters a recess indicated generally at 68 and the contact surface 56 of the prong 44 can engage the contact surface 60 of the boss 26 . When the slider 36 of the inside operator 32 is moved to the right from the position shown in FIG. 10 to the position shown, for example; in FIG. 5 , engagement between the contact surfaces 56 and 60 causes movement of the boss 26 of the primary operator to the right, also. Now that the operators 20 and 32 are aligned, the longitudinal position of the primary operator will now be controlled by longitudinal movement of the inside operator 32 .
[0043] Thus, it will be seen that when the sash 14 is closed and the primary operator 20 and the inside operator 32 are aligned, the longitudinal position of the primary operator 20 is controlled by longitudinal movement of the inside operator 32 . When the sash 14 is closed and the primary operator 20 and the inside operator 32 are not aligned, longitudinal movement of the inside operator 32 will bring them into alignment whereupon the longitudinal position of the primary operator 20 is again controlled by longitudinal movement of the inside operator 32 .
[0044] In FIGS. 2 , 11 , and 12 , the sash 14 is shown in an open position, i.e., it has been pivoted outwardly away from the window frame 12 . A screen S is supported in the window frame. 12 so that access to the primary operator 20 on the sash 14 is prevented from inside of the window 10 . The screen S might as well be a storm window or other transparent or translucent panel. When the sash 14 is closed, a person on the inside of the window 10 can operate the primary operator 20 with the inside operator 32 without having to remove the screen S or the like from the window frame 12 . When the sash 14 is open, the inside operator 32 is ineffective because the primary operator 20 and the inside operator 32 are not engaged and can't engage. With the sash 14 open; longitudinal sliding movement of the inside operator-slider 36 has no effect on the longitudinal position of the primary operator slider 24 .
[0045] The positions of the operators 20 and 32 in FIGS. 2 , 11 and 12 are such that, when the sash 14 is closed, the operators 20 and 32 will be aligned and longitudinal movement of the inside operator slider 32 will effect a corresponding longitudinal movement of the primary operator slider 26 . If the positions of the operators 20 and 32 are such that, when the sash 14 is moved from an open position to the closed position, the operators 20 and 32 will be not aligned but longitudinal movement of the inside operator slider 36 will bring the operators 20 and 32 into alignment as described above.
[0046] The inside operator 32 can be adapted to control the longitudinal position of a primary lift operator. In FIG. 1 , a sash primary lift operator is indicated generally at 70 . The primary lift operator 70 comprises an actuator 72 mounted for longitudinal sliding movement in a track 74 . Such a primary lift operator is available from OEM Shades under the designation SSLT and is described as a magnetically coupled blind lift mechanism for installation in sealed insulated glass units. The lift position of a blind is controlled by the position of an externally mounted magnet assembly which is coupled to a corresponding internal magnet assembly. Thus, the actuator 72 may be an externally mounted magnet assembly and may be provided with a boss 76 for engagement by prongs of an inside operator (not shown) corresponding with the inside operator 32 . Such an inside operator would be mounted for sliding movement on a portion of a window frame, such as a jamb frame insert 77 which is partially shown in FIG. 1 and would extend at least the length of the track 74 . This arrangement would correspond with the arrangement previously described where the inside operator 32 is mounted on the head frame insert 28 , for longitudinal sliding movement. The inside operator may be provided with a lock mechanism for positively locking the inside operator in a particular longitudinal position. A primary blind lift operator is also available from OEM Shades and it includes a magnet although the invention is suitable for use in conjunction with other lift operators.
[0047] The prong 46 ( FIG. 4 ) may comprises a first, proximal leg 78 and a second, distal leg 79 and they form an angle Z between them when the prong is not flexed. The first leg 78 and a corresponding first leg of the prong 44 extend away from each other and the second leg 79 and a corresponding second leg of the prong 44 extend towards each other. When a prong is flexed, the angle between the first leg and the second leg gets smaller as indicated by dotted lines in FIG. 4 for the prong 44 . Good results have been observed with prongs made from an automotive grade of polypropylene.
[0048] The prongs 44 and 46 may be modified so that each includes a brace like the brace 80 shown on prong 46 in FIG. 4 . The brace 80 and a corresponding brace provided on prong 44 connect the outside of the first leg 78 of the prong 46 and the outside of the corresponding first leg of the prong 44 to the slider 36 . The braces prevent or minimize any change in the angle between the first legs and the slider 36 when the prongs are flexed. In this case, most or all of the flexure takes place at an elbow 82 shown on prong 46 and at a corresponding elbow on prong 44 . In this configuration, good results have been obtained in the case where prongs including braces corresponding with the brace 80 are configured so that the angle between a first leg and a second leg of a prong changes, as between the flexed and the unflexed condition, between about 15 and 35 degrees. A preferred range is between about 20 and 30 degrees. When the prongs include braces and one of the prongs is flexed, it is preferred that the upper surface 64 of the boss 26 and the second leg of the flexed prong form an angle between them of about zero degrees to 10 degrees. The prongs 44 and 46 are preferably symmetrical, as shown in the drawing Figures.
[0000] It will be appreciated that the inside operator of the present invention can be adapted to a wide variety of applications. These will be apparent to a person having ordinary skill in the field of fenestration considering the foregoing detailed description of the invention.
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A window assembly comprising a window frame and a window sash is disclosed. The sash is supported on the window frame for pivotal movement between an open position and a closed position. The sash supports an insulated glass unit with an internal blind and includes a primary operator connected to the blind so that linear movement of the primary operator causes movement of said blind. When the sash is closed, a secondary operator supported in the window frame engages the primary operator so that linear movement of the secondary operator causes a corresponding linear movement of the primary operator.
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BACKGROUND AND SUMMARY OF THE INVENTION
The invention relates to a holding frame for an oven pan, particularly an aluminum foil pan.
Aluminum foil pans are widely used for cooking since they are very efficient in quickly distributing heat and are also inexpensive, thus making them disposable. A wide variety of shapes and sizes of aluminum pans have been developed for use with food items baked in an oven. Generally, such pans have an upper curled-over lip which adds a degree of rigidity and strength to the pan. Also, stamped crease lines are provided in both the bottom wall and side wall of the pan for additional reinforcement. However, due to the relatively thin and flimsy nature of the aluminum gauges commonly used, such reinforcement still fails to prevent the pan from buckling or twisting as the user carries the filled pan to or from the oven.
A significant buckling problem is found with pans that are intended for use in baking heavier items, such as turkeys, hams, roasts, etc. This problem is particularly acute when the baking process had ended and the user attempts to extract the pan from the oven when it is very hot. If there are liquids in the pan, such as cooking juices, gravy and the like, the user must take great care to prevent spillage, as well as avoiding burning the hands. Often times, two people must attempt to grasp opposite ends of an aluminum pan and hold it level during transport from the oven.
Numerous holders and racks for conventional cooking receptacles have been used. They are, however, not directed toward use with the disposable type metal foil pans. Other holding frames require cooperative engagement between the frame and a boiler or roaster of a very rigid and thick design.
Accordingly, it is a primary object of the invention to provide a holding frame for a metal foil oven pan.
It is an allied goal of the invention to provide a holding frame which can be used repeatedly with subsequent metal foil pans.
It is an important goal of the invention to provide a holding frame which is completely separable from a metal foil oven pan.
It is another objection of the invention to provide a holding frame for a metal foil oven pan in which the oven pan is supported along its bottom wall and constrained laterally along its side wall.
It is a concomitant object of the invention to provide a holding frame for aluminum oven pans in which the user can individually place the frame and pan into the oven, and later remove them from the oven, without the aid of additional assistance.
It is further a goal of the invention to provide a holding frame for an oven pan in which the user can maneuver the pan without ever contacting any portion of the pan.
It is yet another object of the invention to provide a metal wire holding frame that can be provided in a variety of configurations for the accommodation of differently sized aluminum baking pans.
The invention may be summarized as comprising a metal foil oven pan of the type having a generally flat bottom wall and a peripheral continuous sidewall, in combination with a wire holding frame having coplanar pan support members extending below the bottom wall of the pan. The pan supports terminate at the peripheral edge of the pan bottom in upwardly extending lateral sidewall retaining portions. The lateral retaining portions being provided at about the same vertical angle as the sidewall. At least one pair of lateral retainers at opposing sides of the pan terminate in handle means for lifting the pan and frame as a unit.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in greater detail in the following description of the preferred embodiment, taken in conjunction with the drawings, in which:
FIG. 1 is a side view of a rectangular aluminum oven pan retained in the metal wire holding frame in accordance with the invention;
FIG. 2 is an end view of the combination shown in FIG. 1;
FIG. 3 is a bottom view of the combination shown in FIG. 1;
FIG. 4 is a bottom view of an oval-shaped aluminum oven pan retained in the metal wire holding frame shown in FIGS. 1-3;
FIG. 5 is a bottom view of a square-shaped aluminum oven pan retained by a metal wire holding frame in an alternate embodiment of the invention;
FIG. 6 is a bottom view of a circular oven pan being retained by the holding frame shown in FIG. 5; and,
FIG. 7 is a bottom view of a large-sized oval oven pan retained by a one-piece metal wire holding frame in another alternate embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIGS. 1-3, it will be seen that a conventional rectangular aluminum oven pan 10 is shown. Pan 10 includes a continuous sidewall 11 formed integrally with a generally flat bottom wall 12 along the peripheral edge 13 of the bottom. For extra rigidity in handling the pan, a rolled-over lip 14 extends around the upper edge of the sidewall 11, as best seen in FIG. 2. Pan 10 comprises a relatively thin gauged stamped sheet of aluminum which allows it to very quickly and evenly distribute heat, while at the same time being very inexpensive and thus disposable.
Pan 10 is provided with, in combination, a wire frame 15 which ably retains the pan for transport into and out of an oven. In this preferred embodiment of the invention, frame 15 is a two-sectioned structure having a first section 16 fixedly connected to a transverse second section 17. Section 16 has parallel spaced-apart portions 18 which terminate at their opposite ends in upwardly extending end portions 19. Portions 20 connect the ends of upwardly bent end portions 19 and are arranged generally transverse to portions 18. The upwardly bent end portions 19 and connecting portions 20 form lateral retaining means for the sidewall 11 of the pan. As best viewed in FIG. 2, portions 19 extend upwardly along sidewall 11 for greater than one-half of its height and are bent at substantially the same angle that sidewall 11 extends from bottom 12 in order to provide flush abutting contact with and lateral support for the pan sidewall.
Second section 17 of frame 15 is arranged to centrally cross section 16 at generally right angles thereto. In like manner, section 17 includes two parallel spaced apart wire portions 21 which terminate at their opposite ends in upwardly bent portions 22. The bent portions 22 slope upwardly again generally at the same angle as the sidewall 11 but further include rebent portions 23 which project outwardly of frame 15 in a substantially horizontal plane as shown in FIG. 1. The ends of the horizontal portion 23 are integrally connected by transverse portion 24 and provide opposite handle means for the frame. Welds w fixedly connect the parallel spaced apart wire sections 18 and 21 which are support members for the pan bottom 12. Due to the flexible and deformable nature of aluminum foil, when sufficient food is placed into pan 10, the bottom 12 might deflect downwardly if one were to attempt to carry the pan in the conventional manner. Frame 15 avoids this by supportively retaining bottom 12 across the portions 18 and 21, as shown in FIGS. 1 and 2.
Thus, frame 15 offers horizontal constraint by means of the upwardly bent portions of the frame and vertical support by means of the support portions 18 and 21. This arrangement facilitates the easy maneuvering of pan 10 when it is loaded with food. One peson simply grasps transverse portions 24, or handle means, and lifts the pan to the desired location.
With reference to FIG. 4, it will be understood that an ovalshaped pan 110 may also be used with frame 15. Section 16 extends across the short axis of the oval-shape while section 17 resides along the long axis thereof.
With reference next made to FIG. 5, it will be appreciated that frame 115 is provided for a square-shaped aluminum foil pan 210. In this alternate embodiment of the invention, frame 115 includes equal length sections 16' and 17' having, respectively, parallel spaced apart wire portions 18' and 21' also of equal length. Section 17' is provided with handle means projecting outwardly from its upwardly bent portions in substantially the same manner as frame 15.
In FIG. 6, a circular-shaped aluminum foil pan 310 is provided in combination with frame 115 as described in FIG. 5. The diameter of the pan bottom is substantially of the same dimension as the length and width of the square-pan 210, whereby sections 16' and 17' extend generally along two transverse diameters of the circular shape.
It will be understood, with respect to frames 15 and 115 shown in FIGS. 1-6, that a modification of sections 16, 16' and 17, 17' may be provided to accommodate various sizes of pans. For pans of different sidewall heights, the upwardly bent portions at the ends of the wire portions 18, 21 and 18', 21' may be shortened or lengthened to thereby offer lateral restraint along a major portion of the height of a sidewall. Additionally, the length of the wire portions 18, 18', 21 and 21' may be varied to accommodate an infinite variety of pan bottom sizes.
With reference now made to FIG. 7, another alternate embodiment for the holding frame of the invention is shown and comprises a single wire loop frame 215. Frame 215 is formed to provide a holding frame for an oval pan 410, as shown, In this regard, frame 215 comprises individual loop segments A, B, C, D, E and F. Each segment includes two straight wire portions 25 which are integrally connected by curved connecting portions 26. In this embodiment, the straight portions 25 all extend in radial direction passing through the center point P of oval pan 410. However, the continuous wire loop frame 25 may be provided in a variety of configuratios and is not intended to be limited to the embodiment disclosed. At the peripheral edge of the pan bottom, the straight portions 25 terminate thereat in upwardly bent portions 27, in similar manner to those as described for frames 15 and 115. The upwardly bent portions 27 of loop segments A, B, E and D are connected by transverse connecting portions 28. Loop segments C and F are arranged generally along the long axis of the oval. Segments C and F are provided with handle means wherein their upwardly bent portions 27 are re-bent to form outwardly projecting portions 29 which are integrally connected by transverse handle portions 30. Straight and curved wire portions 25 and 26 of loop segments A-F are arranged in co-planar relationship and provide support for the pan bottom as would be clear. The upwardly bent portions 27 provide lateral restraints for the sidewall of pan 410. Frame 215 is very useful with large-sized oval pans, such as those having a long axis length of 18 inches or more, and a shorter axis length of 12 inches or more. Such type pans are used for baking large items such as turkeys.
Frame 215 is not limited to use with oval-shaped pans and, for example, may be shaped for accommodating circular pans whereby the individual loop portions A-F would all have substantially the same dimensions. A continuous single wire holding frame is also envisioned for square and rectangular pans wherein four loop segments are provided arranged at 90° therebetween.
Within the scope of the invention it is further to be understood that frames 15 and 115 may be provided with pan support sections which do not all cross. For example, a plurality of sections 16 can be provided in parallel relationship with each one crossing section 17 at a different location. Also, with reference to FIG. 6, frame 115 can be provided with more than two sections that radially extend from the center of pan 310.
It will be understood that the holding frame of the invention is not limited to use with flat bottom pans and, while the preferred embodiment has two opposing handle means, handle means can be provided at more than just two upwardly bent portions of the frame.
Accordingly, a metal foil oven pan with a holding frame has been provided which can be re-used with a succession of oven pans allowing the predecessors to be discarded after cooking. The pans are securley supported in the vertical direction and are laterally restrained to afford a very efficient carrying means for the pans. The invention permits one person to easily carry a hot pan from the oven without the need of grasping the hot pan itself and run the risk of deforming the pan and spilling the food contents therefrom.
While particular embodiments for the invention have been disclosed, it is understood that a broad range of equivalent configurations fall within the scope of the invention and the claims appended hereto.
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An aluminum foil oven pan having a holding frame therefor is disclosed. The holding frame comprises wire and has generally co-planar pan support members extending beneath the bottom wall of the pan. The pan support members terminate in upwardly extending lateral portions for restraining the side wall of the pan. At least two of the lateral restraining portions are provided with handle means whereby a retained pan may be easily lifted with the holding frame so that the user need not touch the pan during cooking procedures and risk buckling the pan and spilling the food contents therefrom.
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FIELD OF THE INVENTION
[0001] The invention generally relates to compositions, articles and methods for intercepting and scavenging oxygen in environments containing oxygen-sensitive products, such as food and beverages.
BACKGROUND OF THE INVENTION
[0002] Plastic packaging that provides a means of intercepting and scavenging oxygen as it passes through the walls of the package (herein referred to as an “active oxygen barrier”), can enhance the quality and shelf-life of many products. Such active barrier packaging can be more effective than a “passive barrier” which merely retards oxygen permeation into the package. In contrast, the active barrier can remove oxygen initially present and/or generated in the interior of the package, as well as retard the passage of exterior oxygen into the package.
[0003] The requirements for a commercially successful active barrier package will vary by application, but typically include one or more of the following:
a) ability to process one or more polymer materials on commercial molding (e.g., injection, compression, extrusion, blow molding) equipment; b) ability to provide a multilayer structure with sufficient layer integrity and adherence during processing and in use; c) cost effective use of (typically) more expensive barrier materials, i.e., generally in a multilayer structure; d) avoiding the generation and/or transmission of adverse reaction byproducts which may affect the taste and smell of the packaged material or raise government regulatory issues; e) provide transparency, whereby at least 50% transmission of visible light is preferred; and/or f) enable effective use of the packaging material in a recycling stream and/or as biodegradable waste.
[0010] Thus, there is an ongoing need for compositions and articles which can satisfy the processing, aesthetic and mechanical properties (e.g., top load strength) required of various commercial packaging applications, while also regulating the exposure to oxygen of products contained in such packages in order to maintain and enhance the quality and shelf-life of the product.
SUMMARY OF THE INVENTION
[0011] The following aspects of the invention may be used independently and/or in various combinations to provide an active oxygen barrier composition, article and/or method.
[0012] In one aspect, an active oxygen barrier composition is provided comprising a poly(hydroxyalkanoate) (“PHA”) having the formula H—[O—CHR—(CH 2 ) x —CO] n —OH, and a transition metal, where R is H (hydrogen) or an organic radical having up to about 13 carbon atoms (preferably a hydrocarbon radical), x is from 0 to 3, and n is from 10 to 20,000 (hereinafter referred to as the “active oxygen barrier composition”). Typically, “n” is selected such that the PHA polymer has a molecular weight ranging from about 700 to about 1,440,000 daltons. In a preferred embodiment, the PHA includes or substantially comprises poly(lactic acid) (“PLA”), a polymer derived from lactic acid, also known as 2-hydroxy propionic acid. In various embodiments, the transition metal is provided as a metal compound, with for example an organic ligand, and the metal of the transition metal compound is generally present in an amount of at least about 20 ppm in the PHA. The transition metal may be cobalt, and more particularly the metal compound may be cobalt neodecanoate. The metal compound may comprise from about 0.01 to about 3 percent by weight of the composition; the amount is varied based on the application (e.g., monolayer or multilayer structure, wall thickness, product, desired shelf-life, etc.). The transition metal can be one that is selected from the group consisting of iron, cobalt, nickel, ruthenium, rhodium, palladium, osmium, iridium, platinum, copper, manganese and zinc.
[0013] An article of manufacture may be made from such an active oxygen barrier composition, comprising e.g., at least a portion of a package, preform, container, film, sheet, liner, coating or closure. The article may be either monolithic or multilayer. In various embodiments, the active barrier composition is provided as one or more layers of a multilayer beverage container. In another embodiment, a monolithic beverage bottle (e.g., for water) is provided.
[0014] In one embodiment, the multilayer article includes at least one layer of the active oxygen barrier composition, and at least one adjacent layer of PHA, wherein the PHA of the active barrier composition and/or the at least one adjacent layer is preferably poly(lactic acid). The adjacent layer of PLA may be provided between an oxygen-sensitive product and the active barrier composition in order to allow migration of oxygen molecules, for example from the interior of the package, to reach the layer of the active oxygen barrier composition, thereby enabling consumption of oxygen initially present and/or generated in the product during use.
[0015] In one particular embodiment of the invention, a multilayer preform or container is provided for the packaging of an oxygen-sensitive food or beverage. The article includes one or more alternating layers of the active oxygen barrier composition, and one or more layers of PHA, one or both of which include or substantially comprise poly(lactic acid). Most preferably the active oxygen barrier composition is contained within a layer that is arranged/disposed in the sequence of layers such that this layer does not make direct contact with the food or beverage in the final container product.
[0016] In one embodiment, an active oxygen barrier composition is provided comprising poly(lactic) acid and a transition metal.
[0017] In another embodiment, an active oxygen barrier composition is provided comprising a poly(hydroxyalkanoate) polymer of the formula H—[O—CHR—(CH 2 ) x —CO] n —OH and a transition metal, where R is hydrogen or an organic radical having up to about 13 carbon atoms, x is from 0 to 3, and n is from about 10 to about 20,000.
[0018] In another embodiment, a method is provided of making a multilayer article for holding an oxygen sensitive product, the method including molding an intermediate article having a first layer comprised of a poly(hydroxyalkanoate) polymer and a second layer adjacent to the first layer comprised of a poly(hydroxyalkanoate) polymer and a transition metal, and expanding the intermediate article to form the multilayer article.
[0019] In another embodiment, a method is provided of imparting oxygen scavenging activity to a packaging article that is comprised of multiple layers of poly(hydroxyalkanoate) polymer, the method comprising mixing a transition metal into at least one of the multiple layers of the article.
[0020] In another embodiment, a method is provided of imparting oxygen scavenging activity to a poly(hydroxyalkanoate) polymer composition comprising mixing a transition metal with a poly(hydroxyalkanoate) polymer.
[0021] These and other features of the present invention will be more particularly understood with regard to the following detailed description and drawings.
BRIEF DESCRIPTION OF THE FIGURES
[0022] The invention may be further understood with reference to the drawings wherein:
[0023] FIG. 1 is a side elevational view of a multilayer preform incorporating two layers of an active oxygen barrier composition, according to one embodiment of the invention;
[0024] FIG. 2 is a side elevational view of a multilayer container having a transparent multilayer sidewall, made from the preform of FIG. 1 ;
[0025] FIG. 3 is a horizontal cross section taken along line 3 - 3 of FIG. 2 , showing the multilayer sidewall of the container;
[0026] FIG. 4 is a vertical cross section of a blow molding apparatus for making the container (of FIG. 2 ) from the preform (of FIG. 1 );
[0027] FIG. 5 is a graph of % Oxygen in a closed container vs. Time (in days) comparing the amount of oxygen reduction achieved by a series of PLA plaques made from compositions of the present invention of varying cobalt concentration;
[0028] FIG. 6 is a graph of % Oxygen in a closed container vs. Time (in days) comparing the amount of oxygen reduction achieved by a series of PLA plaques made from compositions of the present invention of varying cobalt concentration;
[0029] FIG. 7 is a graph of % Oxygen in a closed container vs. Time (in days) comparing the oxygen reduction achieved by a series of PLA plaques made from compositions of the present invention of varying cobalt concentration.
DETAILED DESCRIPTION
[0030] It has been found that an active oxygen barrier composition can be formed from a combination of PHA and a transition metal. This composition can be used with and in a variety of articles for the packaging of oxygen-sensitive products. These articles include all or a portion of a molded article, such as a package, preform or container, a closure (e.g., cap, lid or the like) for the package, an insert (e.g., liner, gasket or the like) for the package or closure, a sachet (e.g., for placement in the cavity or interior of the package), a coating, an absorbed layer on a variety of supports, etc.
[0000] Poly(Lactic Acid)
[0031] Poly(lactic acid) (“PLA”) as used herein refers to a polymer having more than 50% by weight lactic acid units, i.e., a repeating chain of lactic acid. The material can be either the right-handed (D) or left-handed (L) enantiomer of an optical isomer, or can be a racemic mixture of the two enantiomers. It is preferably unplasticized, but can also be used in a plasticized state with residual monomer, oligomer, etc.
[0032] One example of a suitable PLA polymer is bottle grade PLA resin available from NatureWorks, 15305 Minnetonka Blvd., Minnetonka, Minn. 55345. For example, NatureWorks PLA 7000D is suitable for injection stretch blow molding (ISBM) applications, using conventional ISBM equipment. Its physical properties include for example a specific gravity of 1.25-1.28 (based on ASTM method D792), a melt density at 230° C. of 1.08-1.12 g/cc (ASTM method D1238), a glass transition temperature of 130-140° F. (55-60° C.) (ASTM method D3417), a crystalline melt temperature (T m ) of 295-310° F. (145-155° C.) (as measured by ASTM method D3418), and a melt volume flow rate (MFR) at 210° C. of 5-15 g/10 min. (ASTM method D1238A and B). The polymer can be stretch blow molded at a preform temperature of 80-100° C., a stretch rod speed of 1.2 to 2 meters per second, and a blow mold temperature of 70-100° F. (21-38° C.).
[0033] PLA is a hygroscopic thermoplastic that readily absorbs moisture from the atmosphere. Thus, PLA is typically thoroughly dried, e.g., to less than 250 parts per million (ppm) moisture, before melt processing to avoid a drop in molecular weight during melt processing (and the resulting reduction in mechanical properties). Virgin PLA is provided by NatureWorks as crystalline pellets (25% crystallinity), for ease of drying.
[0034] The molecular weight of the PHA or PLA polymer will affect the physical properties of an article made from such polymer. For example, NatureWorks 7000D bottle grade PLA resin has a relative viscosity (RV) of 3.9 to 4.1.
[0035] Depending upon the particular application, a preform made from the active oxygen barrier composition of the present invention may be designed with a planar or area (axial times hoop) stretch ratio (SR) of 8 to 11, an axial SR of 2 to 3, and hoop SR of 3 to 4. These are given by way of example only; the specific application will determine the actual preform design and stretch ratio.
[0036] In comparison to polyethylene terepthalate (PET), a polyester polymer widely used in the bottle industry, PHA, and in particular, PLA, exhibits a higher transport rate for water vapor, carbon dioxide and oxygen, i.e., by a factor of about 8-10 times that of PET. For example, PLA may have a water vapor transmission rate of 20 (units of cc-mil/100 in 2-day-atm) at 20° C. and 0% relative humidity (RH); an O 2 transmission rate of 40 (same units), and a CO 2 transmission rate of 172 (same units). The ability to substantially lower the oxygen transmission rate of PLA in accordance with the present invention is thus particularly beneficial as it enables use of PLA in current applications utilizing PET.
[0037] In addition, PLA is a biodegradable polymer, in contrast to many of the commercially important polymers now used in packaging. PLA polymer 7000D has been shown to biodegrade similar to paper under simulated composting conditions (ASTM D5338 at 58° C. (135° F.)) and satisfies proposed European composting certification standards. Composting is a method of waste disposal that allows organic materials to be recycled into a product that can be used as a valuable soil additive. PLA is made primarily of poly(lactic acid), a repeating chain of lactic acid, which undergoes a two-step degradation process. First, the moisture and heat in a compost pile will attack the PLA polymer chains and split them apart, creating smaller polymers, and finally lactic acid. Microorganisms in compost soil consume smaller polymer fragments and lactic acid as nutrients. Since lactic acid is widely found in nature, a large number of organisms metabolize lactic acid. The end result of the process is carbon dioxide, water and also humus, a soil nutrient. See NatureWorks publication literature for NatureWorks PLA polymer 7000D (NWPKG0370205Y2).
[0000] The Transition Metal
[0038] The transition metal can be added to the PHA in the form of the metal itself, as a salt, or as a metal compound. In a preferred embodiment, the active oxygen barrier composition comprises PLA and a transition metal, where the metal is added as a metal compound. Metal compounds typically comprise two components: a metal and a ligand which bonds to the metal, and generally a substantial portion of the ligand is organic.
[0039] The metal can be added to the polymer as a liquid, a solution mixture, in crystalline form, as a pastille, or as a powder, depending upon factors such as processing conditions. Typically, the metal is mixed with the polymer to create a physical blend. The active oxygen barrier composition, however, can eventually comprise a chemical bond between the metal and the PHA or the ligand of the metal compound and the PHA, where a chemical reaction occurs in the physical blend of the metal compound and the PHA. In other words, once the metal compound is processed with the PHA, the metal compound can be present in the PHA polymer as the same initial metal compound, a new metal compound, a salt or a metal atom. A new metal compound can occur where at least a portion of the ligand no longer forms a chemical bond with the metal, and a new ligand bonds to the metal. The new ligand can be the PHA polymer, or any other component such as water, or another organic component. Preferably, the initial metal compound is available in a stable form, i.e., the metal compound is unreactive towards oxygen before addition of the compound to the PHA.
[0040] The amount of metal present in the polymer is defined relative to the amount by weight in the polymer/metal composition. It is understood that the desired metal concentration can depend on a variety of factors or a combination of factors such as the molecular weight of the metal, the molecular weight of the metal compound, and the polymer type or molecular weight of the PHA. In various embodiments, the metal atom (e.g., cobalt) is present in the polymer/metal composition in an amount of at least about 20 ppm based on the composition, more preferably from about 50 ppm to about 6,000 ppm, even more preferably from about 100 ppm to about 5,000 ppm, and still more preferably from about 200 ppm to about 3,000 ppm. The lower limit of the metal concentration may be determined by a desired level of oxygen-scavenging performance (i.e., insufficient concentrations of metal may not achieve a desired scavenging performance for a given application) and/or processability. The upper limit may be determined by factors such as cost, transparency, color, and/or processability depending on the particular application.
[0041] The transition metal can be selected from the group consisting of iron, cobalt, nickel, ruthenium, rhodium, palladium, osmium, iridium, platinum, copper, manganese and zinc. In a preferred embodiment, the metal is cobalt, and more preferably is added as a cobalt carboxylate compound, such as cobalt neodecanoate.
[0000] Articles of Manufacture (e.g., Package), Storage and Shelf-Life
[0042] Preferably, the active oxygen barrier composition is provided in an article that, once formed, can be stored in the presence of an excess of oxygen, such as air, for a significant period of time (e.g., 2 months, preferably 4 months) without substantial loss of scavenging performance when thereafter filled with a product. Preferably, the article is a package capable of being stored under ambient conditions, where ambient conditions is referred to as an atmosphere of 21% oxygen (air) and a relative humidity of 50% at 23° C.
[0043] Also, it is preferable to provide an article (which includes the active oxygen barrier composition) wherein oxygen scavenging will commence upon filling with the product and/or within a short time thereafter (e.g., within 5 days, preferably 2 days, and more preferably within 24 hours of filling).
[0000] Layer Compatibility
[0044] According to another feature of the invention, the active oxygen barrier composition can be provided in one or more layers of a multilayer article, having the desired layer integrity and layer adherence for a given application. Layer adherence and integrity is generally a function of the processability of the material, which for polymers, is typically a function of the melt viscosity.
[0045] A conventional parameter for processability is melt viscosity, as indicated by a melt index. “Melt index” is generally defined as a number of grams of polymer that can be forced through an orifice of a standard unit at a specified temperature and pressure over a defined period of time. The melt index can be measured according to ASTM method D1238-94A. The polymers as used herein, i.e., the active oxygen barrier composition and the other structural and/or barrier polymers utilized in an article, are generally high molecular weight polymers, having a molecular weight of at least about 20,000 daltons for which the melt viscosity is an important process parameter. Generally, as the molecular weight of the polymer increases, both the melt viscosity and melt strength increase. For multilayer applications, those skilled in the art can determine an appropriate combination of melt viscosity and melt strength for a layer of the active oxygen barrier composition positioned adjacent layers of other polymer types.
[0046] Where structural layers are positioned adjacent a layer of the active oxygen barrier composition in the absence of an adhesive, it is preferred that the two layers be “compatible.” Compatibility implies that the multilayer article, having at least two layers positioned adjacent each other, have the structural integrity to withstand delamination, observable deformation from a desired shape, or other degradation of a layer caused by a chemical or other process initiated by an adjacent layer during the article-forming process and in the final product during expected use. Compatibility can be enhanced by selecting melt viscosities, melt indices, and solubility parameters that allow one of ordinary skill in the art to achieve a desired package characteristic. If a recyclable bottle is desired, then it may be desired that the layers readily separate when the bottle is cut to enable separate processing of the different materials.
[0047] The melt index of the active oxygen barrier composition should take into account a decrease in melt index that can occur for example when a metal (e.g., cobalt) is added to a polymer.
[0000] Transparency
[0048] One advantage according to another aspect of the invention is the ability to provide an article including the active oxygen barrier composition which is substantially transparent. By substantially transparent it is meant that at least a portion of the package allows the transmission of at least 50% of visible light. More preferably, transparency can be determined by the percent haze for transmitted light through the wall of the article, which is given by the formula:
H T =[Y d +( Y d +Y S )]×100
where H T is the percent haze for transmitted light through the wall,
Y d is the diffuse light transmitted by the thickness of the specimen, and
Y S is the specular light transmitted by the thickness of the specimen. The diffuse and specular light transmission values are measured in accordance with ASTM method D-1003, using any standard color difference meter such as Model D25D3P manufactured by HunterLab, Inc., Reston, Va., USA. In select embodiments, the relevant portion of the package, e.g., sidewall, has a percent haze of no greater than 30%, more preferably no greater than 20%, and still more preferably no greater than 10%.
EXAMPLE
Oxygen-Scavenging Juice Bottle
[0049] FIGS. 1-4 illustrate a transparent 2-material 5-layer (2M, 5L) preform and container made therefrom, which includes two layers of the active oxygen barrier composition according to the present invention. This multilayer structure enables use of a relatively low weight percentage of the active oxygen barrier composition, e.g., about 3% of the total container weight, while providing a desired level of oxygen scavenging.
[0050] An injection molded multilayer preform 30 is shown in FIG. 1 . The substantially cylindrical (as defined by vertical centerline 32 ) preform includes an upper neck portion or finish 34 having a top sealing surface 31 which defines an open top end of the preform, a cylindrical outer surface with threads 33 and a lower flange 35 . Below the flange is a body-forming portion 36 most of which will be expanded in forming the body of the container 40 . The body-forming portion 36 of the preform includes an upper cylindrical portion 41 , an inwardly tapered shoulder-forming portion 37 (decreasing in outer diameter from top to bottom), a cylindrical panel-forming section 38 , and substantially hemispherical base-forming section 39 with an interior centering nub 50 .
[0051] The preform 30 is adapted for making a 16-ounce container 40 (see FIG. 2 ) for a cold-filled, non-carbonated liquid drink, such as juice. The panel-forming section 38 will undergo an average planar stretch ratio of about 10, where planar stretch ratio is the ratio of the average thickness of the preform panel-forming section 38 to the average thickness of the container panel 46 (as shown in FIG. 2 ), taken along the length of the respective preform and container portions. The average panel hoop stretch is preferably about 3 to 4 and the average panel axial stretch is about 2 to 3. This produces a container panel 46 with a desired biaxial orientation and visual transparency. The specific panel thickness and stretch ratio selected will depend on the dimensions of the bottle, the internal pressure, and the processing characteristics (as determined by for example by the melt viscosity of the particular materials employed).
[0052] Both preform 30 and the resulting container 40 have the two-material five-layer (2M, 5L) structure shown in FIG. 3 . The multiple layers comprise, in serial order, an outermost layer of PLA 57 , an outer intermediate layer of the active oxygen barrier composition 59 , a central core layer of PLA 56 , an inner intermediate layer of the active oxygen barrier composition 58 , and an innermost layer of PLA 55 . The outermost, core and innermost PLA layers may be of any commercially available PLA having a melt index of about 5-15 g/10 min. at 210° C. (ASTM D1238 A, B). The two intermediate layers of the PLA active oxygen barrier composition of the present invention may have a melt index of about 5-15 g/10 min, a T g of about 55° C., and a melting point of about 145° C. The active oxygen barrier composition includes 20-6,000 micrograms of cobalt per gram of polymer (i.e., 20-6,000 ppm cobalt per weight of PLA); the cobalt is added as cobalt neodecanoate. The weight ratio of outermost, innermost and core layers, to the intermediate layers, is preferably in a range of about 99:1 and 80:20.
[0053] The preform shown in FIG. 1 may be injection molded by any of various known processes, including sequential, simultaneous and any combination thereof, including for example the sequential metered process described in U.S. Pat. Nos. 4,550,043, 4,781,954, 5,049,345 and 5,582,788, owned by Graham PET Technologies Inc. (formerly Continental PET Technologies, Inc.), and hereby incorporated by reference in their entirety. In this process, predetermined amounts of the materials are introduced into the gate of the preform mold as follows: a first shot of PLA which forms partially-solidified innermost and outermost preform layers as it moves up the cool outer mold and core walls; a second shot of the active oxygen barrier composition which will form the inner and outer intermediate layers; and a third shot of the PLA which pushes the active barrier composition up the sidewall (to form thin intermediate layers) while the third shot forms a central core layer. After the mold is filled, the pressure is increased to pack the mold against shrinkage of the preform. After packing, the mold pressure is partially reduced and held while the preform cools.
[0054] FIG. 2 shows a 16 ounce cold-filled noncarbonated juice bottle 40 made from the preform of FIG. 1 . The bottle 40 includes a transparent biaxially-oriented container body 50 . The upper thread finish 34 has not been expanded (same as that of preform 30 ), but is of sufficient thickness or material construction to provide the required strength for application of a closure (e.g., screw-on cap). The expanded container body 50 includes an upper shoulder section 43 , an indented annular rib 44 , a dome portion 45 and a cylindrical panel section 46 with a plurality of annular ribs 42 . The panel section 46 preferably has been stretched at an average planar stretch ratio of 10. The body also includes a footed base 47 having a plurality of feet 48 separated by ribs 49 .
[0055] FIG. 3 is an expanded cross-sectional view of the 5-layer container panel wall 46 . The wall 46 comprises three relatively thick layers of PLA: innermost layer 55 , core layer 56 , and outermost layer 57 , and the two relatively thin layers of the active oxygen barrier composition: inner and outer intermediate layers 58 , 59 .
[0056] FIG. 4 illustrates a stretch blow molding apparatus 70 for making the container 40 from the preform 30 . More specifically, the substantially amorphous and transparent preform body-forming section 38 is reheated to a temperature in the orientation temperature range of the innermost/outermost/core PLA layers, and the heated preform is then positioned in a blow mold 71 . A stretch rod 72 axial elongates (stretches) the preform 30 within the blow mold to insure accurate centering and complete axial elongation of the preform. The blowing gas (shown by arrows 73 ) is introduced to radially inflate the preform to match the configuration of an inner molding surface 74 of the blow mold. The formed container 40 remains substantially transparent but has typically undergone strain-induced biaxial orientation to provide increased strength.
EXAMPLE
Preparation and Oxygen-Scavenging Performance of the Composition
[0057] The following example illustrates the effective inclusion of a transition metal in poly(lactic acid) to provide an active oxygen barrier composition according to one embodiment of the invention.
[0058] PLA resin was obtained from NatureWorks, Grade 7000D. Cobalt neodecanoate was obtained from Shephard Chemicals, 4900 Beech Street, Norwood, Ohio, USA.
[0059] The active barrier composition was prepared by grinding pastilles of the cobalt neodecanoate to a powder of less than 100 mesh. The powder was then tumble blended in a sealed container with an appropriate amount of PLA pellets. The polymer/cobalt blend was then input to an injection molding apparatus.
[0060] The amount of cobalt neodecanoate included in the above barrier composition was varied to determine the effect on oxygen scavenging. Plaque samples were prepared for each concentration (weight percentage of cobalt neodecanoate to composition) as shown below in Table 1.
[0061] An injection molded plaque was formed having dimensions of 6.25 inches (158.75 mm) in length by 1.75 inches (44.45 mm) in width, and having five equal sections with increasing step thicknesses of 0.04 inches (1 mm), 0.07 (1.78 mm), 0.10 inches (2.54 mm), 0.13 inches (3.3 mm), 0.16 inches (4.06 mm). Seven plaques were enclosed in a 32 ounce glass jar and one ounce of water added under ambient air (21% oxygen at 23° C.). The plaques rested on a platform above the water in the jar. The jar was capped with a standard canning jar lid, having a rubber septum. A syringe was inserted into the septum to withdraw a gas sample from the jar. The gas sample was then injected into a Mocon model PacCheck 450 Head Space Analyzer to measure the oxygen content (available from Mocon Modern Controls, 7500 Boone Avenue North, Minneapolis, Minn. 55428, USA). After measuring an initial oxygen content of about 21.0%, subsequent measurements were taken over a period of several days (e.g., 1 day, 4 days, 14 days . . . ). The results are shown in the following Table 1:
TABLE 1 Days under test 0 1 4 14 21 67 91 116 119 PLA 21.0 20.8 20.9 20.8 20.4 20.7 20.6 20.8 20.7 PLA + 0.1% CoNeo 21.0 20.9 20.9 20.9 20.5 20.2 19.7 18.9 19.0 PLA + 0.2% CoNeo 21.0 20.8 20.9 20.9 20.5 19.8 18.9 17.6 17.6 PLA + 0.3% CoNeo 21.0 20.8 20.8 20.8 20.3 18.4 16.5 14.1 14.3
[0062] As set forth in Table 1, all compositions which included cobalt neodecanoate (CoNeo) reduced the oxygen concentration in the jar to 20% or less, at least by 91 days. A higher rate of scavenging was achieved with increasing metal content.
[0063] FIG. 5 is a graph of the data contained in Table 1. Starting with an initial oxygen level of 21%, the change in percent oxygen content from 0 to 119 days is illustrated for each of the 4 plaque types (PLA alone; PLA with 0.1% CoNeo; PLA with 0.2% CoNeo; PLA with 0.3% CoNeo). There was little change in oxygen content for the PLA without transition metal. The level of oxygen continued to decrease in each of the samples with transition metal present, the rate of decrease in oxygen concentration increasing with increasing transition metal content.
[0064] FIG. 6 is a similar graph comparing a wider range of transition metal content (from 0.1% to 1.0%), over an initial 14 day period. These plaque samples were stored at 100° F. (compared to room temperature for the plaque samples of FIG. 5 ), which increased the rate of oxygen reduction. Again, in each case where transition metal was present there was an increasing reduction in oxygen content over the 14 days, with the amount of reduction generally increasing along with the increasing transition metal content.
[0065] FIG. 7 is a similar graph showing the performance of the same plaques as in FIG. 6 , but extended to 40 days. Again, the oxygen level content for all of the samples with transition metal continued to decrease over the 40 day period, the reduction increasing with increasing transition metal content.
[0066] As used herein, “oxygen scavenger” and the like means a composition, article or the like which consumes, depletes or reacts with oxygen from a given environment.
[0067] “Polymer” and the like herein means a homopolymer but also copolymers thereof, including random polymers, block polymers, graft copolymers, etc.
[0068] As used herein, an article of manufacture includes a rigid, semi-rigid or flexible article.
[0069] While there have been shown and described several embodiments of the present invention, it will be obvious to those skilled in the art that various changes and modifications may be made without departing from the scope of the invention as defined by the appending claims.
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Active oxygen barrier compositions and articles made therefrom based on poly(hydroxyalkanoate), preferably poly(lactic acid), a polymer derived from lactic acid, also known as 2-hydroxy propionic acid, and a transition metal. This active barrier composition, which has been found to consume (scavenge) oxygen, can be utilized in monolithic and multilayer packaging articles, such as preforms and containers, for regulating the exposure of oxygen-sensitive products to oxygen and thus maintaining and enhancing the quality and shelf-life of the product. When provided in multilayer structures with adjacent poly(hydroxyalkanoate) layers, the package both consumes oxygen and provides a biodegradable package and/or one that may be included in a recycling stream.
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BACKGROUND OF THE INVENTION
This invention relates to new and useful improvements in metal melting furnaces particularly suited to the melting and separation of non-ferrous metals with embedded or attached ferrous components.
It is normally difficult to separate ferrous and non-ferrous components because of the relatively large volume of scrap which must be charged into a furnace which is then heated to the melting point of the material having the lowest melting point, whereupon this melted material is then poured from the furnace and the remainder of the scrap is removed from the furnace and the whole process is again repeated.
In this invention the final configuration of components is established by specific end use. However, the principles of operation remain the same; that is the invention raises the temperature of combustion of pyrolysis gas, by countercurrent heating of this gas and fresh air supply, by waste heat from a combustion chamber or chambers, such that the raised heating effect in the combustion chamber or chambers is significantly improved, while the exhaust gas heat loss is significantly minimized effecting improved thermal efficiency of operation, and by virtue of the temperatures obtained, broadens the scope of application of the device, even to pollution control afterburner service requirements, all functions essentially completed within the aforesaid configurations.
In the following, two specific but non-exclusive uses of the principle of operation receive, more or less, detailed explanation, subject of previous evidence namely, the application of the raised heating effect to melt and/or recover ferrous or non-ferrous metals from scrap utilizing mainly/only the thermal energy obtainable from combustible waste materials and again, the heating of pressurized water to above or below steam generation point for such a process and space heating functions.
Due to the relatively small percentage of low melting point material in normal scrap, the conventional system is expensive and time consuming particularly in view of the fact that, for example, melted aluminum must be removed immediately from contact with ferrous components in order to avoid contamination of the aluminum.
An example of such scrap that might be utilized and, in fact, often is utilized for this purpose, is pistons, piston rings and connecting rods together with the wrist pins attaching the pistons to the connecting rods.
The present invention overcomes these disadvantages by providing a melting furnace together with a source of burner fuel and comprising in combination a main body, means mounting said body for fore and aft tilting action, vertically situated dividing walls in said body defining the interior thereof into a melt chamber and a combustible gas producing pyrolysis chamber, a separate liquid metal holding chamber within said melt chamber, an exhaust gas cleaning chamber, means communicating between said melt chamber and said holding chamber adjacent the front upper side of said holding chamber, a burner assembly for said melt chamber and a further burner assembly for said holding chamber, means operatively connecting said combustible gas producing chamber with said first mentioned burner assembly on a selective basis, exhaust means for said furnace communicating between said melt chamber, said holding chamber and said exhaust gas cleaning chamber, a separate charging door for said melt chamber, and said holding chamber and a metal tapping hole in said holding chamber and selectively communicating through the wall of said main body.
Another aspect of the invention is to provide means whereby combustible waste can be heated to a predetermined temperature to produce combustible gases which can be used in assisting in the firing of the main melt chamber burner and the metal holding chamber burner thus reducing the cost of operation of the device by conventional fuels.
Still another aspect of the invention is to provide a device of the character herewithin described which is simple in construction, economical in manufacture and otherwise well suited to the purpose for which it is designed.
With the foregoing in view, and other advantages as will become apparent to those skilled in the art to which this invention relates as this specification proceeds, the invention is herein described by reference to the accompanying drawings forming a part hereof, which includes a description of the best mode known to the applicant and of the preferred typical embodiment of the principles of the present invention, in which:
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially cut-away oblique view of the metal melting furnace with sections of the upper side removed for clarity.
FIG. 1A is a fragmentary cross sectioned front elevation of the minor chamber per se.
FIG. 2 is a fragmentary vertical section of the steam boiler embodiment.
FIG. 2A is a partial cross sectional elevation of FIG. 2.
FIG. 3 is a longitudinal cross sectional view of one of the burner assemblies per se.
FIG. 3A is a partial end view of FIG. 3.
In the drawings like characters of reference indicate corresponding parts in the different figures.
DETAILED DESCRIPTION
Proceeding therefore to describe the invention in detail, the furnace comprises a substantially rectangular body when viewed in plan and collectively designated 10.
It consists of front walls 11, side walls 12 and a rear wall 13 and these walls are manufactured preferably of steel and are covered internally, where necessary, by refractory material shown schematically by reference character 14, said refractory material being conventional in installation and attachment so that it is not believed necessary to describe same further.
The upper floor designated 22 is of refractory material and is supported by stainless steel flues designated 37D and 37F.
The interior walls 17 and 17A extend from the front wall 11 to the rear wall 13 between the base or floor 15 and the roof 16 divides the furnace into three main chambers, namely a main melt chamber collectively designated 18, a combustible gas generating chamber designated 19 and an exhaust cleaning chamber designated 20.
A fourth minor chamber designated 40 is located above the exhaust cleaning chamber 20 and is defined on its underside by theroof 16A. This chamber 40 subdivides into three compartments, namely an upper exhaust diffusion chamber designated 36A and two air inlet chambers both designated 36.
Situated within the main melt chamber 18 and defined by the upper side of the floor 22 and the roof 16 is a metal melt chamber designated 18A. Also situated within the main melt chamber and defined by the underside of the floor 22 and the refractory lined floor 15 is located a liquid metal holding chamber designated 18B.
The only passage between the upper melt chamber 18A and the lower liquid metal holding chamber 18B is a plurality of apertures designated 25 extending downwardly through the floor 22. The apertures 25 serve both as the flue gas exhaust and liquid metal drainage ports communicating between the upper melt chamber 18A and the lower liquid metal holding chamber 18B.
A metal charging door designed 23 is activated by the fluid operator 24 located in the upper sloped section of the rear wall 13 of the melt chamber 18A. Rake-out doors 23A and 23B are located below the metal charging door 23 in the lower vertical section of the wall 13. These rake-out doors 23A and 23B are utilized for the removal of charged foreign matter and metals of a higher melting temperature than that of the desired liquid load that drains into the liquid metal holding chamber 18B.
A charging door 23C located in the front wall 11 communicating with the metal holding chamber 18B permits the charging of clean metal directly to this holding chamber 18B.
A loading door 23D is located in the front wall 11 that permits the loading of combustible waste to the combustible gas generating chamber designed 19.
An ash clean-out door 23E is located in the wall 13 below the combustible waste loading door 23D.
A door designated 23F permits entry to the exhaust cleaning chamber 20. This exhaust cleaning chamber 20 is in effect, a bag house for removal of dust fines before their entry to the exhaust outlet fan designated 38H.
To initiate the generation of combustible gas in the combustible gas generating chamber 19, a few pieces of waste material are simply ignited therein. When the temperature within the combustible gas generating chamber 19 reaches a certain intensity, waste materials such as old tires, break down by pyrolysis action into highly combustible gases. The air inlet to the combustible gas generating chamber 19 is through a plurality of small apertures 37M communicating with the interiors of the said hollow door frames 22A.
The combustible gas generated by pyrolysis action in the combustible gas generating chamber 19 breaks into limited flame in the proximity of the air inlet apertures 37L and 37M. The flame thus generated is suffocated at a level slightly above and slightly to the rear of the air inlet apertures 37L by the very dense combustible smoke generated in the waste chamber 18. The above desired condition is accomplished by limiting and controlling the air supply by the control dampers 37K located in the branch duct 37J.
The pyrolysis gas thus generated is ducted through the opening designated 49 and on through the ducts designated 50 and 50A respectively, supplying the main fuel burner designated 31, firing the upper melt chamber 18A, also supplying a minor fuel burner designated 32 firing the lower holding chamber 18B.
Additional heat is supplied to the holding chamber 18B by the flow of the exhaust heat from the upper melt chamber 18A through the apertures designated 25 communicating between the melt chamber 18A and the lower holding chamber 18B.
During the warm-up period the pyrolysis gas to the fuel burner 31 and 32 is assisted by conventional fuels such as propane, natural gas or electricity. Conventional fuels are also utilized prior to any furnace shut-down to burn out all carbon accumulation in the combustible gas generating chamber 19 and in the pyrolysis gas ducts 50 and 50A en route to the fuel burners 31 and 32, otherwise air polluting gases will continue to exude for a considerable time from around doors and the exhaust outlet, etc.
The bottom of the pyrolysis gas duct 50 communicating with the gas generating chamber 19 by means of the aperture 49, defines the upper side of a refractory divider designated 52, dividing the duct 50 into an upper and lower section. The divider 52 serves as a bridging in support of the refractory walls 11 and 11A defining the side walls of the duct 50.
The main purpose of this refractory divider is to increase the length and area of surface contact of the pyrolysis gases passing through the aperture 49, with the extremely hot face of the highly conductive refractory wall 11A of the melt chamber 18A that is common to the pyrolysis gas conveying duct 50.
The superheated pyrolysis gas is conveyed through duct 50 to the main burner 31 firing the melt chamber 21 through the branch duct 50A to the fuel burner 32 firing the liquid metal holding chamber 18B.
Details of the construction of the burner assemblies 31 and 32 are given subsequently (FIGS. 3 and 3A).
The exhaust from the furnace is through the exhaust port 36B communicating with the exhaust outlets 38 positioned in the vertical inner side and top upper side of the exhaust duct designated 38A (FIG. 1).
The lower portions of the ducts 38A extend from the duct outlets 38 transversely within the dividing wall 17 to the rear wall 13 and vertically to the underside. The exhaust duct 38A then rises vertically to a position centred between the roofs 16 and 16A. The exhaust gases are then carried horizontally and upwardly through the exhaust outlet 38B to the exhaust gas diffusion chamber 36A, on through the opening 38D, the duct 38E, the opening 38F, the exhaust cleaning chamber 20, and on through the exhaust fan inlet 38G, the fan 38H and finally through the exhaust outlet 38I. The motor powering the exhaust fan 38H is of a variable type in order that the capacity of exhaust fan motor 38J can be varied.
Not shown is a hooded section at the front of the combustible gas generating chamber 19. The purpose of the hood is to trap any smoke leakage that may occur when either the combustible waste charging door 23F or the ash clean-out door 23E are opened.
The hooded section communicates with the intake 33 of the air supply fan designated 34. Thus any smoke trapped is passed to the burners 31 and 32 and consumed.
The air is ducted through inlet 33 to the air supply fan 34. The air fan 34 propels the air through the transition ducts 35 to the air diffusion chambers 37.
The air is then propelled through the air diffusion chambers 37 and outlets 37A to the air ducts 37B positioned around the exhaust ducts 38A.
The air outlets 37A communicating with the air ducts 37B define the beginning of the heat exchanger system designated 39.
The air ducts 37B totally encase the upper and lower sides of the exhaust duct 38A and the exhaust ports 36B that communicate with the metal holding chamber 18B.
The air supply ducts 37B connect with a duct 37C and consecutively with air flues 37D, the rear manifold 37E, the return air flues 37F, the front manifolds 37G and the ducts 37H and 37I, supplying the air for cumbustion to the major burner 31 and the minor burner 32.
The air supplied to the main burner 31 firing the melt chamber 18A and the minor burner 32 firing the holding chamber 18B is superheated, the result of the inner surfaces of the air conveying ducts 37C, 37E and 37G and the outer surfaces of the interconnecting air supply flues 37D and 37F being in contact with the extremely but refractory floor 22 and walls 11 and 13 in which they are embedded.
An important aspect is the heat exchanger system 39, whereby the exhaust duct 38A (extending between the furnace exhaust inlet 38 and its outlet 38B in the diffusion chamber 40) gives up approximately 90% of the exhaust heat to the incoming air being ducted in a reverse direction through the surrounding air ducts 37. Thus 90% of the waste heat is returned to the furnace and is recycled through the air system to the furnace.
The furnace body is mounted on trunions 27 (one only being shown) forwardly of the transverse axis thereof, said trunions being supported on a supporting surface such as a foundry floor.
Fluid operators 28 extend upwardly from the supporting surface, and are pivotally secured to each side adjacent the rear side 13 to the side wall support beams 26 on the end walls 10 and 12. The fluid operator on the right hand side (10) of the furnace is not shown.
In summary, the superheated air and superheated pyrolysis gas is brought near the ignition point of the pyrolysis gas prior to their entry to the burner whereupon, on entry to the extremely hot surface of the burner ports, they fire spontaneously.
It should be noted that the capacity of the exhaust fan 38H is substantially greater than that of the air fan 34 and that the volume of gases moved by exhaust fan 38H is controllable by a variable speed motor designated 38J.
This means that a slight negative pressure can be set up within the entire body portion thereby preventing fumes and/or flames from escaping through any of the doors or the like.
At the same time when it is desired to open the charging doors 23, the speed of the exhaust fan 38H can be increased considerably thus causing an air barrier just inwardly of the doors 23 due to the movement of exhaust gases through the exit apertures 25 as hereinbefore described.
In operation, combustible waste material is loaded into chamber 19 to raise the temperature thereof. Metallic scrap of various types is then loaded into the melt chamber 18A through door 23.
Once sufficient temperature has developed in the burner assemblies as will hereinafter be described, the conventional source of fuel may be reduced or cut-off altogether and combustion can continue by means of combustible gases entering the burner assemblies 31 and 32 via conduits 50 and 50A from chamber 19.
The temperature within the melt chamber is raised to just above the melting point of the metal component of the scrap having the lowest melting point. For example, if aluminum is the lowest melting point material then the temperature is raised so that all of the aluminum within the scrap is melted. The metal drains through the apertures 25 to the molten metal storage regardless of the position of the furnace.
When this metal has completely transferred, the furnace is tilted rearwardly and rake-out doors 23B are opened thus enabling the remainder of the scrap to be ejected and raked from the melt chamber whereupon a further charge can be inserted and the process repeated until the storage chamber 18B is full or all of the scrap has been treated.
At that time, a tapping hole 56 may be opened, the furnace tilted forwardly and the molten metal poured from the storage chamber 18A via the tapping hole 56.
Inasmuch as the tapping hole 56 is conventional, it is not believed necessary to describe same further except to comment that it communicates through the front wall 11 of the body with the intgerior of the storage chamber 18A.
FIGS. 3 and 3A show details of the burner assemblies which consist of an annular casing 57 acting as a rear burner sleeve having an annular casing 58 eccentrically secured to the rear thereof to form a venturi inlet for air passing through ducts 37H and 37I as hereinbefore described.
The conventional fuel supply, either gas or oil, enters the annular duct 57 through nozzle assembly 59 controllable by valve 60 so that a mixture of fuel and air enters the annular body 57 in a well mixed and spiralling helix configuration with considerable centrifugal force between the annular casing 58 and an adjustable inner sleeve 61 havng an outwardly flared end extending forwardly of the end of the burner sleeve 57.
It enters a rear retort chamber 58A and is fired through the lighting port through a wick. It then passes to a front retort portion 59A connected by a connecting duct 60A and the combustible gases enter the burner assembly via duct 50, and into the duct 60A.
It is normal for the fuel burners 31 and 32 to be fired by conventional fuel and when the melting and holding chambers 18A and 18B are sufficiently heated and the front retort area 59A of the burner is in brilliance, the combustible gases pass to the main burner 31 and minor burner 32 where they are instantly ignited. When good ignition is assured the conventional fuel supply is turned off and the furnace is now controlled by the adjustments of the air supplies of the burners 31 and 32.
This is accomplished by movement of the cylindrical sleeve 61 journalled within a bushing 62 at the rear of the burner chamber body 57. The sleeve 61 is supported upon a shaft 63 and is rotatable manually by means of handle 64. A spiral groove 65 in the wall of the shaft 63 is engaged by a pin 66 so that rotation of handle 64 moves the sleeve forwardly or rearwardly within the burner body 57. As the sleeve is moved forward more air is forced between the diverged end on the inner sleeve therefore increasing the aspirating effect and drawing more pyrolysis gas from the pyrolysis gas generating chamber. As the diverging end of the sleeve is withdrawn toward the edge of the burner body 57, the volume of air and aspirating effect is reduced which in turn reduces the quantity of pyrolysis gas being drawn by the diverging air wall. This burner is then focused into a refractory lined retort and on into the melt chamber. When the temperature of the retort, the pyrolysis gas and the super heated air are suitably conditioned, the result is a smokeless exhaust.
Features of the present invention include the following:
An important feature of the furnace design is in the use of the relatively powerful exhaust system which, by using a high capacity exhaust fan along with an amply sized duct and manifold system, creates a pressure level below atmospheric in all areas of the furnace thereby preventing any outward leakage of flame or gases around the doors or burner parts.
Also of importance is the arrangements that prevent an outflow of heat or gas when the charging doors 23 are open to receive a metal charge or to remove scrap from the melt chamber 19.
The exhaust fan 38H is then operated to maximum capacity creating an inflowing air wall by the air being drawn in through the exhaust outlets within the open area of the charging doors. When these doors are closed, the exhaust fan capacity is reduced so that the pressure within the entire furnace is held at a pressure level only slightly below atmospheric pressure. In this way the heat flow through the heat and heat exchanger system is slowed for maximum efficiency.
Another important feature of the design is that the heat supply generated by the burner 31 in the melt chamber 18A is at its greatest intensity within the chamber 18A which, after giving up heat in the melting process, is passed to the lower holding chamber 18B at a more moderate temperature more suited to the holding requirements of this chamber where oxidation loss by overheating is a factor. The minor burner 32 generates additional heat when required.
Another feature of the design is that the lower holding chamber 18B can be loaded to capacity with liquid metal without interfering with the melting of the non-ferrous metals and the emptying of unwanted ferrous components.
When tilted rearwardly for emptying of unwanted ferrous components and reloading of scrap, the molten metal is held in a well formed between the roof and floor of the holding chamber 18B and this feature permits a relatively large accumulation of liquid metal that, by varying the charge, can be brought to a desired analysis. When the holding chamber is loaded to capacity, the whole load is tapped off and is of a uniform analysis.
Finally, it should be stressed that a great deal of the heat required to operate this furnace can be derived from industrial scrap, waste, or even garbage which is readily available thus reducing the overall energy requirements of conventional fuels. Of course, it will be appreciated that the generation of combustible gases by this method can be utilized in other environments than furnaces, such as steam for electric generating plants, etc. The process herein developed could be utilized for dehydrating plants such as for garbage and sewage whereby pyrolysis gases could be generated and burned along with the dried left over wastes, largely carbon, to create a heat source of enormous potential.
A variation of this design locates the melting chamber 18A immediately to the rear rather than above the metal holding chamber 18B with the exhaust and draining ports communicating with 18B. This concept is more suited to the melting of uncontaminated metal and has more liquid metal holding capacity for a given size.
FIGS. 2 and 2A show an embodiment in which the configuration follows the principles of operation as outlined for the melting furnace previously described with similar numbers being given for all significant components thereof. This is used as a pressurized water heater for processing and space heating primarily from the slow combustion of combustible wastes.
It should also be noted that the device is eminently suitable for use in the treatment of solid, liquid or gaseous (evaporative) waste products which may be introduced into the pyrolysis chamber and subsequently burned in the burner assemblies.
Since various modifications can be made in my invention as hereinabove described, and many apparently widely different embodiments of same made within the spirit and scope of the claims without departing from such spirit and scope, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense.
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A refractory lined melting furnace particularly suited for separation of non-ferrous metals with embedded or attached ferrous components, includes a casing or body pivotally mounted and tiltable by means of fluid operators. The interior is divided by two vertical walls into a combustible waste burning portion for the generation of combustible gases to assist in heating the furnace, and a melt chamber into which a variety of metallic waste can be charged for melting. A conventional fire burner is supplied to the melt chamber. The temperature of the melt chamber is raised to the melting point of the metallic waste material having the lowest melting point, e.g. aluminum, and when the aluminum is melted, the aluminum runs through drainage apertures into a liquid metal holding chamber provided on the floor of the melt chamber. When the molten metal has drained, the furnace is tilted rearwardly to discharge the remaining scrap out through rake-out doors at the rear of the melt chamber. The sequence is repeated with heat being supplied from the combustible gases formed in the combustible waste burning portion, until the storage chamber is full whereupon the furnace is tilted and the molten metal discharged from a tapping hole in the front of the storage chamber.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The following patent applications, which are filed herewith, are incorporated by reference:
______________________________________Reference Number/Serial Number Title Author______________________________________RR-1134 Bandwidth Management Greg Graham and Processes and Systems Kim Holmes for Asynchronous Transfer Mode Networks Using Variable Virtual PathsRR-1135 Enhanced Services for Greg Graham and ATM Switching Using Kim Holmes External Control______________________________________
FIELD OF INVENTION
The present invention generally relates to the field of telecommunications equipment and processes and, more specifically, to the field of Asynchronous Transfer Mode ("ATM") network management and control equipment and processes.
BACKGROUND
Modern telecommunications systems and networks are generally built around digital networks that were originally designed for transmitting telephone conversations. These systems and networks typically use digital techniques to multiplex many communication channels designed to carry voice transmissions onto individual transmission facilities (e.g., copper wire, coaxial cable, and optical fiber). One such digital technique, Time Division Multiplex ("TDM"), divides the data transmission bandwidth of the transmission facility into equal sized time slots, which have the exact size needed to carry a telephone voice conversation. TDM generally served its purpose when the network was primarily used for standard, telephony voice transmission, but today telecommunications networks are being used to transmit computer data, video information, and voice information from cellular and traditional telephones alike. Each of these applications have varying data transmission bandwidth requirements that differ from each other and from requirements associated with traditional telephony. As a result, traditional digital techniques, such as TDM, have encountered a number of problems in recent years.
Asynchronous Transfer Mode ("ATM") techniques have provided a new way of dividing the bandwidth of the transmission facilities, physical interfaces, and switches of a network. Where TDM uses time slots to divide the bandwidth into fixed size channels, ATM uses 53 byte cells to divide the bandwidth into virtual channels. Each cell includes a header that identifies a virtual path and virtual channel to which the cell belongs. Cells can be allocated to a virtual channel in response to the needs of the users sending information over the virtual channel and the limits of the transmission facilities, physical interfaces, and switches that carry the virtual channel. Virtual paths are used to group certain virtual channels together to aid in the management and routing of the virtual channels.
To create a virtual path through an ATM network, virtual path connections must be made through each switch that the virtual path traverses, connects, or through which the virtual path connection extends. Similarly, to create a virtual channel through an ATM network, virtual channel connections must be constructed through each switch that the virtual channel traverses, connects, or through which the virtual channel extends. Virtual channel connections can be made through provisioning by the operator, which is called a Permanent Virtual Connection ("PVC"). Alternatively, virtual channel connections can be made through the use of signaling messages to request a connection, which is called a Switched Virtual Connection ("SVC").
A request for either a virtual path connection or a virtual channel connection, whether it is a PVC or SVC, typically includes the quality of service and traffic parameters that characterize the connection. The parameter corresponding to the quality of service indicates whether the requestor of the connection requires any guarantees from the network to transport data over the connection at a certain rate, which is described by the traffic parameter corresponding to the traffic. Parameters corresponding to traffic include features, such as peak cell rate, average cell rate, and cell delay variation. Parameters corresponding to traffic generally describe the network bandwidth that will be taken up by the connection.
When a request is made to set up a virtual channel connection through an ATM switch, software found in the ATM switch determines if the ATM switch and physical interfaces through which the connection is to be made can support the requested bandwidth, which is generally called Connection Admission Control ("CAC"). When a virtual channel connection is requested, it must be placed in a virtual path, so that the CAC software can determine if there is enough bandwidth remaining in the virtual path to support the new virtual channel connection. Since virtual channel connections can only be made over existing virtual paths, virtual paths provide a way to control the maximum bandwidth taken up by virtual channels in the network and, as a result, are helpful in managing the bandwidth in an ATM network. However, because virtual paths are manually provisioned in a switch, the management capabilities that they provide are inflexible and static.
In addition, large private communications networks can span a vast geographic area. In practice, it is cost prohibitive for private networks to install its own transmission facilities between different sites. Instead, private networks often lease dedicated transmission lines from a public carrier (e.g., AT&T or MCI). As a general rule, these leased lines are "nailed up" and are designed to provide full transmission capacity 24 hours a day regardless of its actual utilization. A large mesh of leased lines is typically required to provide connections between every site of a network. Furthermore, each private network will require its own mesh of leased lines. Private networks using leased lines are very expensive, because of the inefficient use of resources. Public carriers have attempted to solve this problem by allowing multiple clients to utilize the carrier's facilities and through software control have them appear as individual dedicated leased lines. This software controlled utilization then forms what has been called a Virtual Private Network ("VPN"). In order for a VPN network to function, it must effectively divide the bandwidth between different customers. Unfortunately, however, existing systems do not adequately address the concern of whether each client consumes an appropriate, necessary portion of the shared resources. There does not presently exist any way to dynamically manage stored resources on a continuous, ongoing, real-time basis.
Existing designs and procedures have other problems as well.
SUMMARY
Preferred embodiments pertain to an apparatus and related methods and systems that generally manage networks and individually and collectively manage ATM switches. Note that preferred methods are preferably performed by the preferred apparatus and systems and are discussed in reference to the preferred apparatus and systems.
Preferred embodiments of the network are generally comprised of at least one virtual private network, which is provided by a service provider. The virtual private network is comprised of a plurality of ATM switches that are interconnected with one another via one or more physical interfaces (e.g., fiber optic, twisted pair, coax, and wireless) to form the backbone of a network, which can span over a large geographical area. Clients using the virtual path network generally have a local private network of one type or another, such as a local private data network and/or a local private voice network. Sometimes, a client's local private network(s) is(are) interconnected to a carrier's network backbone via a common communication infrastructure provided by the service provider. If so, a client's local private network shares transmission facilities with other networks. Virtual connections (e.g., virtual paths, virtual channels, groupings of virtual paths, and any combination thereof) extend from one ATM switch to another ATM switch through the network and are used to transfer various types of information across the network. Preferred embodiments bundle virtual channel(s) into a virtual path and virtual paths into grouping(s) of virtual paths.
Preferred embodiments have a system-wide, centralized control module to manage these virtual paths and/or virtual channels. The control module is in direct communication with at least one ATM switch in the ATM network and in indirect communication with most, if not all, of the other ATM switches in the ATM network. The control module controls the provisioning of each ATM switch in the ATM network, which, among other things, enables the centralized control module to set up and dynamically change virtual paths and virtual channels as well as groups of virtual paths in an ATM network on an ongoing, continuous, real-time basis. The control module specifically has the ability to dynamically control the assigned parameters (e.g., bandwidth) of virtual paths, virtual channels, and groupings of virtual paths.
Specifically, regarding the operation of the control module, the control module considers one or more factors to determine whether the virtual connection through the network can be made. These factors include, but are not limited to, terms and conditions of a network contract agreement covering the virtual connection, type of information that the virtual connection will transfer (e.g., constant bit rate information, voice information, video information, variable bit rate information, data information, connection-oriented information, frame-relay information, and connectionless information), the quality of service expected of the virtual connection, existing traffic load of the network, and the utilization of the network. In particular, regarding the utilization level, the control module determines on an ongoing basis whether the network is in an overload condition. The control module also checks the overload condition and determines whether the virtual connection can be set up for the network. Similarly, the reference to a client agreement concerning the client's use of the network defines acceptable parameter and quality of service requests for the virtual connection that are available to the client. Preferred embodiments of the control module generally perform the following procedure: (i) checks with the agreement to determine whether the parameter requirements of the virtual connections are compliant with the agreement, (ii) checks with the agreement governing quality of service requests to determine whether the quality of service requirements of the virtual connections are compliant with the agreement, and (iii) determines whether the virtual connection has any available capacity. If the network is not in an overload condition and the control module does not otherwise allow(or object to) the creation of the virtual connection, the control module may allow the virtual connection to be set up in unspecified capacity of the network.
Preferred embodiments provide a number of advantages. Preferred embodiments manage an ATM switch dynamically and continuously, which allows for greater use of the available capacity of networks and, particularly, transmission facilities within a network. Preferred embodiments enable telecommunications companies that operate various types of networks for a multitude of clients to "lease" unspecified capacity on virtual paths in a virtual path group having certain features or parameters to other customers on an ATM backbone network, on an `as needed` basis. Some of this capacity may, in fact, be owned by another party or already be leased to another party, but is not being used at the specific time that another party requests permission to use the capacity. Preferred embodiments thereby provide a technique of "throttling" the physical interfaces needed to shape the bandwidth consumed by the overall ATM networks. The importance of this capability should not be underestimated, as it effectively allows carriers to "over book" physical interfaces and transmission facilities (e.g., ATM links, ATM switches, and ATM networks) to ensure existing capacity will be used to the fullest extent possible.
Other advantages of the invention and/or inventions described herein will be explained in greater detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings are incorporated into and form a part of the specification to illustrate several examples of the present inventions. These drawings together with the description serve to explain the principles of the inventions. The drawings are only for the purpose of illustrating preferred and alternative examples of how the inventions can be made and used and are not to be construed as limiting the inventions to only the illustrated and described examples. Further features and advantages will become apparent from the following and more particular description of the various embodiments of the invention, as illustrated in the accompanying drawings, wherein:
FIG. 1A is a diagram showing a preferred embodiment 180 of a virtual private network 170 having centralized control module 160 comprised of call control module 140, centralized call admission control/usage monitor module 145, and bandwidth manager module 150, ATM Edge Switch 130G, ATM Edge Switch 130H, ATM Edge Switch 130I, ATM Edge Switch 130J, and ATM Switch 130K;
FIG. 1B is a diagram showing a preferred embodiment 100 having ATM Network 120 connected directly and/or indirectly to multiple customer networks 110A, 110B, 110C, . . . , and 110K via physical interfaces 133, wherein ATM Network 120 is comprised of ATM Edge Switches 130A, 130B, 130C, . . . , and 130F interconnected with one another via physical interfaces 131, at least one of which, ATM Edge Switch 130A, is connected to centralized control module 160 with bandwidth control module 150, centralized call admission control/usage monitor module 145, and call control module 140 via one physical interface 133;
FIG. 2 is a diagram showing the detailed view of the interrelationship of call control module 140, centralized call admission control/usage monitor module 145, and bandwidth manager module 150 of centralized control module 160 and ATM Switch 130K;
FIG. 3 is an enlarged view of ATM Switch 300 having physical interface 302 extending from ATM Switch 300, physical interfaces 310 and 312 transferring voice information and data information, respectively, for Client A, physical interfaces 314 and 316 transferring voice information and data information, respectively, for Client B, which corresponds to ATM Switch 130K (in FIG. 2), ATM Edge Switches 130G, 130H, 130I, and 130J (in FIG. 1A), and ATM Switches 130A, 130B, 130C, . . . and 130F (in FIG. 1B);
FIGS. 4A, 4B, 4C, and 4D are diagrams that illustrate the relationship between the reserved and available bandwidth for specific ATM physical interfaces 141A, 141B, 141C, and 141D (in FIG. 1A) in which virtual paths are grouped or pooled together for Clients A and B by a number of factors, such as Quality of Service ("QOS") and bandwidth;
FIGS. 5A, 5B, 5C, and 5D are diagrams that show a switch level view of specific ATM physical interfaces 141A, 141B, 141C, and 141D (in FIG. 1A) in which virtual paths are grouped or pooled together for Clients A and B by a number of factors, such as quality of service and bandwidth;
FIG. 6 is a diagram showing a more generalized view of the use of virtual path groups in an ATM physical interface for Clients A and B with varying traffic types by preferred embodiments;
FIGS. 7A and 7B are drawings that highlight the organization and relationship between virtual paths 702 and virtual channels 703 that are managed and controlled by bandwidth manager module 150 of centralized control module 160 (in FIG. 1A);
FIG. 8 is a flow diagram for the procedure implemented by centralized call admission control/usage monitor module 145 in FIGS. 1A, 1B, and 2;
FIGS. 9A and 9B are flow diagrams for subprocedures implemented by centralized call admission control/usage monitor module 145 in FIGS. 1A, 1B, and 2, which are referenced in FIG. 8, that monitor the availability of unspecified virtual paths and check the utilization level of each virtual path group to determine whether an overload condition exists; and
FIG. 10 is a flow diagram for the procedure implemented by bandwidth manager module 150 in FIGS. 1A, 1B, and 2.
DETAILED DESCRIPTION
The present inventions will be described by referring to apparatus and methods showing various examples of how the inventions can be made and used. When possible, like reference characters are used throughout the several views of the drawing to indicate like or corresponding parts.
FIG. 1A shows a preferred embodiment 180. Virtual private network 170 is comprised of centralized control module 160 and ATM Edge Switches 130G, 130H, 130I, and 130J and ATM Switch 130K ATM Switch 130K forms the backbone of virtual private network 170, whereas ATM Edge Switches 130G, 130H, 130I, and 130J have the additional interfaces needed to interact with various Clients A and B in order to concentrate these numerous small physical interfaces 142A, 142B, 142C, . . . , and 142F from clients into larger physical interfaces 141A, 141B, 141C, and 141D. Centralized control module 160 manages calls for virtual private network 170 and is generally comprised of call control module 140, centralized call admission control/usage monitor module 145, and bandwidth manager module 150.
In general, call control module 140 handles the majority, if not all, of the call requests for virtual private network 170. Centralized call admission control/usage monitor module 145 determines whether or not to allow a specific `call` to access to virtual private network 170. Bandwidth manager module 150 controls the size of all virtual paths in virtual private network 170 in response to and in conjunction with call control module 140 and centralized call admission control/usage monitor module 145. Note call control module 140, centralized call admission control/usage monitor module 145, and bandwidth manager module 150 preferably all run on a single computing platform (e.g., a computer), but, alternatively, may be configured to run on more than one separate computer platform at multiple locations. Also, note that a virtual private network may stretch across large geographic distances. For instance, ATM Edge Switches 130H and 130G may reside in Richardson, Tex., whereas ATM Edge Switches 130I and 130J may reside in Raleigh, N.C. And, ATM Switch 130K may reside somewhere else, such as in Knoxville, Tenn. Centralized control module 160 may be positioned in one or more places as well. For the purposes of illustration, all of the transmission facilities or physical interfaces shown in the figures are presumed to be OC-3 interfaces, but other physical interfaces can be used.
FIG. 1B is a diagram showing an overview of a preferred embodiment 100 of an ATM network 120 verses a single virtual private network 170. Multiple virtual private networks, such as virtual private network 170 in FIG. 1A, are preferably installed on an ATM network, such as ATM Network 120 in FIG. 1B. ATM Network 120 has multiple customer networks 110A, 110B, 110C, . . . , and 110K electrically or optically coupled directly and/or indirectly to ATM Network 120 via physical interfaces 133. Customer networks 110A, 110B, 110C, . . . , and 110K may correspond to data networks and/or voice networks, both of which may be selectively grouped together to provide a virtual path network for one or more clients, such as for Clients A and B in FIGS. 1A and 1B.
ATM Network 120 in preferred embodiments is comprised of a plurality of ATM Switches, such as ATM Edge Switches 130A, 130B, 130C, . . . , and 130F, all of which are interconnected with one another via physical interface or transmission facilities 131 to form ATM Network 120. As with the single virtual private network 170 in FIG. 1A, at least one ATM switch, such as ATM Edge Switch 130A, is connected to centralized control module 160, which has submodules therein to manage various parameters used to define virtual paths and/or virtual channels, such as bandwidth and the number of calls. As explained above in reference to FIG. 1A, centralized control module 160 in FIG. 1B is comprised of call control module 140, centralized call admission control/usage monitor module 145, and bandwidth manager 150. Centralized control module 160 utilizes control features typically provided in ATM Edge Switches 130A, 130B, 130C, . . . , and 130F to control each individual ATM Edge Switch 130A, 130B, 130C, . . . , and 130F. In so doing, centralized control module 160 controls the creation and nature of virtual paths and virtual channels extending throughout the overall ATM Network 120 (in FIG. 1B).
FIG. 2 shows the interrelationship between call control module 140, centralized call admission control/usage monitor module 145, and bandwidth manager module 150 of centralized control module 160 and between bandwidth manager module 150 and ATM Switch 130K These interrelationships enable preferred embodiments to use an efficient control scheme to effectively manage and accommodate different traffic service requirements of a virtual path network Call control module 140 implements an overall, network-wide call admission strategy, which determines whether to admit or reject a request to allow a virtual connection to be setup. Using the procedure and apparatus discussed in co-assigned, the pending patent application, entitled "Enhanced Services for ATM Switching Using External Control," which was filed herewith and incorporated by reference above, call control module 140 handles specific client requests for a call requiring access to virtual private network 170 (in FIG. 1A). Using a procedure to implement a call admission strategy procedure, which is outlined in the flow chart shown in FIG. 8, centralized call admission control/usage monitor module 145 handles a request for permission to access virtual private network 170 (in FIG. 1A) that was received by call control module 140. Centralized call admission control/usage monitor module 145 determines what virtual paths and virtual channels are needed and, ultimately, will be connected, depending upon any number of factors, such as virtual path network customer service contract agreement, traffic type, quality of service expectations, and existing or expected traffic load and utilization. Moreover, if necessary, depending upon the current load conditions, centralized call admission control/monitor module 145 instructs bandwidth manager module 150 to dynamically adjust the size of each virtual path, virtual channel, and virtual path group with instructions to and from the CAC at specific ATM switches. ATM Switch 130K (and any other ATM switch in the ATM network) adjusts, alters, creates, or destroys the actual size of the virtual path, as instructed by the bandwidth manager module 150, so that, if possible, the call requested by a client to call control module 140 can be made. The CAC at each ATM switch checks every connection created or changed, no matter how or when it is created.
In using the call admission process outlined in FIG. 8, centralized call admission control/monitor module 145 balances the needs of some clients against the needs of other clients using the virtual path network who may have contracted for varying amounts of capacities in real time. For instance, preferred embodiments of centralized control module 160 consider parameters set in service contract agreements with the clients for the allocation of an available bandwidth for virtual paths and virtual channels. Additional allocations can be negotiated by clients using virtual path resizing to add additional capacity needed to address requirements exceeding the levels specified by the service contract. Centralized call admission control/usage monitor module 145 takes the appropriate actions to guarantee the level of service as specified in the contract agreements. Consequently, preferred embodiments grant priority to connection requests which are compliant to the service contract agreements concerning virtual path networks. In addition, when a client using a virtual private network exceeds its service agreement, as mentioned above, it can "borrow" additional bandwidth from the provider of the virtual private network as long as the provider is not in an "overload" condition. The borrowed bandwidth requests are tagged and returned to the client using (or wanting to use) the virtual private network with a special "over-reserved" condition. Furthermore, bandwidth that is reserved with an "over-reserved" condition is generally not guaranteed and calls using this bandwidth are subjected to call loss in an overload condition. Connections with the "over-reserved" connections are set up in the virtual path with the unspecified quality of service. Finally, clients using the virtual private networks are responsible for accepting or rejecting calls when the virtual path network is in the overload condition. Clients of the virtual private network are also responsible for prioritizing their own calls. For example, in an overload condition, one client may decide to drop calls using a first-in-first-out basis, while another client may decide to drop a data application call to accommodate a voice call. Since this connection may be setup and torn down on demand, necessary computation processing is kept to a minimum.
FIGS. 9A and 8B illustrate the subprocedures implemented by centralized call admission control/usage monitor module 145 in FIGS. 1A, 1B, and 2 and referenced in the flow diagram shown in FIG. 8. The ongoing background processes shown in FIGS. 9A and 9B monitor the traffic load of clients of virtual path networks and dynamically adjust the bandwidth allocation for each client of the virtual path network. Specifically, these background processes detect overload conditions and take necessary actions to address and relieve an overload condition. Flags or indicators of an overload condition are set when the actual utilization exceeds the utilization threshold, which craftsmen specify by provisioning. In addition, the background processes report service contract violations in the form of an alarm. Similarly, these background processes negotiate with the termination side to add a block of additional bandwidth when a maximum utilization threshold is exceeded in order to anticipate periods of over utilization and accommodate the extra bandwidth demand. Finally, these background processes release a block of "borrowed" bandwidth when the load falls below the minimum utilization threshold. Preferred background processes are generally divided into two subfunctions. In particular, as shown in FIG. 9A, one function monitors the client traffic load on the virtual private network and adjusts the bandwidth allocation for each virtual private group. Likewise, as shown in FIG. 9B, another function monitors the client traffic load on a virtual private network and adjusts the bandwidth allocation for each of virtual paths in the virtual path group.
As a result of the above operation, centralized control module 160 specifically directly and indirectly controls the operation of ATM Switch 130K in FIG. 2 (and other ATM Switches not shown in FIG. 2, such as ATM Edge Switches 130G, 130H, 130H, and 130J in FIG. 1A and ATM Switches 130A, 130B, 130C, . . . and 130F in FIG. 1B). This capability is, perhaps, most useful in managing the bandwidth assigned to a specific virtual path and a virtual path group. Centralized control module 160 enables preferred embodiments to dynamically adjust the bandwidth of a virtual path and/or a virtual path grouping to respond to varying requests of clients, which ensures that ATM physical interfaces are used to their fullest capacity. Centralized control module 160 allows a carrier to dynamically respond to changing needs of numerous clients (e.g., Clients A and B) that share the backbone network. In short, if a specific client is not using all of the capacity which the client has a reservation or a right to use (according to the contract), this unused capacity is made available to other clients. This function in centralized control module 160 is generally performed by bandwidth control module 150. Bandwidth control module 150 uses management interfaces found in ATM Switches 130A, 130B, 130C, . . . , and 130F, namely the management interface of each ATM switch that provisions the virtual paths and channels for each ATM switch, to control the size of the virtual path or paths within overall ATM Network 120.
As shown in FIG. 3, the use of ATM switches, such as ATM Edge Switch 300, which corresponds to ATM Edge Switches 130G, 130H, 130I, and 130J shown in FIG. 1A, and ATM Edge Switches 130A, 130B, 130C, . . . , and 130F in FIG. 1B, enables preferred embodiments to consolidate multiple traffic types (e.g., voice and data) with varying quality of service expectations into a single ATM interface or a network. Specifically, note Client A uses physical interface 310 for various traffic and physical interface for data traffic 372, whereas Client B uses physical interface 314 for various traffic and physical interface 316 for data traffic, all of which are consolidated on ATM interface 302 by ATM edge switch 700.
The operation of centralized control module 160 is, perhaps, best understood in relation to an example. The first step performed by centralized call admission control/usage monitor module 145 of centralized control module 160 is to check the service contract agreement for each client for which the call was initiated to determine whether or not to accept the call, what quality of service to provide, what to charge the client, and for directions as to how to make the connections. In the following example, please refer to FIG. 1A and define physical interface 141A as "Interface 1," physical interface 141B as "Interface 2," physical interface 141C as "Interface 3," and physical interface 141D as "Interface 4." Furthermore, suppose that the service contract agreement between the carrier managing the virtual private network 170 (in FIG. 1A) and/or network 120 (in FIG. 1B) and Client A guarantees 93 MB/sec at Interface 1 and 62 Mb/sec at Interface 2. a situation in which Client A desires connection(s) having a maximum total bandwidth of 155 Mb/second total and Client B desires connection(s) also having a maximum total bandwidth of 155 Mb/second total. While other breakups may be possible, one breakup for Clients A and B provided by centralized control module 160 for Interfaces 1, 2, 3, and 4 is shown in TABLE 1:
CLIENT A
BREAKUP BY INTERFACE
Interface 1: 60% total bandwidth=93 Mb
Initial allocation:
______________________________________Quality of Service 1: 20%(of 93Mb) = 18.6MbQuality of Service 2: 50%(of 93Mb) = 46.4MbUnspecified Quality of Service: 30%(of 93Mb) = 27.9Mb______________________________________
Interface 2: 40% total bandwidth (155 Mb)=62 Mb
Initial Allocation
______________________________________Quality of Service 1: 20%(of 62Mb) = 18.6MbUnspecified Quality of Service: 80%(of 62Mb) = 49.6Mb______________________________________
CLIENT B
BREAKUP BY INTERFACE
Interface 1: 40% total bandwidth (155 Mb)=62 Mb
Initial allocation:
______________________________________Quality of Service 1: 20%(of 62Mb) = 18.6MbQuality of Service 2: 50%(of 62Mb) = 46.4MbUnspecified Quality of Service: 30%(of 62Mb) = 18.6Mb______________________________________
Interface 3: 60% total bandwidth (155 Mb)=93 Mb
Initial Allocation
______________________________________Quality of Service 1: 20%(of 93Mb) = 18.6MbUnspecified Quality of Service: 80%(of 93Mb) = 74.4Mb______________________________________
TABLE 1: Breakup for Clients A and B for Interfaces 1, 2, 3 and 4
The assignments of Clients A and B for Interfaces 1, 2, 3, and 4 are shown for this example in the following TABLE 2.
INTERFACE 1
Client A: 93 Mb Assigned
______________________________________ 18.6 Mb for Quality Of Service 1 46.5 Mb for Quality Of Service 2 27.9 Mb Unspecified______________________________________
Client B: 62 Mb Assigned
______________________________________ 12.4 Mb for Quality Of Service 1 31 Mb for Quality Of Service 2 18.6 Mb Unspecified______________________________________
INTERFACE 2
Client A: 62 Mb Assigned
______________________________________ 18.6 Mb for Quality Of Service 1 49.6 Mb Unspecified______________________________________
Available Bandwidth for Reservation: 93 Mb
INTERFACE 3
Client B: 93 Mb Assigned
______________________________________ 18.6 Mb for Quality Of Service 1 74.4 Mb Unspecified______________________________________
Available Bandwidth for Reservation: 62 Mb
INTERFACE 4
Available Bandwidth for Reservation: 155 Mb
TABLE 2: Assignments for Clients A and B for Interfaces 1, 2, 3 and 4
FIGS. 4A, 4B, 4C, and 4D are diagrams illustrating the relationship between the reserved and available bandwidth for specific ATM physical interfaces 141A, 141B, 141C, and 141D (in FIG. 1A) for the above example. The relative size of each enclosed circle or oval reflects the size (e.g., in terms of bandwidth) of the actual virtual path and/or virtual path group. As a general rule, the actual size of the virtual path adjusts (or is adjusted by centralized control module 160) dynamically based upon the utilization level of that virtual path, as indicated by the bidirectional arrows crossing the borders of regions corresponding to virtual paths and virtual channels. The size of each virtual group of virtual paths is dependent upon the terms and conditions within the service contract agreement between a client and the carrier. Once again, the sizes of the virtual path groupings are adjusted by centralized control module 160 based upon the utilization levels. As shown in FIG. 8 and explained in the corresponding text, if the size needed by some client increases beyond a certain contractually defined point, the calls from the client admitted will be tagged as using `over-reserved` capacity within the specific physical interface and will use the unspecified quality of service as defined by the ATM forum.
Specifically, referring to FIG. 4A, in Interface 1, region 401 corresponds to the virtual path group for Client A in the above example, which represents 93 Mb, whereas region 402 corresponds to the virtual path group for Client B in the above example, which represents 93 Mb. Also, note within virtual path group 401, virtual paths 403 and 404 have been created, one for each quality of service promised Client A in virtual path group 401. Similarly, within virtual path group 402 for Client B, virtual paths 405 and 406 have been created, one for each quality of service promised for Client B in virtual path group 402. Additional or leftover capacity (or area) within virtual path group 401 and virtual path group 402 is unspecified. The total bandwidth capacity for virtual group 401 and virtual group 402 equals 155 Mb, which is the total fixed capacity of Interface 1. There is not any unassigned bandwidth capacity that is available for reservation.
Referring to FIG. 4B, in Interface 2, the region 408 corresponds to the virtual path group for Client A in the above example, which represents 62 Mb. Within virtual path group 408 for Client A, virtual path 407 has been created for the specific quality of service for Client A in virtual path group 408. Additional bandwidth capacity (or area) within Interface 2 is available for reservation. Similarly, additional bandwidth capacity within virtual path group 408 is unspecified.
Referring to FIG. 4C, in Interface 3, region 409 corresponds to the virtual path group for Client B in the above example, which represents 93 Mb. Within virtual path group 409 for Client B, virtual path 410 has been created for the specific quality of service for Client B in virtual path group 409. Additional bandwidth capacity (or area) within Interface 3 is available for reservation. Similarly, additional bandwidth capacity within virtual path group 409 is unspecified.
Referring to FIG. 4D, no virtual path groups and/or virtual paths for any client have been assigned to Interface 4, so the entire bandwidth capacity, 155 Mb, of Interface 4 is available for reservations.
FIGS. 5A, 5B, 5C, and 5D are diagrams showing a switch level view of separate ATM physical interfaces (physical interfaces 141A, 141B, 141C, and 141D correspond to FIG. 1A), for Clients A and B. Note that the quality of service has been defined when applicable. For instance, the Quality of Service 1 has been generally defined as Constant Bit Rate ("CBR") traffic and Quality of Service 2 has been generally defined as Variable Bit Rate ("VBR") traffic. Note, as shown in FIG. 6, alternate assignments for other quality of service types can be made. Referring to FIG. 6, for ATM Interface 600 between ATM Switches A and B (not shown), for each virtual path group, a unique virtual path will be provisioned for each specific traffic type as indicated by its quality of service requirements. One additional virtual path will be provisioned for "unspecified" quality of service, which will be used by the virtual path network service provider to offer an "unguaranteed" service or a "best-effort" service. In particular, if Client A requires or contracts for a certain amount of capacity for CBR traffic (for voice and video), VBR traffic (for packetized audio and video), Connection-Oriented traffic (for frame-Relay), and/or Connectionless traffic (for IP traffic), Client A will be assigned a virtual path group 601 having virtual paths 403 for CBR traffic, virtual path 604 for VBR, virtual path 605 for Connection-Oriented traffic, and virtual path 606 for Connectionless traffic. Similarly, if Client B requires or contracts for a certain amount of capacity for CBR and VBR traffic, but not any virtual paths for any other forms of traffic (e.g., connection-oriented traffic and connectionless traffic), Client B will be assigned virtual path group 602 having virtual paths for CBR traffic and virtual path 608 for VBR traffic. As a general rule, the bandwidth requirements are calculated differentiates for each quality of service. Virtual path 609 is not a member of any virtual path group and is unspecified and otherwise available to be used on an `as-needed` case by either Client A, Client B, or another client.
Preferred embodiments take advantage of the fact that each allocation to each client has varying amounts of unspecified quality of service capacity and that, while Interface 1 appears to be completely booked, Interfaces 2 and 3 have varying amounts of bandwidth that is available to be reserved by Clients A and/or B and/or any other client and Interface 4 appears to be completely clear of any reservations. Thus, bandwidth reserved is not necessary equal to bandwidth utilized. Centralized control module 160 simultaneously balances the use of the under utilized bandwidth and the obligations to the service contract agreements and prevents overload conditions to use each ATM Switch and the overall ATM network to the utmost. By comparison, traditional time multiplexed systems dedicate transmission and switching resources when a call "reserves" bandwidth during call setups, which ties up the capacity for the call duration, even if all of the capacity is not needed. Thus, as far as its call admission control system is concerned, bandwidth reserved is equal to bandwidth utilized, which means large portions of physical interfaces are not used on an ongoing basis and there is no way to actively and systematically utilize such unused capacity.
Referring to FIG. 7A, the bandwidth capacity of a transmission facility 700 (e.g., SONET OC-3 fiber optic facility, which has a bandwidth capacity of 155 Megabits per second (Mb/s)), virtual path 702, and virtual channels 703 are conceptually represented by "pipes" of various sizes that are nested inside of each other, wherein the diameter of each pipe represents the bandwidth of transmission facility 700, virtual path 702, and virtual channels 703. Virtual path 702 may be comprised of at least one virtual channel 403, which reside inside virtual path 702. Note, however, a virtual path is not required to hold any virtual channels, but every virtual channel must be in a virtual path. Of course, although not shown in FIG. 7A (see FIG. 6), transmission facilities 700 may contain additional virtual paths, other than virtual path 702 and these additional virtual paths would rest inside transmission facility 700, like virtual path 702. As shown in FIG. 7A, virtual channels 703 consume all of the available bandwidth of virtual path 702. As a result, any attempt to create an additional virtual channel 703 in virtual path 702 will be denied by the CAC of the ATM switch. As shown in FIG. 4B, preferred embodiments of bandwidth manager module 150 effectively increased or otherwise adjusted the size of virtual path 702 to provide extra capacity 704, so that additional virtual channels 703 can be created to accommodate varying demands of clients on an ATM Network, such as ATM network 120 in FIG. 1B.
Bandwidth manager module 150 dynamically manages bandwidths utilized by virtual paths in reaction or anticipation to traffic volume levels. For instance, as shown in TABLE 3, data traffic, such as e-mail and file transfers, and voice traffic, such as telephone conversations, typically vary throughout a day, but data traffic, unlike voice traffic, can be put off until the evening hours. Thus, bandwidth manager module 150 changes the virtual path sizes of virtual paths and virtual path groups according to time of day.
______________________________________TIME VOICE BANDWIDTH DATA BANDWIDTH______________________________________6 a.m.-6 p.m. 60% 40%6 p.m.-6 a.m. 15% 85%______________________________________
TABLE 3: Bandwidth Management Example Schedule
FIG. 10 is a flow diagram for the procedure implemented by bandwidth manager module 150 in FIGS. 1A, 1B, and 2. Specifically, as discussed above, virtual paths are set up for each customer to provide desired connectivity to the specific customer sites and desired bandwidth for each traffic type according to the current time of day. Next, either customers or bandwidth manager module 150 create and destroy corresponding virtual channel(s) within the virtual path(s) as needed. Each virtual channel that is created must be in one of the existing virtual paths, which have been set up for that specific customer. When a virtual channel is created, the CAC of each switch in the ATM network through which the virtual channel extends determines whether or not the virtual channel will fit in the specified (or corresponding) virtual path. Bandwidth manager module 150 then checks the customer contract and current time of day to determine whether it is permissible (the correct time) to make needed bandwidth changes. Remember, as a general rule, different bandwidths are assigned to handle different types of transmissions (e.g., data or voice) on specific virtual channels, depending upon the time of day. If it is not permissible to make the needed bandwidth changes, then bandwidth manager module 150 creates and destroys virtual channels as needed to make space for the requested virtual channel. Alternatively, if it is permissible to make the needed bandwidth changes, bandwidth manager module 150 calculates the sum of the bandwidth for all virtual channels on each virtual path to determine whether the total virtual channel bandwidth is larger than the new virtual path bandwidth specified by the customer contract for the current time of day period. If the requested (or needed) virtual channels do, indeed, fit inside the virtual path, then virtual paths are resized. If the requested (or needed) virtual channels do not fit, bandwidth manager module 150 uses the ATM switch management interface to delete virtual channels until the sum of the virtual channel bandwidth is below the new virtual path bandwidth and, then, the virtual paths are resized, such that preferred embodiments use the ATM management interface to change the size of each virtual path so that it conforms to the customer contract value for the current time of day.
FURTHER MODIFICATIONS AND VARIATIONS
Although the invention has been described with reference to a specific embodiment, this description is not meant to be construed in a limiting sense. The example embodiments shown and described above are only intended as an example. Various modifications of the disclosed embodiment as well as alternate embodiments of the invention will become apparent to persons skilled in the art upon reference to the description of the invention. For instance, while a specific physical interface was described above, other physical interfaces can be used as well, such as T1, T3, 25 Mb ATM, OC-3, OC-12, OC-48, OC-192, and 100 Mb TAXI. Note the ATM Forum, an industry consortium, have approved several of these physical interfaces and may approve other such interfaces in the future that could likely be used in preferred embodiments. In addition, physical interfaces may be based on or utilize conductive wiring, such as twisted pair, fiber optic, coax, wireless transmission facilities and/or any combination thereof. Similarly, in addition to ATM switches, other switches can be used as well, so long as the ATM switches are compatible with UNI 3.0 or greater and provide a management interface that allows the creation, deletion, and resizing of virtual path connections. Northern Telecom's Concorde™, Vector™, and Passport™ switches generally satisfy these requirements and are preferred for that reason, but other switches may also satisfy these requirements and may be used. Also, please note that while the above discussion generally described electrical connections as "connections," or being directly and/or indirectly "connected," it should be noted that these connections may also be coupled electrically, optically, or electromagnetically (e.g., radio signals and wireless transmissions). Control module 160 can use alternate procedures to control the operation of the ATM switches and the sizing and creation of virtual paths and channels, in addition to or in lieu of the preferred procedures shown in FIGS. 8, 9A, and 9B. In addition, note that the procedures that are implemented by centralized control module 160, call control module 140, centralized call admission control/usage module 145, and bandwidth manager module 150 in preferred embodiments use software on a computer equipped platform that directs each individual ATM switch in an ATM network While prewired control systems could be designed and built implementing the following control mechanism and may be used, software control mechanisms are preferred, because software control mechanisms are substantially more flexible and enable the carrier operating ATM network to easily update and refine procedures used to control ATM switches. Software control mechanisms can also be easily updated to handle varying types of ATM switches, when such ATM switches are modified and/or updated.
Thus, even though numerous characteristics and advantages of the present inventions have been set forth in the foregoing description, together with details of the structure and function of the inventions, the disclosure is illustrative only, and changes may be made in the detail, especially in matters of shape, size and arrangement of the parts within the principles of the inventions to the full extent indicated by the broad general meaning of the terms used in the attached claims. Accordingly, it should be understood that the modifications and variations suggested above and below are not intended to be exhaustive. These examples help show the scope of the inventive concepts, which are covered in the appended claims. The appended claims are intended to cover these modifications and alternate embodiments.
In short, the description and drawings of the specific examples above are not intended to point out what an infringement of this patent would be, but are to provide at least one explanation of how to make and use the inventions contained herein. The limits of the inventions and the bounds of the patent protection are measured by and defined in the following claims.
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A system comprises a system control module and a plurality of interconnected asynchronous transfer mode switches the interconnected asynchronous transfer mode switches are interconnected with one another via at least one physical interface to form a network. The network is used to transfer various types of information. Each asynchronous transfer mode switch has a connection admission control module to determine whether a virtual connection, such a virtual path, virtual channel, or grouping of virtual paths, can be connected through that particular asynchronous transfer mode switch. The virtual connection is formed from one asynchronous transfer mode switch to at least one other asynchronous transfer mode switch via a link of the at least one physical interface. The system control module connects to at least one asynchronous transfer mode switch and determines whether the virtual connection can be created in the network. A process of monitoring a utilization level of a grouping of a virtual path on a physical interface comprises checking the utilization level of the virtual path, updating an amount of available bandwidth for the virtual path, and comparing the amount of available bandwidth with a maximum threshold for the available bandwidth and setting an overload condition if the amount exceeds the maximum threshold and clearing the overload condition if the amount is below the maximum threshold. Service contracts governing a client's use of the network and ability to set up a virtual connection are also be checked in certain circumstances.
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FIELD OF THE INVENTION
[0001] The invention relates to devices for use in pool-based rehabilitation therapy practices and specifically to devices for use in spinal rehabilitation or cervical spinal rehabilitation.
BACKGROUND OF THE INVENTION
[0002] It is know in the art to employ various forms of flotation devices when engaged in pool-based rehabilitation therapy, specifically to support one or more parts of the body to address the particular nature of the injury or to reduce pain associated with the in-pool activities. The guiding principle, in most cases, is that the flotation device enables the body part to float in a supported position near, or at, the water surface. It is common for devices such as noodles, flotation belts, inflatable collars and buoyant platforms (such as flutter boards) to be employed for such purposes.
[0003] A challenge arises, however, in the case of certain injuries under rehabilitation care that may require partial immobilization or enhanced support, as most of the known flotation devices provide only limited support and generally allow a wide range of motion. In the case of rehabilitation activities for persons recovering from spinal injuries or cervical spinal injuries, for example, proper head-neck-torso alignment is crucial while performing cervical rotations in water as to reduce attendant pain, sensitivity or discomfort associated with neck injuries. Rehabilitation can even be hampered if the cervical spine freely rotates without maintaining proper alignment with respect the rest of the body; hence, pool-based programs are known to even employ snorkel gear to enable the head of the user to remain as still as possible keeping the neck in proper alignment to the rest of the body while performing rehabilitation exercises.
[0004] Water turbulence in the pool can even cause unwanted rotation(s) of the cervical spine, especially when the person is attempting to float and remain still. The flotation devices are generally incapable of countering the effects of turbulence within the pool environment which may destabilize the neck and head.
[0005] In water-based rehabilitation, even if the injury is below the shoulders, the device can help support the neck and head while rehabilitating other body parts. For example, but not limited to, while rehabilitating knee injuries, the floatation device can be used to float the head to help prevent it from sinking.
[0006] What is needed, therefore, is a flotation device that can be used in a pool rehabilitation environment which helps to support and stabilize the neck and head of the user. Such a device would preferably be of a simple construction, easy to use and would allow for the proper range of movement in standard rehabilitation exercise
SUMMARY OF THE INVENTION
[0007] The present invention therefore seeks to provide a flotation device for use in pool-based rehabilitation practices. The flotation device according to the present invention comprises two opposed flotation members configured to contact the lateral sides of the user's head, while helping to support their neck and head during the rehabilitation practices. The flotation members are connected to each other by means of connecting members positioned across the top of the user's head and across the lower back of the user's head to help maintain proper alignment and balance. The flotation and connecting members collectively form a ring that fits generally to the back and sides of the user's head during pool-based exercise.
[0008] The flotation members may be buoyant, or the connecting members may be buoyant, or both the flotation members and connecting members may be buoyant.
[0009] According to a first aspect of the present invention there is provided a flotation device for supporting and aligning a user's head during pool-based rehabilitation therapy, comprising:
first and second opposed, spaced apart flotation members, each having a first end and a second end; the respective first ends of the second flotation members connected by a first connecting member, and the respective second ends of the first and second flotation members connected by a second connecting member; such that the first flotation member, first connecting member, second flotation member and second connecting member form a ring defining an open space therein, the open space for receiving the back of the user's head, the first and second flotation members arranged to abut the lateral sides of the user's head.
[0013] According to a second aspect of the present invention there is provided a method for using a flotation device in pool-based rehabilitation therapy, the flotation device comprising: first and second opposed, spaced apart flotation members, each having a first end and a second end; the respective first ends of the first and second flotation members connected by a first connecting member, and the respecting second ends of the first and second flotation members connected by a second connecting member; such that the first flotation member, first connecting member, second flotation member and second connecting member form a generally ovoid ring defining an open space therein; the method comprising:
a. positioning the flotation device against the back of a user's head, such that the user's head rests generally within the open space; b. positioning the first and second flotation members against the lateral sides of the user's head; and c. proceeding with the pool-based rehabilitation therapy.
[0017] In exemplary embodiments of the present invention, the first and second flotation member are contoured to contact the user's head along generally the entire length of each of the first and second flotation members, and the first and second flotation members have angled upper surfaces for receiving and supporting the user's head and flattened symmetric lower surface. The first and second flotation members may be buoyant. For example, they may be composed of a buoyant material (for example, but not limited to, polystyrene), or they may be filled with air, or a combination thereof.
[0018] The first connecting member is preferably configured to extend over the top of and in contact with the user's head, and the second connecting member is preferably configured to extend across and in contact with the lower back of the user's head. The first and second connecting members may be composed of a buoyant material or any material that is obvious to one skilled in the arts, (for example, but not limited to elastic material or material filled with air or a combination thereof). In an embodiment, the first and second members are cords. The first and second connecting members may even comprise a single length of cord that is attached or connected to the flotation members, for example passing through holes in the flotation members. At least one of the connecting member is preferably of greater length than the second connecting member, such that the open space is generally ovoid, which may provide a better fit to the back of the user's head. As obvious to one skilled in the arts, the cord may be composed of a buoyant material or air-filled material similar to the connecting members.
[0019] In exemplary embodiments of the method according to the present invention, wherein the first connecting member is configured to extend over the top of and in contact with the user's head, and the second connecting member is configured to extend across and in contact with the lower back of the user's head, the preferred method comprises the further steps after step a and before step c: positioning the first connecting member to extend over the top of and in contact with the user's head, and positioning the second connecting member to extend across and in contact with the lower back of the user's head. Further, wherein at least one of the first and second connecting members are of adjustable length, the preferred method comprises the further step before step c of adjusting at least one of the first and second connecting members to secure the flotation device to the user's head. This adjustment may include the use of a tie, knot, clasping device or similar apparatus known to one skilled in the arts in order to secure the device to the user's head.
[0020] When the first and second flotation members are buoyant, the flotation device can be used to float on one's back. This applies whether floatation members are comprised of buoyant material or they may be filled with air or a combination thereof. However, use of the flotation device to float on one's stomach depends on the type of material and design of flotation members. For example, if the buoyant material is rigid (for example, polystyrene), the design of the flotation device must be modified, in a manner known to one skilled in the art. Furthermore, the width of the base of the floatation members may vary in comparison to their length; however, as the width is reduced, the user experiences less resistance, or if the width is increased, the user will experience more resistance while floating and performing cervical neck rotations on his or her back.
[0021] It is also within the scope of the present invention for each of the first and second flotation members to comprise discrete, spaced-apart anterior and posterior portions, each of the respective anterior and posterior portions parings connected by means of lateral connecting members. These anterior and posterior portions enable the user to use this device while floating on his/her back or stomach and help support the spine.
[0022] A detailed description of exemplary embodiments of the present invention is given in the following. It is to be understood, however, that the invention is not to be construed as being limited to these embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] In the accompanying drawings, which illustrate exemplary embodiments of the present invention:
[0024] FIG. 1 a is a top plan view of a first flotation device according to the present invention;
[0025] FIG. 1 b is a bottom plan view of the flotation device of FIG. 1 ;
[0026] FIG. 2 a is a rear view of the flotation device of FIG. 1 in use;
[0027] FIG. 2 a is a rear view of the flotation device of FIG. 1 in use;
[0028] FIG. 3 is a cross-sectional view across line 3 - 3 of FIG. 1 ;
[0029] FIG. 4 a is a top plan view of a second embodiment of the present invention;
[0030] FIG. 4 b is a rear view of the flotation device of FIG. 4 a in use; and
[0031] FIG. 4 c is a front view of the flotation device of FIG. 4 a in use.
[0032] Preferred embodiments of the present invention will now be described with reference to the accompanying drawings.
DETAILED DESCRIPTION
[0033] Referring to FIGS. 1 a and 1 b , a flotation device 10 a in accordance with the present invention is illustrated. The flotation device 10 a comprises a first flotation member 14 and a second flotation member 16 . As can be seen in the drawings, this embodiment employs a single length of cord 40 which passes through holes 32 to bind the flotation members 14 , 16 together and form the ring with which the open space 26 is defined. The cord 40 comprises the first connecting member 22 and the second connecting member 24 . It will be clear to one skilled in the art that two separate cords may be used for the connecting member 22 , 24 rather than a single long cord 40 . In fact, the connecting members 22 , 24 may, or may not be buoyant. If buoyant, the may be composed of any buoyant material or they may be air-filled or combination thereof. In addition, the connecting members may or may not be elastic as known to one skilled in the arts. The connecting member 22 , 24 —whether discrete elements or part of a signal cord 40 —connect the flotation members 14 , 16 , the first connecting member 22 connecting the first end 18 a of the first flotation member 14 to the first end 18 b of the second flotation member 16 , and the second connecting member 24 connecting the second end 20 a of the first flotation member 14 to the second end 20 b of the second flotation member 16 . At least one of the connecting members ( 22 , 24 ) is adjustable through the use of a tie, knot, clasping device or another apparatus known to one skilled in the arts in order to secure the flotation device to the user's head.
[0034] The use of connecting members 22 , 24 may allow for some limited movements characterized by producing continuous movement that is smoother and more comfortable; and 2) reducing contact of the device with injuries on the body of the user. The flotation device stabilizes and floats the neck and head while making minimal contact with the user's body in order to avoid or minimize contact with body injury sites. Also, connecting members can be employed to provide adjustability for different sized heads. Alternatively, the device 10 a may simply be made in different non-adjustable or self-adjusting sizes. In addition, the user can introduce knots in the cord or some other form of texture to hold the flotation members 14 , 16 in place on the cord 40 . Other means of securing the flotation members 14 , 16 in place on the cord 40 would be obvious to one skilled in the art.
[0035] In the illustrated embodiment, the flotation members 14 , 16 have a distinctive shape that may help with both comfort and smooth operation within the pool. The upper surface 28 of each flotation member 14 , 16 is angled to provide a cradling or nesting of a user's head when wearing the device 10 a . The angle may be between 15 degrees and 45 degrees, or between 20 degrees and 40 degrees, or between 25 degrees and 35 degrees, or roughly 30 degrees off of the vertical. This can be seen most clearly in FIG. 3 , which is a cross-section of both flotation members 14 , 16 . This angled shape better mirrors the contour of a user's head, allowing it to be nestled and braced between the flotation members 14 , 16 . As can be seen in FIG. 3 , the bottom surfaces 30 of the flotation members 14 , 16 are generally flat and symmetric; although this should not be necessary in every embodiment, it may have the advantage of enabling a smoother movement through the water during pool-based exercises due to continuous contact with water.
[0036] The flotation members 14 , 16 is preferably composed of polystyrene but can be composed of another similar buoyant material or air-filled material or a combination thereof. As an example, polystyrene works well as a material that helps to produce an effective counterbalance between opposing flotation members 14 , 16 . In addition, the flotation member 14 , 16 are preferably composed of a material that is not overly smooth, to avoid the risk of shifting and misalignment during use in water, but this may also be addressed by applying texture to the flotation members 14 , 16 , or securing them comfortably snug to the user's head.
[0037] Furthermore, the width of the base of the floatation members may vary in comparison to their length; however, as the width is reduced, the user experiences less resistance, or conversely, if the width is increased, the user will experience more resistance while floating and performing cervical neck rotations on his or her back.
[0038] Turning to FIGS. 2 a and 2 b , the flotation device 10 a of FIGS. 1 a , 1 b and 3 is illustrated in position on a user's head 12 . The first connecting member 22 extends across and is in contact with the top of the user's head 12 , while the second connecting member 24 extends across the back of the lower part of the neck. This position results in the second 20 a, b of the flotation members 14 , 16 being in contact with the lower back of the user's head 12 , with the first ends 18 a, b of the flotation members 14 , 16 being in contact with the upper front of the user's head 12 . This position helps to support the user's head 12 in proper alignment when floating or swimming on their back. For example, but not limited to, the device helps prevent the user's head from sinking. If the device is made out of polystyrene, it is possible that it can be modified such that the user can use it while floating on his or her stomach. Also, it is possible that one or more different materials are employed in the device (for example, but not limited to polyethylene or an air-filled material) which may also enable the user to use it while floating/exercising on the front or back. For example, but not limited to, the device can be composed of polyethylene and modified which may enable the user to use it while floating on their front or back; albeit, these changes may retain several functions related to the preferred embodiment. During rehabilitation exercises, this position also provides for smoother movement through the water while reducing jerking of the head due to turbulence. The symmetrical design of the device 10 a seeks to provide proper balance/counterbalance, with flotation members 14 , 16 providing buoyancy to counter that movement, stabilizing the desired head-neck-body alignment even while the user is moving through the water. Stabilizing the neck and head upright in the water has a further advantage of helping to reduce the anxiety in inexperienced swimmers who are undergoing pool-based rehabilitation therapy. A flotation device wherein the flotation members comprise polystyrene may be used while the user is floating on their backs doing rehabilitation exercises. With modifications, which may include the use of a different material, someone skilled in the arts could enable this device to be used by the user on his or her front or back in the water.
[0039] Turning now to FIGS. 4 a to 4 c , a second embodiment of the present invention is illustrated. In this embodiment, the flotation member 14 , 16 of the first embodiment are replaced by discrete, spaced-apart anterior and posterior portions providing the same utility. The flotation device 10 b comprises an anterior portion 34 a and a posterior portion 36 a on one side of the device 10 b , and a mirror-image anterior portion 34 b and posterior portion 36 b on the other side, thereby providing support in a very similar way as the flotation members 14 , 16 of the first embodiment. The anterior and posterior portions 34 a , 34 b , 36 a , 36 b are provided with flattened surfaces 42 , which are the surfaces which will contact the user's head 12 , as can be seen in FIGS. 4 b and 4 c . Although the anterior and posterior portions 34 a , 34 b , 36 a , 36 b are illustrated as roughly spherical—other than the flattened surfaces 42 —it is not necessary for them to have a spherical shape, as any number of shapes may be easily designed to work as well. The flattened surfaces 42 are necessary to the functioning of this particular embodiment, as otherwise the rounded surfaces would introduce discomfort, pain, shifting and/or instability when making contact with the user's head in and out of the water. The anterior and posterior portions 34 a , 34 b , 36 a , 36 b may be buoyant, be either being comprised of buoyant material (for example, but not limited to, polystyrene) or being air-filled material.
[0040] The anterior portions 34 a , 34 b are connected by a first connecting member 22 , and the posterior portions 36 a , 36 b are connected by a second connecting member 24 , akin to the basic form in the first embodiment. Given that the anterior and posterior portions 34 a , 34 b , 36 a , 36 b are spaced apart; however, additional lateral connecting members 38 are required to complete the connection of all flotation elements and define the open space 26 . As with the first embodiments, the connecting members 22 , 24 , 38 may be composed of some material other than cord, (for example, but not limited to, an air-filled, elastic or buoyant material as obvious to one skilled in the arts) to help with the flotation utility of the device which can be determined by one skilled in the arts. They may be parts of a single cord 40 or discrete sections of cord. A person skilled in the arts can employ more than four portions to represent 14 , 16 of FIG. 1 , which may require more connecting members.
[0041] The connecting member(s) 22 , 24 and 38 whether discrete elements or part of a signal cord 40 —connect the flotation members 34 a , 34 b , 36 a , and 36 b . The first connecting member 22 connects to 34 a , 34 b . One of connecting members 38 connects 34 a and 36 a and the other connects 34 b and 36 b . At least one of the connecting members is adjustable through the use of a tie, clasping device of another adjusting member known by one skilled in the arts in order to secure the flotation device to the user's head.
[0042] As can be seen in FIGS. 4 b and 4 c , the first connecting member 22 extends across and is in contact with the top of the user's head 12 , while the second connecting member 24 extends across the back of the lower part of the neck. This position results in the posterior portions 36 a , 36 b being in contact with the lower back of the user's head 12 , with the anterior portions 34 a , 34 b being in contact with the upper front of the user's head 12 , akin to the positioning of the first embodiment.
[0043] The use of cords as connecting members 22 , 24 and 38 may create limited movements characterized as continuous, thereby producing a more advantageous movement that is smoother and more comfortable. The connecting members may help reduce the contact of the flotation device with the neck and head: the flotation device stabilizes and floats the neck and head while making minimal contact with the body in order to avoid contact with possible sites of injury. Also, the cord connecting members can be employed to provide adjustability for different sized heads by the use of a tie, know, clasping device or another means determined by one skilled in the arts in order to secure the device to the user's head. Alternatively, the device 10 b may simply be made in different non-adjustable or self-adjusting sizes. Furthermore, the user can introduce knots in the cord or some other form of texture to hold the flotation members 34 a , 34 b , 36 a and 36 b in place on the cord 40 . Other means of securing these flotation members in place on the cord 40 would be obvious to one skilled in the art.
[0044] As can be readily seen, then, there are numerous advantages provided by the present invention. A flotation device can be used during front and back floating or swimming, countering both rotational and pivoting motions to maintain proper alignment and thus helping to reduce pain or discomfort while performing rehabilitation exercises. The effects of water turbulence around the user can also be countered or reduced. The device is of simple construction is very simple to use, and can even be made to be adjustable for different head sizes and shapes. A further advantage is provided in that the use of a flotation device in accordance with the present invention can help to reduce anxiety in non-swimmers or inexperienced swimmers who are undergoing pool-based rehabilitation therapy. For example, firstly, they can use the device to help support their neck and head and maintain proper alignment while they float face-up performing rehabilitation exercises. Secondly, the device helps prevent the head from sinking backwards which promotes proper alignment.
[0045] The foregoing is considered as illustrative only of the principles of the invention. Thus, while certain aspects and embodiments of the disclosure have been described, these have been presented by way of example only and are not intended to limit the scope of the disclosure. Indeed, the invention describe herein may be embodied in a variety of other forms without departing from the scope thereof which invention is defined solely by the claims below.
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The invention seeks to provide a therapeutic flotation device for use in a pool-based rehabilitation therapy practices for spinal rehabilitation or cervical spine rehabilitation. The flotation device comprises two opposed flotation members configured to contact the lateral sides of the user's head and support it and the neck during rehabilitation practices, which flotation members are connected to each other by means of connecting members positioned across the top of the user's head and across the lower back of the user's head. The flotation and connecting members collectively form a ring that fits generally to the back of the user's head during pool-based exercises.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to vapor-mist dielectrics, and more specifically to improved electrical strength of vapor-mist dielectrics before voltage application.
2. The Prior Art
The electrical strength of vapor-mist dielectrics results from a combination of the vapor from the droplets enhancing the gas strength and the droplets collecting electrons and ions. The droplets collecting electrons and ions helps prevent the formation of electron avalanches which precede breakdown. Generally, as the mist density increases, the electron collecting properties are enhanced and more electron avalanches are extinguished, and the electrical breakdown strength is improved. Ideally the highest density of mist should be near the electrode surfaces where the electrical stress is highest.
In addition, it is well known that gases such as SF 6 have increased AC breakdown strength in non-uniform fields by corona stabilization or a space charge which develops around sharp edged electrodes. In this way, a needlepoint electrode appears more as a spherical shape at the tip and the AC breakdown strength of certain non-uniform field gaps approaches that of uniform fields. This approach using fine wire electrodes in various electrode configurations has been used. See Uhlig, "The Ultra Corona Discharge, A New Discharge Phenomena Occurring on Thin Wires" National Research Counsel of Canada, 1956, pp. 15-1-15-3. The problem with using fine wire electrodes with power frequency voltages is that a large amount of electrical energy is consumed in generating the required amount of space charge and the system therefore is very inefficient. Also, this method is not adaptable to work under impulse voltage (lasting only microseconds) conditions because there is insufficient time for the necessary space charge to form. An advantage in using vapor-mist with fine wire instead of solid electrodes is better uniformity and flow of mist as it can pass through the electrode body.
There remains therefore a need for improving the electrical strength and performance of vapor-mist by ensuring that the most dense mist is at the electrode surfaces, or regions of highest electrical stress before the application of electrical voltages. Also, there is a need for utilizing fine wire electrode systems without excessive energy consumption at power frequency voltages and also for using fine wire systems with short time impulse voltages.
SUMMARY OF THE INVENTION
The present invention discloses a method in which ionization associated with fine wire electrode systems causes mist droplets to charge and collect on electrode surfaces or at a region of highest electrical stress. The method manipulates droplet clouds to reach high stress regions resulting in improved electrical strength by depositing mist in optimum locations before voltage applications.
It is an object of the present invention to provide a method for improving the electrical strength of vapor-mist dielectrics.
It is another object of the present invention to provide an apparatus suitable for use in vapor-mist dielectrics.
It is another object of the present invention to provide an efficient vapor-mist dielectric.
It is another object of this invention to allow the efficient use of fine wire uniform or non-uniform field electrode systems.
These and other objects of the present invention will be seen upon review of the description of the invention.
BRIEF DESCRIPTION OF THE DRAWING
The Figure illustrates a presently preferred embodiment of a vapor mist dielectric apparatus before system voltage is applied.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The electrical strength of a vapor mist dielectric may be improved by the use of electrodes, preferably fine wire or solid electrodes, generally parallelly spaced, a mist supply disposed proximate to the electrodes and an ionization means. The mist supply generates mist droplets with the electrodes surrounded by a gaseous dielectric the ionization means applies electrons to the gas molecules which deposit on mist droplets which go to regions of high electrical stress. Thereafter, system voltage may be applied. The mist droplets are preferably a liquid dielectric such as C 2 Cl 3 F 3 or C 8 F 16 O. The ionization means may be a transformer which provides a source of AC or a source of DC voltage. Alternatively, the ionization means may be a coating of polonium on the electrodes. Specifically, the ionization means ionizes gas molecules which then collect on the mist droplets and charges them. This method may also be used to extinguish a partial discharge. Moreover, the method may move mist droplets by DC voltage to areas of high electrical stress by means of an electrical field. A separate moveable electrode may be used to move the droplets to a new location.
It is known that AC corona at a point electrode in SF 6 is rapidly suppressed by the application of mist. Thereafter, the applied electrical stress can be increased by a factor of three without any corona occurring. See Harrold "Partial Discharge Suppression in Vapor-Mist Dielectrics", CEIDP, Ann. Rep. Oct. 1984. It is believed that as the micron size mist droplets approach the point, due to ionization of gas molecules near that point, the droplets acquire a charge and immediately migrate to and cling to the point, or more to the region of highest electrical stress. The highly stressed needle electrode becomes coated with liquid which prevents electron emission from the surface and tends to stress grade the tip of the needle.
In order to increase the impulse strength of vapor mist, the uniform field electrodes are formed from closely spaced fine wires and the region close to the wires should be ionized. Ionization may preferably occur by AC or DC voltage of about 1 to 10 kV depending upon the wire diameter (for example, a 3 mil diameter wire at 5 to 10 kV AC). Alternatively, a coating of polonium (ionization by radiation) on the wire, or any other means of ionization (for example, droplets acquiring a charge by turboelectric or friction) effects when liquid is atomized by being forced through a nozzle). When mist is applied to this system, the droplets will charge and collect on the fine wire electrode surface. The mist is preferably a dielectric fluid and more preferably may be in an electronegative gas, an electropositive gas or a mixture thereof. Suitable dielectric fluids and gases include SF 6 , C 2 Cl 3 F 3 , C 8 F 16 O, CF 4 , CF 3 Cl, N 2 CO 2 or mixtures thereof. The most preferred liquid dielectrics are C 8 F 16 O and C 2 Cl 3 F 3 . Then the system voltage, such as power frequency or impulse is applied.
As mist droplets readily collect on the electrode surfaces around which the gas is ionized, it may be desirable to charge the mist droplets as they are generated. Then by application of appropriate voltage fields, the cloud of charge particles may be held in an unused position. The Figure shows a presently preferred embodiment of a vapor-mist dielectric of the present invention. The apparatus 2 has two uniform field wire mesh or solid electrodes 4. A mist supply 6 disposed proximate to the electrodes provides the appropriate misting of the electrodes 4. The electrodes 4 are spaced at an appropriate generally parallel distance.
An appropriate voltage transformer 8, which is electrically isolated from ground and supplies sufficient voltage to the electrodes 4 so that the gas surrounding the electrodes 4 is ionized. Mist droplets collect at the electrodes 4, because the droplets collect a charge from ionization near the wires and are then attracted to the wire. Thereafter an impulse voltage or other desired voltage 10 is applied to the electrodes 4. If another means of ionization is used, then the charged mist droplets will collect on or near the electrodes 4 when the actual test voltage is applied.
It will be appreciated that due to ionization at electrodes and droplets charging, a dense mist will collect at the fine wire or solid electrode surface or at regions of highest electrical stress, prior to the application of system voltage. Mist droplets can be generated and the droplets charged and held by appropriate electrical fields in a particular location for later use. Mist droplets which have been charged and stored can be manipulated by appropriate electrical fields and moved to areas of high electrical stress when desired, either before the application of voltage, or during operation under voltage, when it is desired to extinguish a source of micro-sparking (corona or partial discharges). A separate movable electrode 4A may be used to move the droplets to a new location.
Whereas, particular embodiments of the invention have been described above for purposes of illustration, it will be appreciated by those skilled in the art that numerous variations of the details may be made without departing from the invention as described in the appended claims.
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A method in which ionization associated with fine wire or solid electrode systems causes mist droplets to charge and collect on electrode surfaces or at a region of highest electrical stress. The method includes manipulating droplet clouds to reach high stress regions. This process achieves improved electrical strength by depositing a mist in optimum locations before voltage applications.
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BACKGROUND
[0001] There is a need for a demolition shear having a piercing tip insert and nose configuration to reduce nose wear and to resist retract forces exerted on the piercing tip insert in jamming situations and in the event of snagging of the piercing tip insert.
DESCRIPTION OF THE DRAWINGS
[0002] FIG. 1 is a right side perspective view (from the position of the operator) of one embodiment of a demolition shear attachment.
[0003] FIG. 2 is a left side perspective view of the demolition shear attachment of FIG. 1 .
[0004] FIG. 3 illustrates the shear attachment of FIG. 1 in a typical operating position showing the movement of the upper jaw with respect to the lower jaw during a shearing operation.
[0005] FIG. 4 is an exploded perspective view of the jaw pivot shaft of the shear attachment of FIG. 1
[0006] FIG. 5 is an enlarged view of FIG. 1 showing the jaws of the shear attachment.
[0007] FIG. 6 is the same view as FIG. 5 but with the blade inserts and piercing tip inserts removed.
[0008] FIG. 7 is an enlarged view of FIG. 2 showing the jaws of the shear attachment.
[0009] FIG. 8 is a perspective view of the lower jaw of FIG. 1 with the upper jaw removed to better show the blade-side shear blade inserts and guide blade insert.
[0010] FIG. 9 is another perspective view of the lower jaw of FIG. 1 with the upper jaw removed to show guide-side guide blade insert and cross-blade insert.
[0011] FIG. 10 is the same view as FIG. 7 with the blade inserts and piercing tip insert removed.
[0012] FIG. 11 is the same view of the lower jaw as FIG. 9 with the blade inserts removed.
[0013] FIG. 12 shows different views of an embodiment of a shear blade insert, wherein 12 A is a front perspective view, 12 B is a front elevation view, 12 C is an end elevation view and 12 D is rear elevation view.
[0014] FIG. 13 shows different views of an embodiment of a guide blade insert, wherein 13 A is a front perspective view, 13 B is a front elevation view, 13 C is an end elevation view and 13 D is rear elevation view.
[0015] FIG. 14 shows different views of an embodiment of a cross-blade insert, wherein 14 A is a front perspective view, 14 B is a rear perspective view, 14 C is an end elevation view, 14 D is a front elevation view and 14 E is rear elevation view.
[0016] FIG. 15 shows different views of an embodiment of a blade-side piercing tip half, wherein 15 A is a front perspective view, 15 B is a rear perspective view, 15 C is a front end elevation view, 15 D is an outer side elevation view and 15 E is an inner side elevation view.
[0017] FIG. 16 shows different views of an embodiment of a guide-side piercing tip half, wherein 16 A is a front perspective view, 16 B is a rear perspective view, 16 C is a front end elevation view, 16 D is a inner side elevation view and 16 E is outer side elevation view.
[0018] FIG. 17 is a perspective view of the upper jaw of the shear attachment of FIG. 1 in isolation with the piercing tip inserts shown exploded with respect to the nose seat.
[0019] FIG. 18 is an enlarged side elevation view of the upper and lower jaws of the shear attachment of FIG. 1 with the upper jaw in the fully open position.
[0020] FIG. 19 is an enlarged side elevation view of the upper and lower jaws of the shear attachment of FIG. 1 with the upper jaw in a partially closed position.
[0021] FIG. 20 is an enlarged side elevation view of the upper and lower jaws of the shear attachment of FIG. 1 with the upper jaw about to enter the slot in the lower jaw.
[0022] FIG. 21 is an enlarged side elevation view of the upper and lower jaws of the shear attachment of FIG. 1 with the upper jaw fully closed and extending into the slot of the lower jaw.
[0023] FIG. 22 is an enlarged side elevation view of the upper and lower jaw illustrating forces acting on the piercing tip in a jamming situation.
[0024] FIG. 23 is an enlarged side elevation view of the upper and lower jaw illustrating forces acting on the piercing tip in another type of jamming situation.
[0025] FIG. 24 is an enlarged side elevation view of the upper and lower jaw illustrating forces acting on the piercing tip in the event of snagging of the upper end of the piercing tip due to wear of the parent material from the nose of the upper jaw.
DESCRIPTION
[0026] Referring to the drawings wherein like reference numerals designate the same or corresponding parts throughout the several views, FIGS. 1 and 2 are perspective views from right and left sides, respectively (from the position of the operator), of one embodiment of a demolition shear attachment 10 . The shear attachment 10 has a main body 12 with a forward end 14 and a rearward end 16 . The rearward end 16 is adapted to be operably mounted to the boom or stick 18 ( FIG. 3A ) of an excavator such as by a swivel attachment 19 or other suitable mounting attachment as recognized and understood by those of skill in the art. At the forward end 14 of the main body 12 is a movable upper jaw 40 and a fixed lower 42 (discussed in detail later).
[0027] FIGS. 3A-3C show the shear attachment 10 mounted to the boom or stick of an excavator 18 of an excavator, and positioned in a typical operating position, and illustrating the movement of the upper jaw 40 closing with respect to the lower jaw 42 over an object 11 to be sheared. The object 11 to be sheared may be any structural member, such as a steel I-beam or channel, steel plate, pipe or some other material, such as scrap metal, sheet metal or any other object or material for which a demolition shear is suited for handling or processing.
[0028] Referring to FIGS. 1-4 , the main body 12 is typically constructed of steel side plates 20 , 22 , a top plate 24 and a bottom plate 26 which together define a substantially enclosed area within which a hydraulic actuator 30 ( FIGS. 3A-3C ) and other hydraulic components of the shear attachment 10 are substantially enclosed and protected. The hydraulic actuator 30 is pivotally secured at a rearward end within the main body 12 by an actuator pivot pin 32 extending through the side plates 20 , 22 , internal gussets (not shown) and the cylinder rod clevis 34 . The forward end of the hydraulic actuator 30 is pivotally attached to the movable upper jaw 40 by a cylinder pin 36 extending through the cylinder body clevis 38 and cylinder pin bore 42 (see also FIG. 16 ) in a rearward lobe of the upper jaw 40 . Thus, it should also be appreciated, that as the hydraulic actuator 30 extends and retracts as illustrated in FIGS. 3A-3C , the upper jaw 40 rotates about the longitudinal axis of the jaw pivot shaft 60 (discussed below) to open and close the upper jaw 40 with respect to the lower jaw 42 . An access opening with an access cover 25 ( FIG. 2 ) may be provided in the top plate to gain access to the interior of the body 12 for installation, maintenance, servicing and repair of the hydraulic actuator and other components of the hydraulic system.
[0029] As best illustrated in FIGS. 4 , 8 and 9 , jaw bosses 44 , 46 on each side of the forward end 14 of the main body 12 include hub bores 48 , 50 . A jaw pivot shaft assembly 60 received within the hub bores 48 , 50 and through a pivot shaft bore 54 (see FIG. 17 ) pivotally supports the upper jaw 40 .
[0030] The jaw pivot shaft assembly 60 comprises flanged bushings 56 , 58 fitted within the hub bores 48 , 50 . A main shaft 62 is press-fit into the pivot shaft bore 54 for rotation with the upper jaw 40 . The main shaft 62 includes a central bore 64 which receives a tie rod 66 having threaded ends 68 . End caps 70 , 72 are secured to the flanged bushings 56 , 58 by threaded connectors extending through aligned holes in the flange bushings 56 , 58 and are threadably received by aligned internally threaded holes in the hubs 44 , 46 . Tie rod nuts 74 threadably receive the threaded ends 68 of the tie rods 66 . The tie rod nuts 74 are secured to the end caps 70 , 72 by threaded connectors threadably received into internally threaded aligned holes in the flange bushings 56 , 58 . It should be appreciated that the tie rod 66 and tie rod nuts 74 laterally restrain the hubs 48 , 50 against lateral forces exerted on the jaws during the shearing operation.
[0031] As best viewed in FIGS. 4 and 8 , lateral jaw stabilizing puck assemblies 80 , such as disclosed in U.S. Pat. No. 7,216,575, may be provided along with corresponding wear plates or wear surfaces 82 ( FIG. 17 ) on the adjacent side or sides of the upper jaw 40 to resist lateral movement of the upper jaw 40 during the shearing operation until the upper jaw enters the slot 96 of the lower jaw 42 (discussed below).
[0032] Referring to FIGS. 5-11 , the lower jaw 42 includes forwardly extending, laterally spaced and substantially parallel jaw beams 90 , 92 and a cross-beam 94 extending transversely between the forward ends of the laterally spaced jaw beams 90 , 92 . The laterally spaced jaw beams 90 , 92 and the cross beam 94 together define a slot 96 into which the upper jaw 40 is received during the shearing process (see FIG. 3C and FIG. 4 ). As discussed in more detail below, the forwardly extending jaw beam 90 is adapted to receive shear blade inserts and guide blade inserts and is hereinafter referred to as the blade-side jaw beam 90 . The other forwardly extending jaw beam 92 serves to provide structural rigidity to the lower jaw and also serves to laterally restrain and guide the upper jaw into the slot 96 during the shearing process and is hereinafter referred to as the guide-side jaw beam 92 .
[0033] As best viewed in FIG. 10 , the inner side of the blade-side jaw beam 90 includes a shear blade seat 100 which is adapted to receive a set of hardened steel shear blade inserts 110 ( FIGS. 7 and 8 ). An embodiment of the shear blade inserts 110 is illustrated in FIG. 12 . The shear blade inserts 110 each have generally planar vertical wear surfaces 114 , 116 and generally planar horizontal wear surfaces 118 , 120 . The intersection of the vertical and horizontal wear surfaces define four shearing edges 122 . The shear blade inserts 110 have parallel sloping end surfaces 124 , 126 creating a parallelogram configuration so that when the shear blade inserts 110 are positioned and oriented in the shear blade seat 100 the adjacent end surfaces bear against each another in a downward apex (see FIGS. 7 and 8 ). It should be appreciated, that because the shear blade inserts 110 are in the shape of identical parallelepiped, they may be rotated and oriented with respect to one another within the shear blade seat 100 so that all four shearing edges 122 may be used as the shearing edges wear during use. The planar vertical wear surfaces 114 , 116 include counterbore holes 130 for receiving threaded connectors 132 (preferably socket headed cap screws) to removably attach the shear blade inserts 110 within the shear blade seat 100 . The counterbore holes 130 permit the heads of the threaded connectors 132 to be seated within the counterbore. The threaded ends of the threaded connectors 132 extend through the counterbore holes 130 and through aligned holes 134 ( FIG. 10 ) in the shear blade seat 100 and are secured by nuts 136 ( FIGS. 5 and 9 ), received within counterbore holes 138 on the outer side of the blade-side jaw beam 90 .
[0034] As best viewed in FIG. 10 , the inner side of the blade-side jaw beam 90 also includes a guide blade seat 200 which is adapted to receive a hardened steel guide blade insert 210 (best viewed in FIG. 8 ). An embodiment of the guide blade insert 210 is illustrated in FIG. 13 . The guide blade insert 210 has generally planar vertical wear surfaces 214 , 216 and generally planar horizontal wear surfaces 218 , 220 . The intersections of the vertical and horizontal wear surfaces define four shearing edges 222 . The guide blade insert 210 has parallel sloping end surfaces 224 , 226 creating a parallelogram configurations. The sloping end surfaces 224 , 226 of the guide blade insert 210 are complimentary to the sloping end surfaces 124 , 126 of the shear blade inserts 110 so that when the guide blade insert 210 is positioned and oriented in the guide blade seat 200 one of its end surfaces 224 , 226 will bear against one of the end surfaces 124 , 126 of the adjacently positioned shear blade insert 110 (as best illustrated in FIG. 8 ). It should be appreciated, that because the guide blade insert 210 is in the shape of a parallelepiped, it may be rotated and oriented within the guide blade seat 200 (and switched with the guide-side guide blade seat 300 discussed below) so that all four shearing edges 222 may be used as the shearing edges wear during use. The vertical wear surfaces 214 , 216 include tapped internally threaded holes 230 for receiving threaded connectors 232 (e.g., bolts) to removably attach the guide blade insert 210 within the guide blade seat 200 . The threaded ends of the threaded connectors 232 extend through aligned counterbore holes 234 ( FIGS. 5 and 9 ) on the outer side of the blade-side beam 90 and are threadably received by the tapped internally threaded holes 230 in the guide blade insert 210 .
[0035] As best viewed in FIGS. 9 and 11 , the guide-side beam 92 also includes a guide-blade seat 300 ( FIG. 11 ) which is adapted to receive the same guide blade insert 210 as received in the blade-side guide blade seat 200 so that the guide blade inserts 210 are interchangeable between the guide-side guide blade seat 300 and the blade-side guide blade seat 200 . Accordingly, the guide blade insert 210 is retained and secured in the guide-side guide blade seat 300 in substantially the same manner as the blade-side guide blade seat 200 in that the same threaded connectors 232 (e.g., bolts) extend through aligned counterbore holes 334 ( FIGS. 7 , 8 , 10 ) on the outer side of the guide-side jaw beam 92 and are threadably received by the tapped holes 230 in the guide blade insert 210 .
[0036] As best viewed in FIGS. 9 and 11 , the cross-beam 94 includes a cross-blade seat 400 ( FIG. 11 ) which is adapted to receive a hardened steel cross-blade insert 410 ( FIG. 9 ). An embodiment of the cross-blade insert 410 is illustrated in FIG. 14 . The cross-blade insert 410 has a generally planar front wear surface 414 , generally planar top and bottom wear surfaces 418 , 420 , generally planar end surfaces 424 , 426 and a back side 428 . The back side 428 includes four equally radially spaced internally threaded holes 430 . The back side 428 is also keyed with a projection 432 which seats within a recess 434 ( FIG. 11 ) in the cross-blade seat 400 . The intersection of the front vertical wear surface 414 with the top and bottom wear surfaces 418 , 420 and end surfaces define four cutting edges 422 . The cross-blade insert 410 is preferably square with four radially spaced holes 430 so that it may be rotated 90 degrees four times within the cross-blade seat 400 so that all four cutting edges 422 may be used as the shearing edges wear during use. The cross-blade insert 410 is secured within the cross-blade seat 400 by threaded connectors 436 (such as bolts) extending through counterbore holes 438 ( FIGS. 5 and 7 ) in the cross-beam 94 . The ends of the threaded connectors 436 are received within the aligned internally threaded holes 430 in the back side surface 428 of cross-blade insert 410 .
[0037] The upper jaw 40 has a blade-side and a guide-side which correspond to the adjacent blade-side jaw beam 90 and guide-side beam 92 of the lower jaw 42 . The blade-side of the upper jaw 40 includes a shear blade seat 500 ( FIG. 6 ) which is adapted to receive the same shear blade inserts 110 ( FIG. 5 ) as used in the shear blade seat 100 of the lower jaw 42 so that the shear blade inserts 110 are interchangeable between the upper and lower jaws, thereby reducing the number of different blade configurations needed for the shear attachment 10 . However, in the upper jaw, the shear blade inserts 110 are oriented in an upward apex as opposed to the downward apex in the lower jaw (compare FIGS. 5 and 7 ). The shear blade inserts 110 are secured in the upper jaw in substantially the same manner as the lower jaw. The threaded ends of the threaded connectors 132 extend through the counterbore holes 130 and through aligned holes 534 in the upper shear blade seat 500 and are secured by nuts 136 received within counterbores 538 ( FIG. 7 ) on the guide-side of the upper jaw 40 .
[0038] Referring to FIGS. 6 , 10 and 17 , the forward most end of the upper jaw 40 or nose 601 includes a nose seat 600 adapted to receive a hardened steel piercing tip insert 610 ( FIGS. 5 , 7 , 17 ) to protect the parent material of the upper jaw nose from wear during use. The nose seat 600 includes a blade-side nose seat 602 ( FIGS. 6 and 17 ), a guide-side nose seat 604 ( FIG. 10 ), and a front nose seat 606 ( FIGS. 6 , 10 , 17 ) which results in a narrowed nose portion 608 . The forward most nose tip 609 of the nose seat 600 is preferably radiused to minimize stress concentrations on the nose portion 608 , both during the manufacturing process and during use. The piercing tip insert 610 is comprised of two halves 620 , 622 which are substantially mirror images of each other except for the connector holes in each half (discussed later). The half which extends over the blade-side of the nose is hereinafter referred to as the blade-side half 620 , and the half which extends over the guide-side of the nose is hereinafter referred to as the guide-side half 622 .
[0039] FIG. 15 shows various views of an embodiment of the blade-side half 620 . FIG. 16 shows similar views of an embodiment of the guide-side half 622 . Each of the piercing tip halves 620 , 622 includes an outer sidewall 630 having a substantially planar vertical wear surface 632 and a substantially planar vertical inner bearing surface 634 . Each half 620 , 622 also includes a laterally inward projecting front wall 636 having an outer curved wear surface 638 and an inner bearing surface 640 . Each piercing tip half 620 , 622 also includes a laterally inward projecting bottom leg 642 having a bottom planar wear surface 644 and an upper leg bearing surface 646 . Each of the piercing tip halves 620 , 622 further includes an end bearing surface 648 and an ear 650 having upper ear bearing surface 651 and a lower ear bearing surface 653 . The ear 650 may have a radiused periphery to reduce stress concentrations. The lower ear bearing surface 653 extends rearwardly of the end bearing surface 648 , the purpose of which is discussed later in connection with FIGS. 22 and 23 . The intersection of the planar vertical wear surface 632 and the bottom planar wear surface 644 defines a shearing edge 652 . The intersection of the curved wear surface 638 of the front wall 636 and the bottom planar wear surface 644 defines a front piercing edge 654 (the front piercing edge may be chamfered).
[0040] As best viewed in FIGS. 6 , 10 and 17 , the nose seats 602 , 604 , 606 define peripheral bearing edge surfaces 656 which complimentarily receive the outer peripheries of the piercing tip halves 620 , 622 . It should be appreciated that the inner surface 640 of the laterally inward projecting front wall 636 and the upper surface 646 of the laterally inward projecting bottom leg 642 of each piercing tip half 620 , 622 is approximately half the width of the narrowed nose portion 608 so that when the piercing tip halves 620 , 622 are mounted in the nose seat 600 , the inner bearing surfaces 640 of the sidewalls 630 and the upper leg bearing surfaces 646 of the bottom legs 642 of the piercing tip halves 620 , 622 bear against the respective bearing surfaces of the blade-side nose seat 602 , the guide-side nose seat 604 and the front nose seat 606 . Additionally, the upper ear bearing surface 651 and the lower ear bearing surface 653 of the tip halves 620 , 622 bear against peripheral bearing edge surfaces 656 of the nose seat 600 . On the blade-side of the nose 601 , one of the sloping ends 124 , 126 (depending on orientation) of the upper shear blade insert 110 abuts and bears against the back end bearing surface 648 of the blade-side half 620 . As such, the blade-side piercing tip half 620 is rotationally restrained from outward rotation (as discussed later) by both the blade insert 110 and the peripheral bearing edge surfaces 656 which mateably receive of the upper ear bearing surface 651 and the lower ear bearing surface 653 of the blade-side nose seat. The guide-side piercing tip half 622 is rotationally restrained from movement by the peripheral bearing edge surfaces 656 which mateably receive of the upper ear bearing surface 651 and the lower ear bearing surface 653 of the guide-side nose seat 604 .
[0041] It should be appreciated that when the two piercing tip halves 620 , 622 are mounted in the nose seat 600 , the narrowed nose portion 608 is completely surrounded by the hardened steel piercing tip insert 610 thereby protecting the parent material of the nose 601 from wear during use.
[0042] In addition to being rotationally restrained by the peripheral bearing edge surfaces 656 , the two piercing tip halves 620 , 622 are secured to the narrowed nose tip 608 with threaded connectors 670 . In a preferred embodiment, the threaded connectors are socket headed cap screws. The two halves 620 , 622 include aligned holes 660 through their respective outer sidewalls 632 . Corresponding aligned holes 664 are provided through the narrowed nose tip 608 . Concentric counterbores 668 are provided over the holes 660 in the outer wall 632 of the blade-side half 620 . The aligned holes 660 in the outer wall 632 of the guide-side half 622 are tapped with internal threads. The counterbores 668 permit the heads of the threaded connectors 670 to be seated within the counterbores 668 . The threaded ends of the threaded connectors 670 extend through the holes 660 in blade-side half 620 and through the aligned holes 664 in the narrow nose tip 608 and are threadably received by the internally threaded aligned holes 660 of the guide-side tip half 622 . Obviously, the counterbores 668 and the internal threaded holes 660 in the two tip halves 620 , 622 could be reversed if desired. Alternatively, counterbores 668 could be provided in outer walls 632 of both tip halves 620 , 622 for receiving the heads of the threaded connectors 670 and to receive a nut (not shown) on the opposing tip half rather than tapping the holes 660 of one of the halves. As discussed in more detail later in connection with FIGS. 18 and 22 , the holes 660 , 664 are aligned along an arc concentric with the front edge of the piercing tip 610 (i.e., the outer curved wear surface 638 ) to ensure a more uniform loading across the threaded connectors 670 .
[0043] It should be appreciated that when mounted to the upper jaw 40 , the planar vertical wear surfaces 114 , 116 (depending on orientation) of the shear blade inserts 110 are substantially co-planar with the vertical wear surface 632 of the blade-side tip half 620 and the shearing edges 122 , 652 of the shear blade inserts 110 and piercing tip insert 610 are substantially aligned. Similarly, on the lower jaw 42 , the planar vertical wear surfaces 114 , 116 (depending on orientation) of the shear blade inserts 110 are substantially coplanar with the vertical wear surface 214 of the blade-side guide blade insert 210 and their respective shearing edges 122 , 222 are substantially aligned. It should also be appreciated that the substantially coplanar vertical wear surfaces 114 , 116 , 632 and shearing edges 122 , 652 of the upper shear blade inserts and piercing tip insert 610 are slightly laterally, inwardly offset from the shearing edges 122 , 232 of the shear blade inserts 110 and blade-side guide blade insert 210 of the lower jaw (preferably between a range of about 0.01 inches and 0.05 inches), to permit the upper shearing edges to pass by the shearing edges of the lower jaw as the upper jaw moves through its range of motion and into the slot 96 of the lower jaw 42 . Likewise, the shearing edge 652 of the guide-side piercing tip half 622 is laterally inwardly offset from the shearing edge 222 of the guide-side guide blade insert 210 preferably between a range of about 0.01 inches and 0.05 inches. Accordingly, the width of the piercing tip insert 610 is less than the width between the opposing shearing edges 222 of the blade-side and guide-side guide blades 210 (preferably between a range of about 0.02 and 0.1 inches), such that the piercing tip insert 610 can pass between the lower dual guide blades 210 as the upper jaw closes into the slot 96 of the lower jaw 42 . Shims may be inserted between the various inserts 110 , 210 , 610 and their respective seats 100 , 200 , 300 , 500 , 600 to maintain the close tolerances between the respective shearing edges.
[0044] FIGS. 18-22 are enlarged side elevation views of the jaws 40 , 42 to better illustrate the relationship of the blade inserts 110 , 210 and piercing tip insert 610 cross-blade insert 410 during movement of the upper jaw—i.e., from the fully open position ( FIG. 18 ), to the fully closed position ( FIG. 21 ) in which the upper jaw reaches full depth into the slot 96 of the lower jaw 42 . FIG. 19 , shows the upper jaw partially closed wherein the front piercing edge 654 of the piercing tip insert 610 is perpendicular or normal to the ground surface. FIG. 20 , shows the upper jaw in a position where the front piercing edge 654 intersects the lower jaw 42 .
[0045] A nose wear shoe 700 is secured (such as by welding) to the nose 601 of the upper jaw 40 above the piercing tip insert 610 to protect the parent material of the upper jaw from wear during use. As the nose wear shoe 700 wears down, it may be removed and replaced with another wear shoe 700 . The wear shoe 700 may be fabricated from the same material as the parent material or it may be fabricated from hardened steel. Referring to FIG. 20 , the nose wear shoe preferably extends along the nose a sufficient distance to ensure that the parent material of the nose is protected to at least the full depth of entry of the upper jaw 40 into the lower jaw 42 . In an alternative embodiment, the piercing tip insert 610 may be extended along the nose 601 to the full dept of entry of the upper jaw into the lower jaw. In such an embodiment, the nose seat 600 would likewise be extended and additional holes 660 may be necessary to adequately restrain the longer piercing tip insert 610 to the narrowed nose 608 .
[0046] It should be appreciated that the parent material of the nose 601 above the piercing tip insert 610 is more susceptible to wear than the hardened steel piercing tip insert 610 . Accordingly, without a wear shoe 700 , the nose 601 could wear down to the point that the upper edge of the piercing tip insert 610 projects above the nose. If the upper edge of the piercing tip insert 610 projects outwardly from the nose 601 , the projection could potentially snag on material caught in the jaws as the upper jaw re-opens or is retracted from the lower jaw. If sufficient retract force is exerted on the upper jaw, the piercing tip insert could be pulled away from the nose by the snagged material, shearing the threaded connectors in the process or breaking the piercing tip insert. Accordingly, as hereinafter described, the nose 601 of the upper jaw is configured to minimize the risk of snagging, even when a wear shoe 700 is not mounted to the nose 601 or where the wear shoe itself is worn down such that the parent material of the nose is no longer protected by the wear shoe.
[0047] FIGS. 18 and 21 illustrate a preferred configuration of the nose 601 to avoid or minimize occurrences of snagging. The phantom line designated by reference numeral 800 identifies the arc created by the forward most front piercing tip edge 654 of the piercing tip insert 610 as the upper jaw moves through its range of motion. The arc 800 has a radius R 1 to the center axis of the jaw pivot shaft 60 . The outermost periphery of the nose 601 from the forward piercing edge 654 of the piercing tip 610 to the end of the nose wear shoe 700 or to the point on the nose which corresponds to the maximum depth that the nose 601 penetrates the lower jaw is configured to transitions away from the front piercing tip edge arc 800 in a substantially smooth nose arc 802 . The nose arc 802 has a radius R 2 which is less than the radius R 1 , such that radial distances from the central axis of the jaw pivot shaft 60 to points along the nose 601 or nose arc 802 continually decrease relative to the front piercing tip edge arc 800 . Stated another way, the distance between the piercing tip front edge arc 800 and the nose arc 802 continually increases along the nose 601 or nose arc 802 from the piercing tip front edge 654 . This configuration allows the nose 601 to only make contact at the piercing tip front edge 654 , thereby avoiding or reducing the likelihood of the nose 601 scraping along objects being pierced by the piercing tip 610 , thereby minimizing wear along the nose. Additionally, because the nose increasingly transitions away from the piercing tip edge arc 800 , it reduces the likelihood of snagging of material caught in the jaws even if the parent material of the nose becomes worn down to where the upper edge of the piercing tip insert 610 projects outwardly from the worn parent material of the nose.
[0048] Furthermore, the piercing tip seat 600 and piercing tip insert 610 are configured to ensure retention of the piercing tip if a projecting edge of the piercing tip becomes snagged or if the upper jaw becomes jammed by material trapped in the jaws. For example, in FIG. 22 the hatched area 900 is intended to represent trapped or lodged material caught between the wear surfaces of the piercing tip insert 610 and the guide shear blade inserts 210 causing the upper jaw to become jammed within the slot 96 of the lower jaw 42 such that the upper jaw 40 cannot retract or re-open. The retract force F of the upper jaw 40 (exerted by the hydraulic actuator 30 pulling on the upper jaw) attempts to pull the piercing tip insert 610 in the direction perpendicular to the radial line 806 extending from the center axis of the jaw pivot shaft 60 to the midpoint of the trapped material 900 . It should therefore be appreciated that any bearing surface which is less than 90 degrees to the radial line 806 , will resist the retract force F. Accordingly, the rearwardly projecting ears 650 of the piercing tip insert 610 ensure that a bearing surface is provided to resist the retract force F.
[0049] Referring to FIG. 22 , the lower ear bearing surface 653 is at an angle less than 90 degrees to the radial line 806 and therefore provides a bearing surface designated by arrows R against which the peripheral bearing edge surfaces 656 of the nose seat 600 engage to resist the retract force F. Similarly, the inner bearing surface 640 of the front wall 636 bears against the nose seat 606 as designated by arrows R to resist the retract force F. Thus, the resistance or reactionary forces R will reduce the shearing forces being exerted on the connectors 670 by the retract force F, thereby preventing or minimizing the piercing tip insert 610 from being pulled off the nose or otherwise fracturing.
[0050] Furthermore, because the holes 660 in the piercing tip insert 610 are aligned along an arc 804 having a radius R 3 which is less than the radius R 2 but which is concentric with the nose arc 802 , a more uniform load is applied across all of the connectors 670 thereby further reducing the shearing stresses exerted on any one connector or causing stress concentrations which could shear the connectors or cause the piercing tip insert to fracture.
[0051] FIG. 23 illustrates another example wherein the hatched area 902 is intended to represent material trapped between the piercing tip insert 610 and the cross-blade insert 410 . In this example, the retract force F again pulls the piercing tip in the direction perpendicular to the radial line from 806 extending from the center axis of the jaw pivot shaft 60 to the center point the trapped material, which, in this example, is assumed to be at the piercing tip front edge 654 . The retract force F will cause the piercing tip insert 610 to attempt to roll outwardly or away from the nose 601 as indicated by arrow 810 . However, the upper ear bearing surface 651 engages with the peripheral bearing edge surfaces 656 of the nose seat 600 as designated by reactionary forces R to resist the outward rotation of the piercing tip insert 610 thereby reducing shearing forces on the connectors 670 and preventing or reducing stress fracturing of the piercing tip insert 610 .
[0052] FIG. 24 illustrates an example of the retract force F acting on the upper edge of the piercing tip insert 610 in the unlikely event that the nose 601 is worn down to create a ridge upon which material could snag as described above. Such an occurrence is unlikely in view of the configuration of the nose 601 having a continually increasing distance between the nose arc 802 and the piercing tip front edge arc 800 for the reasons explained above, but nevertheless, if the nose is worn down to create a ridge on which material could snag, the upper ear bearing surface 651 would engage against the peripheral bearing edge surfaces 656 of the nose seat 600 as indicated by reaction forces R to resist the retract force F attempting to roll the piercing tip edge outwardly as indicated by arrow 810 thereby reducing shearing forces on the connectors 670 and preventing or reducing stress fracturing of the piercing tip insert 610 .
[0053] The foregoing description is presented to enable one of ordinary skill in the art to make and use the invention and is provided in the context of a patent application and its requirements. Various modifications to the embodiments described herein, and the general principles and features of the embodiments described herein will be readily apparent to those of skill in the art. Thus, the present invention is not to be limited to the embodiments described herein and illustrated in the drawing figures, but is to be accorded the widest scope consistent with the spirit and scope of the appended claims.
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A demolition shear and a piercing tip insert and nose configuration for a demolition shear which resists nose wear and resists retract forces exerted on the piercing tip insert in jamming situations and in the event of snagging of the piercing tip insert. There is a need for a demolition shear having a piercing tip insert and nose configuration to reduce nose wear and to resist retract forces exerted on the piercing tip insert in jamming situations and in the event of snagging of the piercing tip insert.
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FIELD OF THE INVENTION
The field of the invention relates to completion techniques involving fracturing and more particularly the ability to gravel pack and fracture discrete segments of a formation in a desired order through dedicated valved ports followed by configuring another valve for screened sand control duty to let production begin. A crossover tool and a separate run for sand control screens after the fracturing operation is not required.
BACKGROUND OF THE INVENTION
Typical completion sequences in the past involve running in an assembly of screens with a crossover tool and an isolation packer above the crossover tool. The crossover tool has a squeeze position where it eliminates a return path to allow fluid pumped down a work string and through the packer to cross over to the annulus outside the screen sections and into the formation through, for example, a cemented and perforated casing or in open hole. Alternatively, the casing could have telescoping members that are extendable into the formation and the tubular from which they extend could be cemented or not cemented. The fracture fluid, in any event, would go into the annular space outside the screens and get squeezed into the formation that is isolated by the packer above the crossover tool and another downhole packer or the bottom of the hole. When a particular portion of a zone was fractured in this manner the crossover tool would be repositioned to allow a return path, usually through the annular space above the isolation packer and outside the work string so that a gravel packing operation could then begin. In the gravel packing operation, the gravel exits the crossover tool to the annular space outside the screens. Carrier fluid goes through the screens and back into the crossover tool to get through the packer above and into the annular space outside the work string and back to the surface.
This entire procedure is repeated if another zone in the well needs to be fractured and gravel packed before it can be produced. Once a given zone was gravel packed, the production string is tagged into the packer and the zone is produced.
There are many issues with this technique and foremost among them is the rig time for running in the hole and conducting the discrete operations. Other issues relate to the erosive qualities of the gravel slurry during deposition of gravel in the gravel packing procedure. Portions of the crossover tool could wear away during the fracking operation or the subsequent gravel packing operation, if the zone was particularly long. If more than a single zone needs to be fractured and gravel packed, it means additional trips in the hole with more screens coupled to a crossover tool and an isolation packer and a repeating of the process. The order of operations using this technique was generally limited to working the hole from the bottom up. Alternatively, one trip multi-zone systems have been developed that require a large volume of proppant slurry through the crossover tool and that increases the erosion risk.
What the present invention addresses are ways to optimize the operation to reduce rig time and enhance the choices available for the sequence of locations where fracturing can occur. Furthermore, through a unique valve system, fracturing can occur in a plurality of zones in any desired order followed by operating another valve to place filter media in position of ports so that production could commence with a production string without having to run screens or a crossover tool into the well. These and other advantages of the present invention will be more readily apparent to those skilled in the art from the description of the various embodiments that are discussed below along with their associated drawings, while recognizing that the claims define the full scope of the invention.
SUMMARY OF THE INVENTION
A completion tubular is placed in position adjacent the zone or zones to be fractured and produced. It features preferably sliding sleeve valves one series of which can be put in the wide open position after run in for gravel packing and fracturing zones one at a time or in any desired order. These valves are then closed and another series of valves can be opened wide but with a screen material juxtaposed in the flow passage to selectively produce from one or more fractured zones. An annular path behind the gravel is provided by an offset screen to promote flow to the screened production port. The path can be a closed annulus that comes short of the production port or goes over it. For short runs an exterior screen or shroud is eliminated for a sliding sleeve with multiple screened ports that can be opened in tandem.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a section view of an embodiment with a proppant control shroud shown in the run in position;
FIG. 2 is the view of FIG. 1 with a valve open for proppant deposition and fracturing;
FIG. 3 is the view of FIG. 2 with the frac valve closed and the production valve open with a screen in the flow path of the production valve;
FIG. 4 is the view of FIG. 1 but with an alternative embodiment where the proppant shroud straddles the production valve;
FIG. 5 is the view of FIG. 4 with the fracture and proppant deposition valve open;
FIG. 6 is the view of FIG. 5 with the fracture and proppant deposition valve closed and the production valve open with a screen in the flow path;
FIG. 7 is an alternative embodiment with no external proppant shroud and instead having a sleeve to open multiple production ports with screened openings and a frac valve all shown in a closed position for run in;
FIG. 8 is the view of FIG. 7 with the frac valve in the wide open fracturing position;
FIG. 9 is the view of FIG. 8 with the frac valve closed and the production sliding sleeve in the open position;
FIG. 10 is a view of a frac valve in the closed position;
FIG. 11 is the view of FIG. 10 with the frac valve in the open position;
FIG. 12 is the view of FIG. 11 with the frac valve in the open position and an insertable screen in position for production;
FIG. 13 is the view of the insertable screen shown in FIG. 12 ;
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a schematic illustration of a wellbore 10 that can be cased or in open hole. There are perforations 12 into a formation 14 . A string 16 is shown in part if FIG. 1 to the extent it spans a production interval defined between seals or packers 18 and 20 . These seal locations can be polished bores in a cased hole or any type of packer. The two barriers 18 and 20 define a production interval 22 . While only one interval is shown the string 16 can pass through multiple intervals that preferably have similar equipment so that access to them can occur in any desired order and access can be to one interval at a time or multiple intervals together.
The string 16 for the interval 22 that is illustrated has a frac valve 24 that is preferably a sliding sleeve shown in the closed position in FIG. 1 for run in. Valve 24 regulates opening or openings 25 and is used in two positions. The closed position is shown in FIG. 1 and the wide open position is shown in FIG. 2 . In the FIG. 2 position, gravel slurry can be squeezed into the formation 14 leaving the gravel 28 in the annular interval 22 just outside the proppant screen or shroud 29 . Shroud 29 is sealed on opposite ends 30 and 32 and in between defines an annular flow area 34 . While the shroud 29 is shown as one continuous unit, it can also be segmented with discrete or interconnected segments. The gravel 28 stays in the interval 22 and the carrier fluid is pumped into the formation 14 to complete the fracturing operation schematically represented as 15 . At that point the valve 24 is closed and excess proppant 28 that is still in the string 16 can be circulated out to the surface using, for example, coiled tubing 36 .
At this point the production valve 26 which is preferably a sliding sleeve with a screen material 38 in or over its ports to make a first layer is brought into alignment with ports 40 and production from the formation 14 begins. Alternatively, the screen material 38 can be fixed to either side of the string 16 to make a second layer. In short, the open position of production valve 26 results in the production flow being screened through two layers with one being the string 16 and the other being the production valve 26 with the screen material 38 located on the port or ports in one of the production valve 26 or the string 16 , regardless of screen position and screen type. Flow can take a path of less resistance through the flow area 34 to reach the port 40 . While such flow avoids most of the gravel pack 28 by design, the presence of passage 34 allows a greater flow to reach the ports 40 so as not to impede production. The presence of a screen material 38 at ports 40 serves to exclude solids that may have gotten into passage 34 through the coarse openings in shroud 29 . The screen material 38 can be of a variety of designs such as a weave, conjoined spheres, porous sintered metal or equivalent designs that perform the function of a screen to keep gravel 28 out of the flow passage through string 16 .
It should be noted that while only a single port 25 and 40 are shown that there can be multiple ports that are respectively exposed by operation of valves 24 and 26 . While valves 24 and 26 are preferably longitudinally shiftable sliding sleeves that can be operated with a shifting tool, hydraulic or pneumatic pressure or a variety of motor drivers, other styles of valves can be used. For example, the valves can be a sleeve that rotates rather than shifts axially. While a single valve assembly in an interval between barriers 18 and 20 is illustrated for valves 24 and 26 and their associated ports, multiple assemblies can be used with either discrete sleeves for a given row of associated openings or longer sleeves that can service multiple rows of associated openings that are axially displaced.
FIGS. 4-6 correspond to FIGS. 1-3 with the only difference being the shroud 29 having an end 32 that is past the openings 40 so that the passage 34 goes directly to the ports 40 . Here, as opposed to FIGS. 1-3 , once the flow from the formation 14 passes through the shroud 29 it doesn't have to pass through that shroud 29 a second time. In all other respects the method is the same. In FIG. 4 the valves 24 and 26 are closed for run in. When the string 16 is in position and the barriers 18 and 20 are activated, the valve 24 is opened, as shown in FIG. 5 , and proppant slurry 28 is delivered through ports 25 . There is no crossover needed. When the proper amount of proppant is deposited in the interval 22 , the valve 24 is closed and valve 26 is opened to place the screen material 38 over openings 40 to let production begin. As before, with the design of FIGS. 1-3 and the variations described for those FIGS., the same options are available to the alternative design of FIGS. 4-6 . One advantage of the design in FIGS. 4-6 is that there is less resistance to flow in passage 34 because of the avoidance of going through the shroud 29 a second time to get to the ports 40 . On the other hand, one of the advantages of the design of FIGS. 1-3 is that the inside dimension of the string 16 in the region close to valve 26 can be larger because the shroud 29 terminates at end 32 well below the ports 40 .
In both designs the length of shroud 29 can span many pipe joints and can exceed hundreds if not thousands of feet depending on the length of the interval 22 . Those skilled in the art will appreciate that short jumper sections can be used to cover the connections after assembly so that the passage 34 winds up being continuous.
FIGS. 7-9 work similarly to FIGS. 1-3 with the only design difference being that the shroud 29 is not used because the application for this design is for rather short intervals where a bypass passage such as 34 around a shroud 29 is not necessary to get the desired production flow rates. Instead valve 26 has a plurality of screen sections 38 that can be aligned with axially spaced arrays of openings 40 . In this case as with the other designs, the valves 24 and 26 can be located within or outside the tubular string 16 . In all other ways, the operation of the embodiment of FIGS. 7-9 is the same as FIGS. 1-3 . In FIG. 7 for run in the valves 24 and 26 are closed. The string 16 is placed in position and barriers 18 and 20 define the producing zone 22 . In FIG. 8 , the valve 24 is opened and the gravel slurry 28 is squeezed into the formation 14 leaving the gravel in the interval 22 outside of openings 40 . In FIG. 9 the gravel packing and frac is completed and the valve 24 is closed. Then valve 26 is opened placing screen material 38 in front of openings 40 and production can begin. In essence, valve 26 with its screen sections 38 and openings 40 act as a screen that is blocked for run in and gravel deposition and frac and then functions as a screen for production. Again multiple assemblies of valves 24 and 26 can be used so that if one fails to operate another can be used as a backup. In the same manner if one set of screen sections 38 clog up, another section can be placed in service to continue production.
FIG. 10 illustrates a valve 50 that uses as sliding sleeve 52 to selectively cover ports 54 . The ports 54 are closed in FIG. 10 and open in FIG. 11 . A latch profile 56 is provided adjacent each sleeve 52 . An array of valves 50 and associated ports 54 is envisioned. The configuration of the latch profile 56 is preferably unique so as to accept a specific screen assembly 58 , one of which is shown in FIG. 13 . Each screen assembly has a latch 60 that is uniquely matched to a profile 56 . FIG. 12 shows a screen assembly 58 that has a latch 60 engaged in its mating profile 56 . In that position a screen 62 has end seals 64 and 66 that straddle ports 54 with sleeve 52 disposed to uncover the ports 54 . One or more such assemblies are envisioned in an interval 22 between isolators 18 and 20 in the manner described before. In operation, the ports 54 are closed for run in as shown in FIG. 10 . After getting the string 16 into position and setting the barriers (not shown in FIG. 10 ) to define an interval 22 , as before, the ports 54 are exposed and gravel slurry is forced into the formation as the formation is fractured. At this time the screen assembly 58 is not in string 16 . When that step is done and the excess slurry is circulated out, the valves 50 to be used in production are opened. A screen assembly 58 with a latch 60 that matches the valve or valves 50 just opened is delivered into the string 16 and secured to its associated profile 56 . In this manner, the ports 54 that are now open each receive a screen assembly 58 and production can begin. Any order of producing multiple intervals can be established. The screen sections 58 can be dropped in or lowered in on wireline or other means. They are designed to release with an upward pull so if they clog during production they can be released from latch 56 and removed and replaced to allow production to resume. The screen assemblies can have a fishing neck 68 to be used with known fishing tools to retrieve the screen section 58 to the surface. One screen section can cover one array of ports 54 or multiple arrays, depending on its length and the spacing between seals 64 and 66 .
Optionally, the shroud 29 of from the other embodiments can be combined into the FIGS. 10-13 embodiment and it can be positioned to come just short of ports 54 or to straddle them as previously described and for the same reasons.
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 completion tubular is placed in position adjacent the zone or zones to be fractured and produced. It features preferably sliding sleeve valves one series of which can be put in the wide open position after run in for gravel packing and fracturing zones one at a time or in any desired order. These valves are then closed and another series of valves can be opened wide but with a screen material juxtaposed in the flow passage to selectively produce from one or more fractured zones. An annular path behind the gravel is provided by an offset screen to promote flow to the screened production port. The path can be a closed annulus that comes short of the production port or goes over it. For short runs an exterior screen or shroud is eliminated for a sliding sleeve with multiple screened ports that can be opened in tandem.
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BACKGROUND OF THE INVENTION
Heretofore, various types of deviated wellbores have been drilled from a primary wellbore. One particular type of deviated wellbore, known as a drain hole, is drilled from a primary wellbore through a sharp radius of curvature so as to extend laterally away from the primary wellbore. Normally, although not necessarily, the primary wellbore is essentially vertical and the drain hole, after passing through its sharp radius of curvature extends essentially horizontally away from the primary wellbore out into the producing geologic formation. Drain holes, and the method for drilling same, are fully and completely disclosed in U.S. Pat. Nos. 3,349,845 and 3,398,804.
BRIEF SUMMARY OF THE INVENTION
Often the drain hole is deliberately drilled into a liquid, e.g. crude oil, producing formation or strata to maximize the recovery of liquid therefrom. Such a formation or strata sometimes has adjacent thereto a gas, e.g. natural gas, producing formation or strata overlying or otherwise adjacent the liquid producing formation. In those cases, the potential is present for producing both gas and liquid from the drain hole into the primary wellbore for recovery of both gas and liquid at the surface of the earth.
It has been found that in some such situations, the gas may preferentially sweep into the drain hole, particularly in the area of the radius of curvature of the drain hole, thereby reducing the amount of liquid produced from the drain-hole. According to this invention, a method for drilling drain hole wellbores is provided which enhances liquid production from the drain hole by drilling at least a first portion, but not necessarily all of, the drain hole wellbore. Thereafter, a portion of the primary wellbore and only the first portion of the drain hole wellbore are completely filled with a hardenable material which is then allowed to harden. The hardened material is then re-drilled to leave a primary wellbore and first portion of the drain hole wellbore lined with the hardened material, and an unlined extension of the drain hole wellbore passing outwardly into the liquid producing formation.
Accordingly, it is an object of this invention to provide a new and improved method for increasing the productivity of new or old primary wellbores. It is another object to provide a new and improved method for drilling for and producing hydrocarbonaceous fluids from the earth. It is another object to provide a new and improved method for enhancing the recovery of fluids by way of a drain hole wellbore when gas is closely associated with a liquid.
Other aspects, objects and advantages of this invention will be apparent to those skilled in the art from this disclosure and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a cross-section of a primary wellbore and drain hole wellbore in the earth.
FIG. 2 shows an enlarged cross-section of the primary and drain hole wellbores of FIG. 1 when gas and oil are produced without the practice of this invention.
FIGS. 3 and 4 show an enlarged cross-section of the same primary and drain hole wellbores and the production of gas and oil therefrom in accordance with this invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows the surface of the earth 1 with drilling rig 2 set over a primary wellbore 3 which extends essentially vertically downwardly into the earth 4. In area A of primary wellbore 3 are two fluid producing geologic formations, for example, an upper formation 5 which produces natural gas, and a lower formation 6 which produces liquid crude oil. A drain hole wellbore 7 has been drilled laterally from wellbore 3 and, after passing through a radius of curvature portion B, extends essentially horizontally away from wellbore 3 out into oil producing formation 6. Wellbore 7 thereby enhances the flow of oil from formation 6 into drain hole 7 for production to the earth's surface 1 in a conventional manner by way of primary wellbore 3.
Wellbores 3 and 7 can be either cased or uncased, cemented or uncemented, as far as the application of this invention goes. Wellbore 3 can be a newly drilled well or an old well that is being worked over for drain hole purposes. The invention will be described hereinafter, only for sake of simplicity, as though both the wellbores were newly drilled and not cased or cemented. However, it should be understood that this invention also applies to cased and/or cemented wellbores, work overs, and the like.
FIG. 2 shows the situation of oil and gas production into primary wellbore 3 after production has been carried out for a while. What sometimes occurs in such a situation is that gas, because of its greater mobility in the earth, will cone downwardly toward drain hole 7 as indicated by dotted line 8 and arrows 9 and 10, so that gas enters primary wellbore 3 ahead of liquid oil, as represented by arrows 10 and 11. Gas coning into the drain hole prematurely decreases the amount of liquid produced by way of the drain hole. This is disadvantageous because, ideally, all liquid is produced from reservoir 6 first taking advantage of the pressure drive from the gas in reservoir 5 to help drive the oil out of reservoir 6. However, if gas prematurely escapes to primary wellbore 3 by coning, the gas cap can be depleted and its assistance in removing oil from reservoir 6 reduced before the optimum amount of oil has been recovered from reservoir 6 by way of drain hole 7.
FIG. 3 shows primary wellbore 3 after the radius of curvature portion B of drain hole wellbore 7 is drilled and terminated at point 30. Point 30 is the approximate location at which drain hole wellbore 7 reaches essentially a horizontal attitude and starts to head directly away from wellbore 3. After the radius of curvature portion B is drilled, primary wellbore 3 has set therein a conventional bridge plug or other packoff means 31 which plugs wellbore 3 so that a fluid material can be pumped into wellbore 3 and come to rest on and be supported by packoff 31. Thereafter, wellbore 3, at least in area A and all of the radius of curvature portion B of drain hole wellbore 7, is filled with a hardenable material which is then left to harden. The hardened material 32 completely fills primary wellbore 3 in area A and the drilled portion of drain hole wellbore 7.
Thereafter, as shown in FIG. 4, hardened material 32 is re-drilled, including bridge plug 31, to re-establish primary wellbore 3. Radius of curvature portion B of drain hole wellbore 7 is also re-drilled and wellbore 7 further extended to the desired distance away from wellbore 3 as represented by 7'. Thus, drain hole wellbore 7 ultimately ends up as a continuous but two segment wellbore. The first segment is adjacent primary wellbore 3 and is lined with hardened material 32. The second segment is unlined so that fluids from formations 5 and 6 can enter drain hole wellbore 7 and pass therethrough into primary wellbore 3 for production to the earth's surface. By leaving an outer layer of hardened material 32 in primary wellbore 3 in area A and in the radius of curvature portion B of drain hole wellbore 7, these portions of both wellbores are rendered essentially gas impermeable so that gas coning, such as that shown for FIG. 2 above, can no longer occur. Thereafter, gas passing downwardly from formation 5 into formation 6, as shown by arrows 40 and 41, must pass essentially completely through formation 6 to reach unlined drain hole wellbore portion 7'. In so doing, the gas must push essentially all of the oil present in formation 6 ahead of it into drain hole wellbore 7 before any gas reaches that drain hole wellbore. This substantially enhances the production of liquid oil from formation 6 before any gas from formation 5 reaches the drain hole wellbore.
Generally, any material which will become rigid under down hole wellbore conditions can be employed for hardenable material 32. The most useful material which is readily available in the oil patch is cement or cementitious materials which are normally used to fill in spaces between steel wellbore casing and the earth surrounding that casing. Thus, any cementing material normally used in current wellbore applications can be used as hardenable material 32. Cementitious compositions and techniques for displacing and hardening same are already well known in the art. Of course, other hardenable materials such as polymeric materials and the like can be employed, but by far the most available and well known material will be cement based.
Although it has been described hereinabove that essentially the full radius of curvature B is drilled and filled with hardenable material, it is within this invention to drill and fill more or less than the full radius of curvature B. For example, wellbore 7 can be drilled for a distance greater than radius of curvature B so that a portion of the essentially horizontal section 7' of FIG. 4 beyond end 30 will have an outer hardened layer 32. Similarly, less than the full length of radius of curvature B can be lined with hardened material 32. It is only required by this invention that a sufficient portion of the drain hole wellbore be lined with hardened material to reduce gas coning. It is not critical whether that portion is the same as, less than, or greater than radius of curvature portion B so long as a portion of the drain hole wellbore is lined and gas coning is substantially reduced or eliminated. It will depend upon the particular circumstances of the specific well in question as to how much of drain hole wellbore 7 needs to be lined in order to accomplish the goals of this invention.
Other obvious approaches can be taken to achieve the results of this invention and these approaches are also within the scope of this invention. For example, instead of stopping drain hole wellbore 7 drilling at point 30 of FIG. 3, the entire wellbore 7 could be drilled as shown in FIG. 4 before any hardenable material is introduced into the primary or drain hole wellbores. Thereafter, a conventional packoff, such as bridge plug 31 of FIG. 3, could be employed at point 30 in drain hole wellbore 7 or any other desired point in wellbore 7 to plug that wellbore. Wellbore 3 would also be plugged with bridge plug 31 as shown in FIG. 3. After plugging both wellbores 3 and 7, hardenable material can be pumped into wellbores 3 and 7 upstream of bridge plugs 31 and allowed to harden. The hardened material is then re-drilled, including drilling through the bridge plugs 31 in both wellbores, to achieve a lined wellbore 3 and partially lined wellbore 7, essentially as shown in FIG. 4. Other obvious approaches to achieve the same result can be devised by those skilled in the art once advised of this invention and the advantages therefor, and such approaches are also within the scope of this invention.
Reasonable variations and modifications are possible within the scope of this disclosure without departing from the spirit and scope of this invention.
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A method for enhancing the recovery of liquid products from a wellbore having at least one laterally extending drain hole wellbore extending therefrom, wherein a portion of the primary wellbore near the drain hole wellbore and a portion of the drain hole wellbore itself are completely filled with a hardenable material and the hardened material is then re-drilled leaving an outer layer of hardened material to line the primary wellbore and part of the drain hole wellbore so that gas cannot prematurely cone into the primary wellbore, thereby enhancing liquid recovery by way of the unlined portion of the drain hole wellbore before any gas reaches the drain hole wellbore.
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BACKGROUND
Events and data for content and format are unable to be fully predicted in advance. Generally applications for processing data and the related user interfaces (UI) are developed as static engine code shipped with the product. Any changes to the application or UI must be made through the download and installation of updates to the static application code. In the case of applications for presenting information related to live events, for example, news events and sports, there is no ability to react to changing events and input data over time (e.g., in the sports metaphor, seasons, teams, leagues, players, scores, game events, etc.). There is further no ability to change the application to respond to changing external business conditions or rules (e.g., legal deals or prohibitions, etc.). Traditional patching mechanisms are infrequent, not dynamic enough, involve high overhead to develop the software update, and require procedures such as restarting the entire computer. A static, pre-constructed application thus offers users a sub-optimal experience or, in some cases, none at all.
SUMMARY
A dynamic and interchangeable set of application behaviors is implemented up on the same underlying software engine. Downloadable data provider behavior descriptors configure the UI generation application dynamically on demand to meet needs that are unknown at ship time, or otherwise cannot be predicted in advance. The list of inputs, their format and contents, and the optimal user interface or experience, all change over time. The data provider supplies the data source locations, data feeds, poll/pull intervals on feeds, parameter definitions, data binding definitions, lists, groups, data transformation logic, resources, and UI templates to plug into the base application engine, which transforms the supplied data to create a UI experience tailored to match the appropriate events and available data over time. The base application engine is agnostic to both the data provider and the input data received. The base application takes on an identity defined by the data provider, including appearance, functionality, and content.
This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Other features, details, utilities, and advantages of the claimed subject matter will be apparent from the following more particular written Detailed Description of various embodiments and implementations as further illustrated in the accompanying drawings and defined in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of an exemplary system and network environment for providing a mutable application experience.
FIG. 2 is a schematic diagram of an exemplary media processing device for providing a mutable application experience.
FIG. 3 is a flow diagram of an exemplary implementation of a process for creating a mutable application experience.
FIG. 4 is a schematic diagram of a first implementation of an exemplary user interface for presenting regularly updated data.
FIG. 5 is a schematic diagram of a revised implementation of the exemplary user interface of FIG. 4 for presenting regularly updated data.
FIG. 6 is a schematic diagram of a second implementation of an exemplary user interface for presenting regularly updated data from a particular data provider.
FIG. 7 is a schematic diagram of an alternate implementation of an exemplary user interface for presenting regularly updated data from an alternate data provider.
FIG. 8 is a schematic diagram of a general purpose computing system that may be configured to provide the mutable application experience described herein.
DETAILED DESCRIPTION
A dynamic application platform 100 for implementing an exemplary configuration of a mutable application experience is depicted in FIG. 1 . The platform 100 is composed, in part, of a media processing device 102 in which several modules may operate to provide the mutable application experience. The media processing device 102 may be a personal computer configured to run a multi-media software package, for example, the Windows® XP Media Center Edition operating system (Microsoft Corporation, Redmond, Wash.). In such a configuration, the personal computer effectively operates to integrate full competing functionality within a complete home entertainment system.
The media processing device 102 may also include other components, for example: a personal video recorder (PVR) to capture live television show for future viewing or to record the future broadcast of a single program or series; a compact disc (CD) or digital video disc (DVD) drive for disc media playback; a media drive for integrated storage of and access to a users recorded content, e.g., television shows, music pictures, and home video; and an electronic program guide (EPG). Instead of a conventional personal computer, the media processing device 102 may be provided by an alternate hardware device capable of storing and distributing media content including, for example, a notebook or portable computer, a tablet computer, a workstation, a main frame computer, a server, an internet appliance, a handheld device, or combinations thereof. The media processing device 102 may also be a set-top box, primarily used for receiving and tuning cable or satellite television signals, but which may additionally be connected within a network to operate as a media processing device 102 .
The media processing device 102 may include a binding engine module 104 and a user experience engine module 106 . The binding engine module 104 may be considered the base or core application within the platform 100 . The binding engine 104 is agnostic to any particular type of data or source of data that it processes. The purpose of the binding engine 104 is to collect data of various types and forms from one or more data providers and bind the data to management objects. The management objects may then be used by the user experience engine 106 to create a particular application experience for a user through a UI output to a presentation device 108 . The presentation device 108 may be a television, a computer monitor, a display panel, or any other visual presentation device and may further include audio output devices such as speakers.
The data collected by the binding engine 104 may include any kind of data that may be formatted for presentation in a UI. For example, in one implementation the data may relate to live sporting events. The data received and processed by the binding engine 104 may be in the form of scores, game status, player statistics, team statistics, real-time player actions, audio clips, video clips, and any other data that may be formatted for presentation to a user. It should be apparent that the data received by and processed by the binding engine 104 need not be limited to sports data, but may comprise data related to any topic available for presentation, for example, data related to other live events, movies, and standard television shows.
The binding engine 104 may be connected to a network 110 , for example, the Internet, through which it accesses receives the various types of data for processing. The data may be generated by one or more data providers 112 , 114 , that are similarly connected to the network 110 . The data providers 112 , 114 may be alternate sources of similar data, e.g., competing sports networks, or they might provide data relating to wholly different subject matters that may be alternately displayed in the mutable application experience. Continuing with the sports theme as an exemplary implementation, the first data provider 112 may be the ESPN network, which provides information about sporting events that it is contemporaneously monitoring. A second data provider 114 may be, for example, Fox Sports Net, which may provide alternate sports information related to the events in its broadcasting schedule.
Additionally, a data transform package 116 may be transmitted or accessed across the network 110 by the binding engine 104 . The media processing device 102 may use the data transform package 116 to transform data received in various forms into a data that is manageable by the binding engine 104 . For example, the data from a first data provider 112 , e.g., ESPN, may be in a data format particularly developed by ESPN. The ESPN data may be formatted differently than similar data developed by a second data provider 114 , e.g., Fox Sports Net. In this case, the data transform package 116 provides the necessary instructions and functions to transform both the information received from the first data provider 112 and the information in the different format provided by the second data provider 114 into a common data format understood by the binding engine 104 .
For example, the information provided by the first data provider 112 may be coded in a first extensible mark-up language (XML) format while data from the second data provider 114 is provided in a second XML format. The data transform package 116 may contain an extensible style-sheet language transform (XSLT) to transform the data from its original format into a common format recognizable by the binding engine 104 . XSLT is an XML-based language used for the transformation of XML documents, e.g., to convert data between different XML schemas. The original document is not changed; rather, a new document is created based on the content of an existing one.
In an alternate implementation, the data transformation may be provided by a service accessible over the network. The data transform service may reformat the data received from the data providers 112 , 114 in a format that is readably usable and recognizable by the binding engine 104 . This implementation may be less desirable as receipt of the transformed data from a network service may reduce the bandwidth of the network connection. Generally, the processing speed of the media processing device 102 and standard software platforms installed thereon are more than adequate to handle such XML transforms.
In addition to the content-related data received from the data providers 112 , 114 , the media processing device 102 may further receive a library package 118 of UI elements from an external source over the network 110 . The UI elements may include UI templates, graphics, images, video clips, audio clips, and other resources for combination and presentation in the mutable UI. Many of the UI templates may incorporate the data as it is received and exposed in real time. The UI library package 118 may be developed by the data providers 112 , 114 or by any other developer of UIs for the media processing device 102 . The UI library package 118 may be received directly by the media processing device 102 where the UI elements are stored until accessed for linking with data exposed by the binding engine 104 . The UI elements are arranged into the desired layout of the UI by the user experience engine 106 for presentation with the incorporated data on the presentation device 108 .
Various exemplary components of a media processing device 200 are shown in greater detail in FIG. 2 . As in FIG. 1 , the primary components of the media processing device 200 include the binding engine 202 and the user experience engine 204 . An additional component of the binding engine 202 not previously discussed, may be a network monitor 206 . Receipt of the data transform package 208 and the provider data 110 are coordinated by the network monitor 206 . The network monitor 206 acts as a manager for various data feeds that may be received from various data providers. Data feeds may be received via any of several known push protocols (e.g., Really Simple Syndication (RSS)). Alternatively, the network monitor 206 may function as a timer to regularly pull data from known locations accessible via the network. For example, the data transform package 208 may be updated regularly, but is not a constant-feed data source as may be received from the data providers. Thus, the network monitor 206 may query the source location for the data transform package 208 on a regular schedule, for example, once a day in the middle of the night in order to minimize the effect on network bandwidth. If a request to the source location confirms that a new data transform package 208 is available, the network monitor 206 may initiate and coordinate download of the updated data transform package 208 .
The data transform package 208 may be understood as a set of rules or functions that are provided to the binding engine 202 in order to direct the transformation of the provider data 210 into a format that can be used by the binding engine 202 . In one exemplary implementation, the provider data 210 may be provided as groupings of tagged data values, for example, data values identified using extensible mark-up language (XML). The provider data 210 tagged in such an XML schema provides a simple mechanism for data providers to identify the type and nature of data values transmitted to the media processing device 200 . An exemplary XML schema for tagging provider data 220 in the context of sports related data is set forth below.
- <Templates>
<Template Type=“Alert”
Source=“data://ThisDataProvider!this_provider_alerts.mcml#NewsAlertContent”
/>
<Template Type=“AlertHeader”
Source=“data://ThisDataProvider!this_provider_alerts.mcml#NewsAlertHeader”
/>
<Template Type=“AlertHeader” Key=“FinalScore”
Source=“data://ThisDataProvider!this_provider_alerts.mcml#FinalScoreHeader”
/>
<Template Type=“RealtimeAlertHeader” Key=“FinalScore”
Source=“data://ThisDataProvider!this_provider_alerts.mcml#FinalScoreHeader”
/>
<Template Type=“Branding”
Source=“data://ThisDataProvider!this_provider_brand.mcml#Branding”
/>
</Templates>
- <League Id=“5” Name=“NFL”>
- <Positions>
<Position Name=“Quarterback” Contains=“QB” />
<Position Name=“Running Back” Contains=“RB” />
<Position Name=“Fullback” Contains=“FB” />
<Position Name=“Wide Receiver” Contains=“WR” />
<Position Name=“Tight End” Contains=“TE” />
<Position Name=“Punter” Contains=“P” />
<Position Name=“Kicker” Contains=“K” />
</Positions>
- <PositionGroups>
<Position Name=“Quarterbacks” Contains=“QB” />
<Position Name=“Running Backs” Contains=“FB,RB” />
<Position Name=“Wide Receivers” Contains=“WR” />
<Position Name=“Tight Ends” Contains=“TE” />
<Position Name=“Kickers” Contains=“K” />
<Position Name=“All” Contains=“QB,FB,RB,WR,TE,K” />
</PositionGroups>
- <PlayerGroup>
<Positions>QB</Positions>
<Name>QUARTERBACKS</Name>
<Column Name=“COMP” Path=“nfl-player-stats-
passing/completions/completions” />
<Column Name=“ATT” Path=“nfl-player-stats-passing/attempts/attempts” />
<Column Name=“YDS” Path=“nfl-player-stats-passing/yards/yards” />
<Column Name=“TD” Path=“nfl-player-stats-passing/touchdowns/touchdowns” />
<Column Name=“INT” Path=“nfl-player-stats-
passing/interceptions/interceptions” />
<Column Name=“RUSH” Path=“nfl-player-stats-rushing/yards/yards” />
<Column Name=“RATE” Path=“nfl-player-stats-passing/qb-rating/rating” />
</PlayerGroup>
* * *
- <ScoresFeed>
<FeedId>nfl_scores</FeedId>
<GroupType>ByDate</GroupType>
<Transform>nfl_scores_transform.xsl</Transform>
<Latency>10</Latency>
- <Url>
- <![CDATA[
http://feeds.ThisDataProvider.com/scores/NFL.XML?partnerKey=cfGT1kpvLFSEko2OXNeVDckXXKjOHH3H
]]>
</Url>
</ScoresFeed>
* * *
- <RealtimeAlerts>
<FeedId>nfl_realtimealerts</FeedId>
<Transform>nfl_alerts_transform.xsl</Transform>
<Latency>10</Latency>
- <Url>
- <![CDATA[
http://feeds.ThisDataProvider.com/livexml/NFL/NFL_ALERTS.XML?partnerKey=cfGT1kpvLFSEko2OXNeVDckXXKjOHH3H
]]>
</Url>
</RealtimeAlerts>
- <Templates>
- <!-- Scores -->
<Template Type=“Score”
Source=“data://ThisDataProvider!nfl_scores.mcml#Score” />
<Template Type=“Score” State=“InProgress”
Source=“data://ThisDataProvider!nfl_scores.mcml#Score_InProgress” />
<Template Type=“Score” State=“Final”
Source=“data://ThisDataProvider!nfl_scores.mcml#Score_Final” />
<Template Type=“ScoreRollover” State=“PreGame”
Source=“data://ThisDataProvider!nfl_scores_detail.mcml#ScoreRollover_PreGame”
/>
<Template Type=“ScoreRollover” State=“InProgress”
Source=“data://ThisDataProvider!nfl_scores_detail.mcml#ScoreRollover_InProgress”
/>
<Template Type=“ScoreRollover” State=“Final”
Source=“data://ThisDataProvider!nfl_scores_detail.mcml#ScoreRollover_Final”
/>
* * *
- <!-- Realtime Alerts -->
<Template Type=“RealtimeAlertHeader”
Source=“data://ThisDataProvider!nfl_alerts.mcml#RealtimeAlertHeader” />
<Template Type=“RealtimeAlert” Key=“StatusTwoMinute”
Source=“data://ThisDataProvider!nfl_realtime_alerts.mcml#TwoMinuteWarning
” />
<Template Type=“RealtimeAlert” Key=“FinalScore”
Source=“data://ThisDataProvider!nfl_realtime_alerts.mcml#FinalScore” />
<Template Type=“RealtimeAlert” Key=“RushingTouchdown”
Source=“data://ThisDataProvider!nfl_realtime_alerts.mcml#RushingTouchdown”
/>
<Template Type=“RealtimeAlert” Key=“PassingTouchdown”
Source=“data://ThisDataProvider!nfl_realtime_alerts.mcml#PassingTouchdown”
/>
<Template Type=“RealtimeAlert” Key=“ReturnTouchdown”
Source=“data://ThisDataProvider!nfl_realtime_alerts.mcml#ReturnTouchdown”
/>
* * *
</Templates>
</League>
This schema may be specific to a particular data provider. In the context of the sports example, the transform data may consist of game scores, player statistics, identification of players presently in the game, player rosters, game statistics, news alerts, and other real-time alerts associated with a particular sporting event. As in the above example, XML schema data related to NFL football may be tagged with various data types. As expressed above, the data may include information about player positions (e.g., who is actually playing the position), player statistics (e.g., passing attempts and related yardage), and scoring at various stages of the game as well as a final score. The data may also include a variety of real-time alerts as indicated, for example, touchdown occurrences and the type of play used to score (e.g., rushing, passing, or punt return).
The data transformation engine 212 may be a separate standalone module or it may be a standard part of particular operating system, for example, the “.NET” platform from Microsoft Corporation. The data transform package 208 is input into the data transform engine 212 to provide a framework and instructions for processing the provider data 210 . The data transform engine 212 first processes the data transform package 208 to determine the appropriate data feed transforms for processing the provider data 210 . The data transform engine 212 may employ standard transform scheme for example, an extensible style-sheet language transform (XSLT) in order to provide data in a format useful to the binding engine 202 . In an alternate implementation, the binding engine 202 may unpack the instructions in the data transform package 208 , e.g., in the form of an XSLT document, and takes the incoming provider data 210 , e.g., in the form of an XML document, and supplies both as inputs to the data transform engine 212 , e.g., a .NET runtime engine. Once the data feed transforms 214 are understood, the data transform engine 212 can read the data feed descriptors 216 , for example, XML tags that identify specific data types in the provider data 210 , and then transform the data feed descriptors into a descriptor format used by the binding engine 202 .
The data transform engine 212 may further develop data object lists 218 to pass to the binding engine 202 . The data object lists 218 may be understood as linking instructions that tell the binding engine 202 how to bind 230 the provider data 210 to particular data management objects 228 in the binding engine 202 . Once the transformation of the provider data 210 within the data transform engine 212 is complete, the transformed data is loaded back into the binding engine 202 as indicated by the operational loading indicator 220 in FIG. 2 . When the transformed data is loaded 220 into the binding engine 202 from the data transform engine 212 , it may be organized by a provider manager 222 according to the data object lists 218 . In one implementation, the data object lists 218 may organize the transformed data 220 according to the particular data provider source 226 a , 226 b , 226 n.
This type of organization by data provider may be desirable, for example, because different providers of similar information may provide different types or categories of information. Further, the associated display instructions and UI templates and resources may be particular to that data provider. Alternatively, the data from different data providers may be relevant to completely unrelated subject matter designed to provide a completely different application experience to a user. For example, one data provider may provide only information related to sporting events, while a second data provider may provide information related to the Academy Awards ceremony. In this scenario, one can understand that the ultimate UI experiences are likely to be significantly different.
As shown in the provider manager 222 in FIG. 2 , in addition to separation and organization of the data into different data provider sources 226 a , 226 b , 226 n , a generic null data provider block 224 may be used. The null data provider block 224 may be selected by the binding engine 202 to provide a generic or default UI experience when the program is initialized. This allows the user to select between any of the other application experiences specific to the available data providers 226 a , 226 b , 226 n and provides an opportunity for the media processing devices to load the relevant data in a selected UI. The UI corresponding to the null data provider block 224 thus dynamically changes into a revised UI 242 experience corresponding to the chosen data provider. Note, however, the revised UI 242 does not result from the launch of a separate application. The revised UI 242 is prepared by the user experience engine 204 from alternate data and instructions exposed by the binding engine 202 and alternate UI templates 236 and resources 238 selected from the dynamic UI library 234 as further described below.
The binding engine 202 may also use the data object lists 218 to instantiate appropriate data management objects 228 that bind 230 with the transformed data in particular arrangements defined by the data management objects 228 . The data management objects 228 represent the primary functionality of the binding engine 202 and perform operations to collect and group together additional information related to a particular type of provider data 210 received from a data provider.
These binding operations may be better understood again in the context of a sports media example. Suppose, for example, that a data provider provides a data feed with the score of a NBA basketball game. The data feed may include the names of the teams, the quarter presently being played, and the score. Upon receipt of this data, the binding engine 202 will select an appropriate data management object 228 to bind with the data. For example, there may be a particular data object that is designed to manage NBA basketball games. The NBA game object may have further associated behaviors for the collection of additional related information. For example the NBA game object may use team ID information in the data to seek out additional information about the teams to bind with the NBA game object. This information could include things like the team rosters, game schedules, and win/loss record information. The NBA game object may look for this information within the other data in the present data feed or it may instruct the network monitor 206 to seek out additional information over the network in order to fulfill such data requests. The NBA game object may further consult an EPG guide on the media processing device 200 to provide information about any relating programming, for example, whether a broadcast network is presently carrying the game.
The NBA game object may further instantiate other related management objects 228 to seek additional information for possible presentation to a user. For example, the NBA game object may instantiate a NBA league object that seeks information at a league level rather than a game level in either the provider data 210 or through requests of the network monitor 206 . Such information could include the regular season schedule for the entire league or team standings. The NBA league object could further consult the EPG for a schedule of network broadcasts of any NBA game within a certain time frame. Any relevant data that the NBA league object finds may be bound to the NBA league object by the binding engine 202 . The NBA game object may further instantiate a player object which seeks data regarding individual players on the teams participating in the particular game, for example, player names, player statistics, and news items regarding particular players, and can bind such data within the object.
Alternatively, any new data found may not actually be bound, but rather looked up when needed by an object itself or by another object, e.g., a “collection manager” object managing a list of league objects. The link to the extra information may be provided by an object via runtime-accessible properties and methods, but the object itself may or may not cache or store that additional data.
Once the appropriate data management objects 228 are bound 230 with transform data specific to one of the particular data providers 226 a , 226 b , 226 n , the populated data management objects 228 and any UI instructions related to a particular data provider are exposed 232 to the user experience engine 204 . The user experience engine 204 queries the dynamic UI library 234 and requests the appropriate UI templates 236 for building a UI particular to the chosen data provider based upon the associated UI instructions 232 . The user experience engine 204 further requests any additional resources and images 238 , for example, music, pictures, logos, and other presentation information responsive to the UI instructions 232 .
Recall that the dynamic UI library 234 may be regularly updated with packages of new or changed templates 236 and new and alternative resources, images, or other presentation information 238 . The UI templates 236 may be authored by the data providers and may thus include identification information and function calls for associating specific UI templates 236 and resources 238 with the bound data objects 232 related the particular data provider. Thus, the UI 242 presented to the user may be dynamically changed and updated whenever desired. The user experience engine 204 then combines the data exposed by the data management objects 228 with the appropriate UI templates 236 and, in conjunction with the resources and images 238 , creates a UI 242 unique to the data provider for presentation to the user.
It should be understood that the provider data 210 may be constantly received at the media processing device 200 or requested by the network monitor 206 in order to provide real-time data for presentation within the UI 242 . This real-time aspect of presentation of data may be particularly important or desirable in the context of an application experience presenting sports related information. Data pertaining to live sporting events is constantly in flux and may be regularly updated. For example, scores constantly change; players are constantly substituted; game status changes as it progresses into new innings, periods, or quarters; and statistics related to individual teams, players, and even leagues change as each game progresses. Thus, the binding engine 202 constantly binds the data management objects 228 with update transformed data 220 from the data feeds and exposes 232 data management objects 228 bound with updated data to the user experience engine 204 . Similarly, the selected UI templates 236 may be regularly updated and output for presentation as part of the UI 242 .
FIG. 3 depicts an exemplarily UI generation process for creating a mutable application experience on a media processing device, for example, as described with respect to FIGS. 1 and 2 . The UI generation process 300 begins with a requesting operation 302 in which the network monitor requests provider data and monitors data feeds from data providers. In a receiving operation 304 , data is received or downloaded from a particular data provider for use in creating the application experience. As previously indicated, the data is transformed in a transformation operation 306 by a data transform engine in order to provide the data in a format that the binding engine can use. Once the data is transformed, it is bound with the data management objects in a binding operation 308 . The data management objects then proceed to build structures of associated data from additional available data, incoming data feeds, EPG schedules, and other data sources in building operation 310 . In addition, as previously indicated the building operation 310 may include the instantiation of additional related management objects that collect and provide additional related data for exposure and potential presentation to a user. Once the data management objects have linked with all available related data, the data management objects are exposed to the user experience engine in exposing operation 312 .
In parallel with the transformation and linking of provider data, the UI generation process 300 also includes receiving UI templates and related resources as part of a UI library package in receiving operation 314 . The UI templates and resources are stored in a dynamic UI library associated with the binding engine in storing operation 316 . The user experience engine then links the data from the data management objects with related and appropriate UI templates in order to construct a custom UI associated with the data in linking operation 318 .
In one exemplary implementation, the user experience engine may interrogate the data management objects in a search for particular designations for rendering a particular UI, e.g., a incorporating a UI template unique to a particular data provider as shown in query operation 318 . If a unique UI is specified, the user experience engine will select that specific UI template from the dynamic UI library in selecting operation 320 . Alternatively, if no specific UI template is requested, then the user experience engine may select a default template to handle the types of data exposed by the data management objects and arrange them for presentation as indicated in selecting operation 322 . Once the appropriate UI templates, associated resources, and images are selected, a UI is compiled and output for presentation on a presentation device in outputting operation 324 . The UI generation process 300 then iterates and returns to requesting operation 302 to monitor the data feeds and update the information that is ultimately presented to the user in outputting operation 324 .
FIGS. 4 and 5 show one example of how the process of FIG. 3 may be implemented to create a mutable application experience for a user. FIG. 4 depicts a first implementation 400 of a UI 402 presenting sport scores information. The UI 402 includes a pivot menu element 404 , a ticker element 408 , and an alert element 410 . The pivot menu element is a horizontal scrolling menu UI element. In this particular example, several professional sports leagues are available for selection to view related sport scores. In the example depicted, the NBA is selected 406 and the ticker 408 provides information about a basketball game between the Cleveland Cavaliers and the Detroit Pistons. The ticker shows that with 11 minutes and 17 seconds expired in the second quarter, the Cavaliers are besting the Pistons by a score of 24 to 21. Note that the information in the ticker 408 may be updated on a regular and frequent basis with information from a data feed as the score of the basketball game changes from minute to minute. In addition, an alert template 410 provides information identifying the best performing players in the game at any given moment. In this implementation, the alert template 410 is populated with the highest scoring player, his team, and the number of points scored; the player with the most rebounds, his team, and the number of rebounds made; and the player with the most assists, his team, and the number of assists made. Again this information may vary from moment to moment, and the alert template 410 and the UI 402 will be constantly updated to reflect any changes. In addition, one or more logos 412 may be presented within the UI 402 to identify a network partner or data provider providing the information. Again, such logos or other images are entirely mutable and may be changed based upon the data or UI instructions received.
FIG. 5 depicts a second implementation 500 of UI 502 for presentation of professional sport scores and information. Again the UI 502 depicts a pivot menu 504 , a ticker 508 , and an alert 510 . As in FIG. 4 the NBA is selected 506 on the pivot menu and the ticker 508 displays information about the Cavaliers and Pistons game. As noted in the ticker 508 , the game has progressed a little over a minute and the Cavaliers are now beating the Pistons 28-21. Thus, the data indicating the time lapse in the game as well as the scores has been updated via a data feed processed by the binding engine. In addition, the ticker 508 has also been updated in its presentation format as the period indication no longer says “2ND QTR” as in FIG. 4 and now only says “2ND.”
Similarly, the alert 510 is based on a completely different template than the alert in FIG. 4 . The alert 510 presents information regarding the most recent play in the game that has been provided in the data feed. In this case the last play alert 510 indicates the time the play was made, the team making the play, the player making the play, and the action performed, in this case a 2 point field goal by LeBron James. Notice the disparity in the time of the play as opposed to the time the ticker shows along with the present score. This disparity may be a normal occurrence with respect to data feeds from sporting events in which it is much easier to quickly update a score than it is to input data regarding actual occurrences within the game. As before, a graphic 512 such as a logo of the data provider may be presented as part of the UI 502 . Again, it is notable that the UI experience has been changed between FIGS. 4 and 5 . However, the underlying applications creating the user experience, i.e., the binding engine and the user experience engine, are completely agnostic to the data received and the UI templates provided; their functions remain the same while the UI may be varied widely.
FIGS. 6 and 7 provide another example of mutable application experiences that may be provided to a user. In these examples, application experiences may be understood as particular to different data providers. In FIG. 6 , a first form of the application experience 600 for a first data provider is rendered in the UI 602 . At the top of the UI 602 is a pivot menu 604 , beneath which is program gallery 606 . The program gallery 606 generally provides the user a selection of programs for viewing. In this implementation of the UI 602 , the program gallery 606 is constructed using a series of game tickers in addition to more standard types of gallery objects such as the program identifier blocks 630 , 632 . The selected ticker 608 identifies a baseball game currently in progress. Instead of merely indicating the game is available for viewing, the tickers in the gallery 606 provide additional real-time information about the games in progress.
The selected ticker 608 identifies the teams playing in the team column 610 and the score of the game in the score column 612 . As this is a baseball game, the ticker 608 also includes an indicator 614 to indicate whether it is the top or bottom of a particular inning and an inning indicator 616 identifying the present inning. Additionally, the ticker 608 includes an out status indicator 615 , in this case indicating that there are two outs, and a on-base indicator 618 , in this case showing the runners presently at first base and third base. Clearly, such a gallery using a ticker with real-time information provides significantly more information about the status of a live event than merely indicating that the program is available to watch.
A second ticker 620 for a baseball game also indicates the teams, the score, the top or bottom of the inning, the inning number, the number of outs, and the base-running status. This game may also be available for viewing if the user so selects. This is the last of the baseball games for viewing in the program gallery 606 .
Another ticker 622 indicates that a basketball game is available for viewing, which is further indicated by the NBA heading in the pivot menu 604 . The basketball ticker 622 is based upon a different gallery UI template then the baseball games. The basketball ticker 622 includes a team name column 624 , a score column 626 , and period indication column 628 . No additional information about the basketball game is included in the basketball ticker 622 .
The UI further includes an alert item 634 providing headline information related to sports programming available. In addition to the alert 634 , there is a related link 636 that, upon selection, will access and present to the user additional information related to the alert 634 , for example, a full news story related to the headline in the alert 634 . A logo 638 indicating the particular data provider or network partner associated with the information in this application experience 600 may also be provided in the UI 602 .
In this particular implementation of the UI 602 and in conjunction with this particular data provider is an instructional UI 640 that teaches a user how to operate the pivot menu 604 and the program gallery 606 to make a program selection from the gallery 606 for viewing. An instructional message 642 may accompany the graphical image 640 to aid in explaining how to select a program from the gallery for viewing. This particular UI 602 additionally includes a marketing message 644 for presentation to a user.
In contrast FIG. 7 provides an alternate application experience 700 in a modified UI 702 associated with a different data provider than the data provider in FIG. 6 . The UI 702 similarly provides a pivot menu 704 with a program gallery 706 for selection of various sports programs for viewing. At the tope of the UI 702 is a pivot menu 704 , beneath which is program gallery 706 . In this implementation of the UI 702 , the program gallery 706 is constructed using a series of game tickers 708 in addition to more standard types of gallery objects such as the program identifier blocks 730 , 732 . As above, the selected ticker 708 identifies a baseball game currently in progress. Instead of merely indicating the game is available for viewing, the selected ticker 708 in the gallery 706 provides additional real-time information about the game in progress.
The selected ticker 708 identifies teams playing in the team column 710 and the score of the game in the score column 712 . As this is a baseball game, the ticker 708 includes an indicator 714 to indicate whether it is the top or bottom of a particular inning and an inning indicator 716 identifying the present inning. Additionally, the ticker 708 includes an out status indicator 715 , in this case indicating that there are two outs, and an on-base indicator 718 , in this case showing the runners presently at first and third.
A second ticker 720 for a baseball game also indicates the teams, the score, the top or bottom of the inning, the inning number, the number of outs, and the base-running status. This game may also be available for viewing if the user so selects. This is the last of the baseball games for viewing in the program gallery 706 . Another ticker 722 indicates that a basketball game is available for viewing, which is further indicated by the NBA heading in the pivot menu 704 . The basketball ticker 722 is based upon a different gallery UI template than the baseball games. The basketball ticker 722 includes a team name column 724 , a score column 726 , and period indication column 728 . In this respect the user application experience for the second data provider is similar to the experience provided by the first data provider as they may have both selected standard pivot menu and program gallery UI templates for implementation.
However, the remainder of the UI 702 in FIG. 7 is somewhat different than the UI 602 in FIG. 6 . For example, the alert 734 , although providing similar information to the alert in FIG. 6 , is actually different textually, because the source of the data is different. The UI 702 still allows the user to select a link 736 to read more information corresponding to the alert 734 . A data provider or network partner logo 738 is also presented, but it is in a different location than the logo placement in FIG. 6 and also indicates the source as a different provider. Finally, instead of providing a tutorial on program selection from the program gallery, the UI 702 presents a large graphic 740 branding this particular implementation of the user experience.
An exemplary hardware and operating system for implementing a mutable application experience as described above is represented in FIG. 8 . The system includes a general purpose computing device in the form of a computer 800 , including a processing unit 802 , a system memory 804 , and a system bus 818 that operatively couples various system components, including the system memory 804 to the processing unit 802 . There may be only one or there may be more than one processing unit 802 , such that the processor of computer 800 comprises a single central processing unit (CPU), or a plurality of processing units, commonly referred to as a parallel processing environment. The computer 800 may be a conventional computer, a distributed computer, or any other type of computer; the invention is not so limited.
The system bus 818 may be any of several types of bus structures including a memory bus or memory controller, a peripheral bus, a switched fabric, point-to-point connections, and a local bus using any of a variety of bus architectures. The system memory 804 may also be referred to as simply the memory, and includes read only memory (ROM) 806 and random access memory (RAM) 805 . A basic input/output system (BIOS) 808 , containing the basic routines that help to transfer information between elements within the computer 800 , such as during start-up, is stored in ROM 806 . The computer 800 further includes a hard disk drive 830 for reading from and writing to a hard disk, not shown, a magnetic disk drive 832 for reading from or writing to a removable magnetic disk 836 , and an optical disk drive 834 for reading from or writing to a removable optical disk 838 such as a CD ROM or other optical media.
The hard disk drive 830 , magnetic disk drive 832 , and optical disk drive 834 are connected to the system bus 818 by a hard disk drive interface 820 , a magnetic disk drive interface 822 , and an optical disk drive interface 824 , respectively. The drives and their associated computer-readable media provide nonvolatile storage of computer-readable instructions, data structures, program modules and other data for the computer 800 . It should be appreciated by those skilled in the art that any type of computer-readable media that can store data that is accessible by a computer, for example, magnetic cassettes, flash memory cards, digital video disks, RAMs, and ROMs, may be used in the exemplary operating environment.
A number of program modules may be stored on the hard disk 830 , magnetic disk 832 , optical disk 834 , ROM 806 , or RAM 805 , including an operating system 810 , one or more application programs 812 , other program modules 814 , for example, the binding engine and the user experience engine, and program data 816 , for example, the data feeds from the data providers, the data transform packages, and the UI library packages.
A user may enter commands and information into the personal computer 800 through input devices such as a keyboard 840 and pointing device 842 , for example, a mouse. Other input devices (not shown) may include, for example, a microphone, a joystick, a game pad, a tablet, a touch screen device, a satellite dish, a scanner, a facsimile machine, and a video camera. These and other input devices are often connected to the processing unit 802 through a serial port interface 826 that is coupled to the system bus 818 , but may be connected by other interfaces, such as a parallel port, game port, or a universal serial bus (USB).
A monitor 844 or other type of display device is also connected to the system bus 818 via an interface, such as a video adapter 846 . In addition to the monitor 844 , computers typically include other peripheral output devices, such as a printer 858 and speakers (not shown). These and other output devices are often connected to the processing unit 802 through the serial port interface 826 that is coupled to the system bus 818 , but may be connected by other interfaces, such as a parallel port, game port, or a universal serial bus (USB). A media tuner module 860 may also be connected to the system bus 818 to tune audio and video programming (e.g., TV programming) for output through the video adapter 846 or other presentation output modules.
The computer 800 may operate in a networked environment using logical connections to one or more remote computers, such as remote computer 854 . These logical connections may be achieved by a communication device coupled to or integral with the computer 800 ; the invention is not limited to a particular type of communications device. The remote computer 854 may be another computer, a server, a router, a network personal computer, a client, a peer device, or other common network node, and typically includes many or all of the elements described above relative to the computer 800 , although only a memory storage device 856 has been illustrated in FIG. 8 . The logical connections depicted in FIG. 8 include a local-area network (LAN) 850 and a wide-area network (WAN) 852 . Such networking environments are commonplace in office networks, enterprise-wide computer networks, intranets and the Internet, which are all types of networks.
When used in a LAN 850 environment, the computer 800 may be connected to the local network 850 through a network interface or adapter 828 , e.g., Ethernet, a wireless access point or router, or other communications interfaces. When used in a WAN 852 environment, the computer 800 typically includes a modem 848 , a network adapter, WiFi card, or any other type of communications device for establishing communications over the wide area network 852 . The modem 848 , which may be internal or external, is connected to the system bus 818 via the serial port interface 826 . In a networked environment, program modules depicted relative to the personal computer 800 , or portions thereof, may be stored in a remote memory storage device. It is appreciated that the network connections shown are exemplary and other means of and communications devices for establishing a communications link between the computers may be used.
The technology described herein may be implemented as logical operations and/or modules in one or more systems. The logical operations may be implemented as a sequence of processor-implemented steps executing in one or more computer systems and as interconnected machine or circuit modules within one or more computer systems. Likewise, the descriptions of various component modules may be provided in terms of operations executed or effected by the modules. The resulting implementation is a matter of choice, dependent on the performance requirements of the underlying system implementing the described technology. Accordingly, the logical operations making up the embodiments of the technology described herein are referred to variously as operations, steps, objects, or modules. Furthermore, it should be understood that logical operations may be performed in any order, unless explicitly claimed otherwise or a specific order is inherently necessitated by the claim language.
The above specification, examples and data provide a complete description of the structure and use of exemplary embodiments of the invention. Although various embodiments of the invention have been described above with a certain degree of particularity, or with reference to one or more individual embodiments, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the spirit or scope of this invention. In particular, it should be understand that the described technology may be employed independent of a personal computer. Other embodiments are therefore contemplated. It is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative only of particular embodiments and not limiting. Changes in detail or structure may be made without departing from the basic elements of the invention as defined in the following claims.
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A dynamic and interchangeable set of application behaviors is implemented upon the same underlying software engine. Downloadable data provider behavior descriptors configure the UI generation application dynamically on demand to meet needs that are unknown at ship time, or otherwise cannot be predicted in advance—inputs, formats, contents, and the optimal user interface or experience, all change over time. A data provider supplies the data source locations, data feeds, poll/pull intervals on feeds, parameter definitions, data binding definitions, lists, groups, UI templates, data transformation logic, resources, and UI templates to plug into the base application engine, which transforms the supplied data to create a UI experience tailored to match the appropriate events and available data over time. The base application engine is agnostic to both the data provider and the input data received.
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INCORPORATION BY REFERENCE
The following documents are incorporated herein by reference as if fully set forth: U.S. Provisional Application No. 61/787,702, filed Mar. 15, 2013.
FIELD OF INVENTION
This application is generally related to doors and more particularly related to a sliding door assembly.
BACKGROUND
Radiation therapy facilities, especially those involving high energy X radiation or neutron radiation, require particularly thick walls, doors, and barriers. Particle accelerators, such as linear particle accelerators, use electromagnetic fields to propel charged particles, such as electrons, protons, or ions, at high speeds along defined beams. Due to radiation from particle accelerators, particle facilities must be designed and constructed to provide adequate shielding.
Known radiation therapy facilities are generally constructed as a room housing the source of radiation, with concrete walls, ceilings, and floors that can reach thicknesses of up to 15 feet. In addition, a maze entry is usually used to provide a wing wall to capture scatter radiation. The entrance to a maze entry or direct entry radiation therapy room can include at least one shielded door to further prevent radiation leakage outside of the room. The shielded door for a radiation therapy room can be constructed as a hinged door having a very thick core, for example 20 inches thick, to provide sufficient shielding. Known shielded doors are also extremely heavy, typically 10,000-20,000 lbs for radiation therapy rooms, and cannot be opened and closed quickly. The time that it takes to open and close a hinged shielded door is especially important in radiation therapy rooms where an operator may need to enter and exit the room repeatedly to make adjustments. For example, in medical applications, several rounds of low energy radiation may be used for diagnostic purposes and patient positioning before treating the patient's tumor with the high energy radiation. After each round of low energy radiation, the operator must either progress down a very long maze corridor leading to the treatment room or alternatively wait for the shielded door to fully open before entering the treatment room to make adjustments to the patient, and then wait for the shielded door to fully close again before starting the next round of low energy radiation testing or high energy radiation treatment. This process can be very time consuming and tiring to the patient.
Bi-parting sliding doors typically permit shorter opening and closing times compared to hinged doors. Because existing bi-parting sliding doors have a relatively linear leading edge at the seam between both doors, they lack the necessary seal required to prevent radiation leakage. One known method to reduce radiation leakage is to equip one of the bi-parting doors with an astragal at its leading edge to cover the seam between the doors.
The increased speed of heavy radiation shielded doors introduces additional safety concerns especially when objects obstruct the closing path of the sliding doors.
A need exists for a sliding door for radiation therapy rooms that provides a sufficient seal to eliminate radiation leakage and improved safety when closing.
SUMMARY
A sliding door assembly is disclosed. The sliding door assembly can consist of a single sliding door or a bi-parting sliding door, a door frame including a drive assembly, and guide track. The leading edge of the single door or one of the bi-parting doors has a tortuous path, such as a sine-wave shape, which mates with an edge of a fixed member or leading edge of a second door in a bi-parting door assembly having a complementary tortuous path.
The drive assembly directly drives the sliding doors along a linear track using magnetic force, such as magnetic propulsion, to open and close the sliding door assembly.
A secondary door assembly is arranged outside a primary sliding door assembly. The secondary door assembly closes before the primary sliding door assembly. The primary sliding door assembly does not close if the secondary door assembly fails to close. A control system directs the drive assembly. Either or both the primary sliding door assembly and the secondary door assembly can include leading edges having a tortuous path.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing summary, as well as the following detailed description of the preferred embodiments of the invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there is shown in the drawings embodiments which are presently preferred. It should be understood, however, that the invention is not limited to the precise arrangement shown.
FIG. 1 is a plan view of a direct entry radiation therapy room equipped with a sliding door assembly.
FIG. 2A is a top view of a direct entry radiation therapy room equipped with an embodiment of a bi-parting door assembly having a leading edge in the shape of a sine-wave.
FIG. 2B is a top view of an alternative embodiment of the bi-parting door assembly.
FIG. 2C is a top view of another alternative embodiment of the bi-parting door assembly.
FIG. 3 is a top view a single sliding door.
FIG. 4 is a view of the biparting door assembly of FIG. 2A in a closed configuration.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Certain terminology is used in the following description for convenience only and is not limiting. The words “top,” “bottom,” “inner,” and “outer” designate directions in the drawings to which reference is made. The terminology includes the words specifically noted above, derivatives thereof, and words of similar import.
FIG. 1 shows a direct entry radiation therapy room 2 equipped with a sliding door assembly 10 . The direct entry radiation therapy room 2 can be a particle facility, proton facility, linear accelerator room, or any other radiation therapy room that can involve high energy radiation, such as high energy X radiation, neutron radiation, proton radiation, X-ray radiation, or the like. Due to the high costs associated with constructing modular radiation facilities, maximizing space within the facility radiation therapy room 2 is desirable. The sliding door assembly 10 is positioned outside an existing entryway 30 formed in a wall 42 , such as a shielded wall of the radiation therapy room 2 , in order to maximize space within the radiation therapy room.
FIG. 2A shows an embodiment of a bi-parting door assembly 10 according to the present invention in an open position. FIG. 4 shows the bi-parting door assembly 10 of FIG. 2A in a closed configuration showing the seam 11 formed by the doors 12 , 13 . The bi-parting door assembly 10 is positioned outside the entryway 30 and includes two doors 12 , 13 , a door frame 14 , a track 15 , and a drive assembly 16 . The doors 12 , 13 and door frame 14 define a passageway 60 therebetween. The two doors 12 , 13 are of sufficient thickness to shield radiation from leaking out of the particle facility, and each door 12 , 13 preferably has a thickness of approximately 12 inches to 60 inches, and more preferably has a thickness of 20 inches to 50 inches. In one embodiment, each door 12 , 13 has a thickness of approximately 49 inches. In another embodiment, each door 12 , 13 has a thickness of approximately 25 inches. Each door 12 , 13 preferably weighs approximately 12,000 lbs. to 65,000 lbs., and more preferably weighs 20,000 lbs. to 60,000 lbs. In one embodiment, each door 12 , 13 weighs approximately 20,000 lbs. In another embodiment, each door 12 , 13 weighs approximately 60,000 lbs. The doors 12 , 13 preferably consist of a core constructed of high-density material adapted to reflect, attenuate, or capture charged particles, such as that described in U.S. patent application Ser. No. 13/060,157 and PCT Application Nos. PCT/US2011/036934, which are incorporated by reference as if fully set forth herein. The core of the doors 12 , 13 can be comprised of a high-density concrete. In an embodiment, the core of the doors 12 , 13 preferably have a density between 200 to 400 pounds per cubic foot, and more preferably have a density of 250 pounds per cubic foot. In another embodiment, the core of the doors 12 , 13 preferably have a density of 313 pounds per cubic foot. The core of the doors 12 , 13 can be formed from a high-Z material, i.e. a material with a high atomic number and number of protons, such as, for example and without limitation, lead, steel, and tungsten. In another embodiment, the core of the doors 12 , 13 can be formed from boron or lithium based materials, which are suitable for capturing neutron particles and byproduct radiation. In another embodiment, the core of the doors 12 , 13 can be formed from a metallic aggregate material that can include high-Z materials, such as, for example and without limitation, iron, lead, steel, and tungsten. High-Z target materials which could be used in the core of the doors 12 , 13 include but are not limited to copper, aluminum, titanium, and brass. The core of the doors 12 , 13 can include a material having high-Z aggregates, high hydrogen content, and/or a high macroscopic neutron cross-section to capture byproduct radiation. Such a material can include, but is not limited to, boron, lithium, cadmium, steel, and carbon. The core of the doors 12 , 13 can include any combination of the materials described above, and can include a plurality of layers of any combination of the materials described above.
The outer surface of the doors 12 , 13 are preferably constructed of carbon steel plate face panels and a minimum ½ inch thick edge banding along the top, bottom, and trailing edge of the door. The outer surface of the doors 12 , 13 can be coated and finished with any suitable material including plastic, wood or metal laminates.
The leading edge of each of the bi-parting doors 12 , 13 preferably have complementary tortuous paths to prevent radiation leakage when the doors 12 , 13 are closed. The tortuous paths extend the length of the doors 12 , 13 in a direction perpendicular to the seam 11 formed between the two doors 12 , 13 when the doors 12 , 13 are closed.
As shown in FIG. 2A . the leading edges of the bi-parting doors 12 , 13 can include complementary sine-wave shaped edges 126 , 127 . Alternatively, as shown in FIG. 2B , the leading edges of the bi-parting doors 12 , 13 can include triangular interlocking shaped edges 226 , 227 . As shown in FIG. 2C , the leading edges of the bi-parting doors 12 , 13 can also include interlocking curved edges 326 , 327 . Any shape of the leading edges is sufficient so long as the leading edges form a tortuous path in a direction that is perpendicular to the seam 11 between the doors 12 , 13 to prevent radiation leakage. Due to the tortuous path of the leading edge of the doors 12 , 13 , astragals are not necessary as are typically required with straight edge doors.
In an alternate embodiment shown in FIG. 3 , the door assembly 10 can consist of a single sliding door 412 . The single sliding door 412 has a leading edge 426 with a tortuous path, which can include, but is not limited, to the tortuous paths shown in FIGS. 2A, 2B, and 2C . A fixed member 422 , such as, and without limitation, a panel or fixed door, is preferably secured to the wall 42 outside of the radiation therapy room 2 and includes an edge 427 having a complementary tortuous path to the leading edge 426 on the single door 412 .
Highly efficient hinged shielded doors used in direct entry radiation therapy rooms take approximately 10-12 seconds to move from an open position to a closed position, and vice-versa. The bi-parting door assembly 10 of the present application can move from an open position to a closed position in approximately 5-6 seconds, which reduces the waiting time for a treatment technician to move in and out of the room.
A drive assembly 16 drives the bi-parting doors 12 , 13 or single door 412 between an open and closed configuration. The drive assembly 16 can include any suitable driving mechanism. Preferably, the drive assembly 16 includes magnets to magnetically propel the doors 12 , 13 along a track 15 preferable having a linear shape. Because the doors 12 , 13 are magnetically propelled, there are fewer mechanical problems related to gears and drive systems. Due to the lack of moving parts in the drive assembly 16 , the overall failure rate of the sliding door assembly 10 is reduced. Alternatively, a track support mechanism having guidance rollers can be used to opening and closing the doors 12 , 13 .
The width of the passageway 60 to the radiation therapy room 2 when the sliding door assembly 10 is open may vary depending on the type of room the sliding door assembly 10 is used in, but should at least be suitable for a person to walk through, for example approximately 36-46 inches wide. In research or medical particle facilities, the passageway 60 may be wider to accommodate equipment to be moved in and out of the room, such as wheel chairs, stretchers, and lab equipment. In addition, the sliding door or doors 12 , 13 can be removable in order to create additional space to move equipment in and out of the room.
To prevent the sliding door assembly 10 from closing when a person or object is in the passageway 60 , a sensor 18 may be arranged to detect whether an object is in the passageway 60 . A sensor 18 may be placed in the floor, ceiling, or in the area adjacent to the sliding door assembly 10 to detect when a person or object is approaching the passageway 60 . Preferably, a plurality of sensors are used to enhance accuracy. The sensor 18 may be, for example and without limitation, a pressure sensor arranged in the floor of the sliding door assembly 10 , an ultrasonic presence detecting sensor, or an infra-red light sensor. The sensor 18 may be configured to relay signals to a control system 40 which includes a programmable touch screen interface and is electrically connected to the drive assembly 16 to control operation of the sliding door assembly 10 . When the sensor 18 detects a person or object in the passageway 60 , the control system 40 prevents the drive assembly 16 from moving the door or doors 12 , 13 .
A secondary sliding door assembly 34 comprised or one or more sliding panels 32 can be positioned exterior to the sliding door assembly 10 as an additional safety precaution against the sliding door assembly 10 closing on a person or object in the passageway 60 . The panel or panels 32 are preferably made of a thin, lightweight material, such as plastic or Plexiglas. The panel or panels 32 can be operated to close before the sliding door assembly 10 . The panel or panels 32 can be driven by either the same drive assembly 16 or a separate drive assembly as the sliding door assembly 10 . The panels 32 are prevented from closing if the sensor 18 detects an object or person within the detection area.
The sliding door assembly 10 preferably operates on a 220 volt, three-phase, 30 amp power supply with low voltage wiring to the drive assembly 16 , control system 40 , sensor 18 , and any other electronic components. In the event of a power failure, the magnetic propulsion drive assembly 16 would fail. The sliding door assembly 10 includes a manual operation mode wherein at least one of the doors 12 , 13 and the panel 32 can manually open and close under their own power or by a battery back-up system.
While a sliding door assembly has been described herein, one of ordinary skill in the art would also recognize that the sliding door assembly could also be modified for use as a window. As shown in FIG. 4 , a window 48 can be positioned in the wall 42 for an operator or other person to view the radiation therapy room. The window 48 includes a similar single sliding panel or bi-parting sliding panels, track, and drive assembly as described herein with respect to the sliding door assembly.
While various methods, configurations, and features of the present invention have been described above and shown in the drawings, one of ordinary skill in the art will appreciate from this disclosure that any combination of the above features can be used without departing from the scope of the present invention. It is also recognized by those skilled in the art that changes may be made to the above described methods and embodiments without departing from the broad inventive concept thereof.
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A sliding door assembly is provided comprising a first door having a tortuous leading edge, a door frame, a guide track, and a member having a complementary tortuous edge to that of the door. The drive assembly includes magnets to drive the door between open and closed positions.
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FIELD OF THE INVENTION
[0001] The invention relates to surfactants, and in particular to monounsaturated fatty alcohol derivatives useful therein.
BACKGROUND OF THE INVENTION
[0002] Fatty alcohol derivatives, particularly alkoxylates, sulfates, and ether sulfates, are versatile surfactants. They are used across a broad array of industries and end uses, including personal care, laundry and cleaning, emulsion polymerization, agricultural uses, oilfield applications, industrial compositions, and specialty foamers.
[0003] Fatty alcohols are usually made by reducing the corresponding fatty acids or esters, typically by catalytic hydrogenation. Often, the catalyst includes zinc or copper and chromium. U.S. Pat. No. 5,672,781, for instance, uses a CuCrO 4 catalyst to hydrogenate methyl esters from palm kernel oil, which has substantial unsaturation, to produce a mixture of fatty alcohols comprising about 52 wt. % of oleyl alcohol, a monounsaturated fatty alcohol. For additional examples, see U.S. Pat. Nos. 2,865,968; 3,193,586; 4,804,790; 6,683,224; and 7,169,959.
[0004] The fatty acids or esters used to make fatty alcohols and their derivatives are usually made by hydrolysis or transesterification of triglycerides, which are typically animal or vegetable fats. Consequently, the fatty portion of the acid or ester will typically have 6-22 carbons with a mixture of saturated and internally unsaturated chains. Depending on source, the fatty acid or ester often has a preponderance of C 16 to C 22 component. For instance, methanolysis of soybean oil provides the saturated methyl esters of palmitic (C 16 ) and stearic (C 18 ) acids and the unsaturated methyl esters of oleic (C 18 mono-unsaturated), linoleic (C 18 di-unsaturated), and α-linolenic (C 18 tri-unsaturated) acids.
[0005] Among fatty alcohols with internal unsaturation, oleyl alcohol has been used as a starting material to make ether sulfonates that have surfactant properties (see, e.g., U.S. Pat. Nos. 7,427,588 and 7,629,299).
[0006] Monounsaturated feedstocks having reduced chain length have potential value for making surfactants, but the feeds have not been readily available. Recent improvements in metathesis chemistry (see, e.g., J. C. Mol, Green Chem. 4 (2002) 5 and U.S. Pat. Appl. Publ. Nos. 2010/0145086, 2011/0113679, and 2012/0071676) will soon make such reduced chain unsaturated feedstocks available, but alternatives are needed.
[0007] Undecylenic acid (10-undecenoic acid) is produced industrially along with heptaldehyde by pyrolyzing the ricinoleic acid in castor oil (see U.S. Pat. No. 1,889,348 ; J. Chem. Ed. 29 (1952) 446 ; J. Sci. Ind. Res. 13B (1954) 277; and J. Am. Oil Chem. Soc. 66 (1989) 938). It is used primarily to manufacture pharmaceuticals, fragrances, and cosmetics.
[0008] Undecylenic acid is easily reduced to undecylenic alcohol with hydride reducing agents (e.g., lithium aluminum hydride) or selective hydrogenation catalysts (see, e.g., J. Am. Chem. Soc. 59 (1937) 1. It is known to ethoxylate undecylenic alcohol for possible use in laundry detergents (JP 10140195). Undecylenic alcohol ethoxylates have also been studied as principal components of self-assembled monolayers, which can mimic membrane structure and function (see, e.g., U.S. Pat. No. 6,809,196 and J. Am. Chem. Soc. 113 (1991) 12).
[0009] Undecylenic alcohol has been converted to sodium 10-undecenyl sulfate, and this compound has been used as a monomer for making polymerizable surfactants (see, e.g., Electrophoresis 25 (2004) 622 ; New J. Chem. 16 (1992) 883; and Langmuir 9 (1993) 2949).
[0010] Sulfation of alcohols produces alcohol sulfates, which have an C—O—SO 3 X group, where X is typically an alkali metal or ammonium ion from a subsequent neutralization step. Sulfonation of unsaturated hydrocarbons gives sulfonates, which have a C—SO 3 X group. When an unsaturated alcohol is the starting material, the unsaturated sulfate can be produced under some conditions (see, e.g., WO91/13057). With other reagents, alcohol sulfation and carbon-carbon double bond sulfonation may compete, with most of the reaction product resulting from sulfation, although the nature of the sulfonated by-products is generally not well understood (see, e.g., U.S. Pat. No. 5,446,188). Because of the competing side reactions, unsaturated alcohols are usually avoided when the goal is to make an alcohol sulfate or ether sulfate.
[0011] In sum, despite the known value of longer-chain fatty alcohols and shorter-chain saturated fatty alcohols for making ethoxylates, sulfates, and ether sulfates for use as surfactants, it is less clear what value the surfactants would have if they were made using shorter-chain unsaturated (e.g., C 10 -C 12 ) fatty alcohols. The availability of undecylenic acid and undecylenic alcohol as feedstocks invites further investigation.
SUMMARY OF THE INVENTION
[0012] In one aspect, the invention relates to a composition comprising water and 1 to 99 wt. % of a surfactant. The surfactant comprises an alkoxylate, a sulfate or an ether sulfate of a C 10 -C 12 monounsaturated alcohol. In particular aspects, the alkoxylate, sulfate, or ether sulfate derives from readily available undecylenic acid or undecylenic alcohol. In other aspects, the surfactant comprises 40 to 60 wt. % of a monounsaturated C 10 -C 12 primary alcohol sulfate and 40 to 60 wt. % of a secondary hydroxyalkyl C 10 -C 12 primary alcohol sulfate.
[0013] We found that alkoxylate, sulfate, and ether sulfate surfactants made from C 10 -C 12 monounsaturated alcohols offer unexpected advantages. Compared with their saturated analogs, the monounsaturated alkoxylates, sulfates, and ether sulfates are less irritating, making them valuable for personal care, laundry, cleaners, and other household applications. Additional advantages are apparent from microscopy studies, which indicate that the monounsaturated alkoxylates, sulfates, and ether sulfates have favorable phase behavior over a wide range of actives levels. This enables formulation of products with greater compaction, allowing formulators to ship more product and less water in a given container. When combined with cationic surfactants, the alkoxylates, sulfates and ether sulfates exhibit considerable synergy, and they have improved solubility compared with their saturated analogs.
[0014] The surfactants will be useful in many applications and industries, including personal care, laundry and cleaning, emulsion polymerization, agricultural products, oilfield applications, and specialty foams.
DETAILED DESCRIPTION OF THE INVENTION
[0015] In one aspect, the invention relates to a composition comprising water and 1 to 99 wt. % of a surfactant. The surfactant comprises an alkoxylate, a sulfate or an ether sulfate of a C 10 -C 12 monounsaturated alcohol. Preferably, the composition comprises 2 to 98 wt. % of the surfactant. More preferably, the composition comprises 5 to 95 wt. % of the surfactant.
[0016] As used herein, “monounsaturated” refers to compositions that comprise principally species having a single carbon-carbon double bond but may also include a minor proportion of one or more species that have two or more carbon-carbon double bonds. The skilled person will appreciate that it is not necessary and may be impractical to produce a purely “monounsaturated” species, and that mixtures comprising principally (but not exclusively) monounsaturated alcohols and their alkoxylate, sulfate, and ether sulfate derivatives are contemplated as within the scope of the invention.
[0017] The alkoxylates, sulfates, and ether sulfates derive from a C 10 -C 12 monounsaturated alcohol. The unsaturation can be terminal or internal. Preferably, the alcohol is a primary alcohol. Thus, suitable C 10 monounsaturated alcohols include 9-decen-1-ol, 8-decen-1-ol, 7-decen-1-ol, 6-decen-1-ol, 5-decen-1-ol, 4-decen-1-ol, and 3-decen-1-ol. Suitable C 11 monounsaturated alcohols include 10-undecen-1-ol, 9-undecen-1-ol, 8-undecen-1-ol, 7-undecen-1-ol, 6-undecen-1-ol, 5-undecen-1-ol, 4-undecen-1-ol, and 3-undecen-1-ol. Suitable C 12 monounsaturated alcohols include 11-dodecen-1-ol, 10-dodecen-1-ol, 9-dodecen-1-ol, 8-dodecen-1-ol, 7-dodecen-1-ol, 6-dodecen-1-ol, 5-dodecen-1-ol, 4-dodecen-1-ol, and 3-dodecen-1-ol.
[0018] Other surfactant components may be present in addition to the alkoxylate, sulfate, or ether sulfate of the C 10 -C 12 monounsaturated alcohol. Preferably, however, the surfactant comprises at least 10 wt. %, more preferably at least 20 wt. %, and most preferably at least 50 wt. %, of the alkoxylate, sulfate, or ether sulfate of the C 10 -C 12 monounsaturated alcohol.
[0019] Undecylenic acid, because of its ready availability, is a preferred starting material for making many of the unsaturated alcohols, particularly undecylenic alcohol. Reduction of the acid or its ester derivatives using catalytic hydrogenation (see J. Am. Chem. Soc. 59 (1937) 1) or hydride reducing agents such as lithium aluminum hydride or the like provides undecylenic alcohol (10-undecen-1-ol).
[0020] Other C 11 monounsaturated alcohols having an internal carbon-carbon double bond can be made by isomerizing undecylenic alcohol to more-substituted olefins, typically using a base catalyst (see, e.g., Synthesis (1969) 97). Isomerization normally affords a mixture of monounsaturated alcohols, which may be desirable from a cost and/or performance perspective.
[0021] When C 10 -C 12 monounsaturated alcohols having the carbon-carbon double bond in a particular location are needed, the Wittig reaction (see, e.g., Angew. Chem., Int. Ed. Engl. 4 (1965) 830 ; Tetrahedron Lett. 26 (1985) 307; and U.S. Pat. No. 4,642,364) can be used. The choice of starting materials for the Wittig reaction will depend on availability of starting materials. In one approach, an w-hydroxyaldehyde and a phosphonium ylide (from the reaction of an alkyl halide and triphenylphosphine to give a phosphonium salt, followed by deprotonation to give the ylide) are used:
[0000]
[0022] In another approach, an aldehyde and a phophonium ylide prepared from an w-hydroxy alkyl halide are used:
[0000]
[0023] 4-Hydroxybutanal, which is produced in the manufacture of 1,4-butanediol, can be reacted with the phosphonium ylide reagent from a C 6 , C 7 , or C 8 alkyl halide to make, respectively, 4-decen-1-ol, 4-undecen-1-ol, or 4-dodecen-1-ol.
[0024] The Wittig reaction can also be used to produce terminally unsaturated alcohols, e.g., with reagents such as triphenylphosphonium methylide. In some cases, however, it may be more desirable to generate terminally unsaturated alcohols in another way. For instance, reaction of an α,ω-diol with a suitable dehydrating agent (e.g., Ba 2 P 2 O 7 , HMPA, or even a fatty acid) can provide good yields of terminally unsaturated alcohols (see, e.g., J. Org. Chem. 36 (1971) 3826 and U.S. Pat. Nos. 4,250,343; 4,288,642; 4,447,659; 4,695,661, and 5,981,812, the teachings of which are incorporated herein by reference).
[0025] Ester precursors to terminally unsaturated alcohols are also available from metathesis chemistry. As an example, cross-metathesis of unsaturated fatty esters with ethylene can be used to generate terminally unsaturated C 10 -C 12 unsaturated esters. Reduction of the esters provides the terminally unsaturated C 10 -C 12 alcohol. For instance, cross-metathesis of methyl oleate and ethylene provides 1-decene and methyl 9-decenoate. The ester can be reduced to 9-decen-1-ol (see, e.g., U.S. Pat. No. 4,545,941, the teachings of which are incorporated by reference, and references cited therein). See also J. Org. Chem. 46 (1981) 1821 ; J. Catal. 30 (1973) 118 ; Appl. Catal. 70 (1991) 295 ; Organometallics 13 (1994) 635 ; Olefin Metathesis and Metathesis Polymerization by Ivin and Mol (1997), and Chem . & Eng. News 80(51), Dec. 23, 2002, p. 29, which also disclose useful metathesis catalysts.
[0026] In other aspects, undecylenic acid is used for the production of a C 10 monounsaturated alcohol. In one approach, the terminal carbon-carbon double bond is ozonized to give an aldehyde in which the chain length is reduced by one carbon. Reduction to a diol, followed by dehydration as described above provides 9-decen-1-ol.
[0027] In other aspects, undecylenic acid is used for the production of a C 12 monounsaturated alcohol. In one approach, the carboxylic acid group is homologated (see, e.g., J. Org. Chem. 66 (2001) 5606 and Tetrahedron Lett. 21 (1980) 4461; 42 (2001) 7099), and the resulting unsaturated carboxylic acid is reduced to give 11-dodecen-1-ol. In another approach, undecylenic alcohol is hydroformylated, and the resulting aldehyde (or aldehyde mixture) is hydrogenated to give a diol. The diol is then dehydrated to give 11-dodecen-1-ol as the major product.
[0028] In other aspects, the monounsaturated alcohol or alcohol precursor (e.g., a fatty acid or ester) is generated using a microorganism or bioengineered microorganism, such as an algae, bacterium, or yeast-based microbe.
[0029] Reduction of monounsaturated ester or acid precursors to produce the C 10 -C 12 monounsaturated alcohols is performed using well-known catalysts and procedures. The reducing agent is typically either a hydride reducing agent (sodium borohydride, lithium aluminum hydride, or the like) or molecular hydrogen in combination with a metal catalyst, frequently copper and/or zinc in combination with chromium (see, e.g., U.S. Pat. Nos. 2,865,968; 3,193,586; 4,804,790; 5,124,491; 5,672,781; 6,683,224; 7,169,959 and 7,208,643, the teachings of which are incorporated herein by reference).
[0030] The skilled person will appreciate that the reduction process, particularly when transition metal catalysts are used to convert precursors to alcohols, can induce some degree of isomerization or migration of the carbon-carbon double bond from its original position. Moreover, because hydrogenation catalysts are not always completely selective, a proportion of the carbon-carbon double bonds might be hydrogenated during the ester or acid reduction, resulting in a mixed product that may have saturated C 10 -C 12 fatty alcohols in addition to the desired unsaturated C 10 -C 12 fatty alcohols. The skilled person can control the degree of unsaturation to any desired amount.
[0031] The skilled person will, of course, recognize other desirable ways to arrive at the C 10 -C 12 monounsaturated alcohols used to produce the inventive alkoxylate, sulfate, and ether sulfate-based compositions.
[0032] Monounsaturation can also impart advantages to formulated products (including consumer products) that are often not available with the corresponding saturated fatty alcohol derivatives. Because crystallinity is disrupted by the presence of a carbon-carbon double bond, monounsaturated alkoxylates, sulfates, and ether sulfates usually have lower viscosities than their saturated analogs. Moreover, the monounsaturated alkoxylates, sulfates, and ether sulfates can be concentrated and formulated at higher actives levels—sometimes much higher—than their saturated counterparts. For instance, a saturated ether sulfate might allow a maximum 30 wt. % actives level to give a flowable liquid, whereas an otherwise similar monounsaturated ether sulfate could allow the actives level to be as high as 70 or 80 wt. %. Thus, the seemingly minor structural change to a monounsaturated product can enable shipment of more concentrated products, reduce or eliminate the need for special handling equipment, and/or ultimately provide substantial cost savings. The monounsaturated alkoxylates, sulfates, and ether sulfates are also more effective as compatibilizers for surfactants or other components in the fully formulated products.
[0033] The inventive alkoxyaltes, sulfates, or ether sulfates are made by alkoxylating, sulfating, or alkoxylating (preferably ethoxylating) and sulfating the monounsaturated C 10 -C 12 alcohol compositions using well-known techniques.
[0034] For instance, the unsaturated C 10 -C 12 alcohol can be alkoxylated by reacting it with ethylene oxide, propylene oxide, or a combination thereof to produce an alkoxylate. Alkoxylations are usually catalyzed by a base (e.g., KOH), but other catalysts such as double metal cyanide complexes (see, e.g., U.S. Pat. No. 5,482,908) can also be used. The oxyalkylene units can be incorporated randomly or in blocks. A series of products with different degrees of alkoxylation can be easily produced using a single reactor. This is illustrated in the examples below in the sequential ethoxylation of undecylenic alcohol to produce ethoxylates having, on average, 1, 3, or 7 moles of oxyethylene units per mole of unsaturated C 10 -C 12 alcohol starter.
[0035] The unsaturated C 10 -C 12 alcohol can be sulfated, with or without a prior alkoxylation, and if applicable, neutralized to give a monounsaturated alkyl sulfate or a monounsaturated alkyl ether sulfate according to known methods (see, e.g., U.S. Pat. No. 3,544,613, the teachings of which are incorporated herein by reference). Sulfamic acid is a convenient reagent that sulfates the hydroxyl group without disturbing the unsaturation. Thus, warming the monounsaturated alcohol or alkoxylate with sulfamic acid optionally in the presence of urea or another proton acceptor conveniently provides the desired C 10 -C 12 monounsaturated alkyl ammonium sulfate or ether sulfate (see examples below). The ammonium sulfate is easily converted to an alkali metal sulfate by reaction with an alkali metal hydroxide or other ion-exchange reagents. In the examples below, monounsaturated alkyl sodium sulfates are prepared from the corresponding ammonium sulfates by reacting the latter with aqueous sodium hydroxide.
[0036] Other reagents can be used to convert hydroxyl groups of a C 10 -C 12 unsaturated alcohol or alkoxylate to sulfates. For instance, sulfur trioxide, oleum, or chlorosulfonic acid may be used. Some of these reagents can, under the right conditions, also react with the unsaturation to form a sulfonate (having a carbon-sulfur bond), which may or may not be the desired outcome. Sulfur trioxide, for instance, can be used to sulfate the hydroxyl group of an unsaturated alcohol or alkoxylate, but it may also react with a carbon-carbon double bond to generate a β-sultone, which can ring open to give mixtures of hydroxyalkane sulfonates and alkene sulfonates. Thus, it is possible, and may be desirable, to perform both sulfation and sulfonation in one pot, and often with a single reagent. A product having at least some proportion of material that is both sulfonated and sulfated might be desirable. For instance, a combined sulfate/sulfonate can impart beneficial properties to the bulk surfactant, including reduced viscosity, better concentratability, better compatibilizing properties, or other advantages.
[0037] The invention includes processes for making alkoxylates, sulfates, and ether sulfates of C 10 -C 12 monounsaturated alcohols. The processes comprise reacting a composition comprising a C 10 -C 12 monounsaturated alcohol with an alkoxylating agent, a sulfating agent, or an alkoxylating agent followed by a sulfating agent, to make, respectively, an alkoxylate, a sulfate, or an ether sulfate. Thus, one suitable process comprises sulfating the monounsaturated C 10 -C 12 alcohol composition to give an alkyl sulfate. Another suitable process comprises alkoxylating the C 10 -C 12 alcohol composition with one or more alkylene oxides, preferably ethylene oxide, to give a monounsaturated alkoxylate, followed by sulfation to give a monounsaturated alkyl ether sulfate.
[0038] As discussed earlier, the inventive surfactant compositions comprise water and 1 to 99 wt. % of a surfactant comprising an alkoxylate, a sulfate, or an ether sulfate of a C 10 -C 12 monounsaturated alcohol. In one aspect, the surfactant comprises: (a) 40 to 60 wt. % of a monounsaturated C 10 -C 12 primary alcohol sulfate; and (b) 40 to 60 wt. % of a secondary hydroxyalkyl C 10 -C 12 primary alcohol sulfate. Preferably, the surfactant comprises 45 to 55 wt. % of the monounsaturated C 10 -C 12 primary alcohol sulfate; and 45 to 55 wt. % of the secondary hydroxyalkyl C 10 -C 12 primary alcohol sulfate. The sulfate composition may further comprise 0.1 to 20 wt. %, preferably 0.5 to 15 wt. %, of sulfonated products.
[0039] Although sulfation and sulfonation are known to compete when an unsaturated fatty alcohol is the starting material, we surprisingly found that certain sulfation conditions, such as falling-film sulfation using sulfur trioxide, can provide roughly equal amounts of (a) a monounsaturated C 10 -C 12 primary alcohol sulfate and (b) a secondary hydroxyalkyl C 10 -C 12 primary alcohol sulfate. Without wishing to be bound to any particular theory, we believe that the products may result from formation of an intermediate dialkylsulfate. Upon neutralization of the acid, the dialkylsulfate may undergo both elimination, to revert back to the unsaturated C 10 -C 12 alcohol sulfate, as well as hydrolysis to afford the hydroxyalkyl alcohol sulfate (see scheme below). The hydrolysis appears to be selective, providing preferentially the secondary alcohol and the primary alcohol sulfate. Consequently, the product mixture from reaction of a C 10 -C 12 monounsaturated alcohol, particularly one that is not ethoxylated, typically comprises about 90% sulfates—with roughly equal amounts of monounsaturated C 10 -C 12 primary alcohol sulfate and C 10 -C 12 secondary hydroxyalkyl alcohol sulfate—and about 10% sulfonated products. As illustrated for a C 12 monounsaturated alcohol:
[0000]
[0040] In contrast, when ethoxylated C 10 -C 12 alcohols are subjected to falling-film sulfation with sulfur trioxide, the unsaturated ether sulfate predominates. For instance, an ethoxylate from 1 mole of EO gives about 70% unsaturated ether sulfate, and a 3 mole ethoxylate gives about 80% unsaturated ether sulfate (see examples below).
[0041] In a preferred aspect, the monounsaturated C 10 -C 12 primary alcohol sulfate and the secondary hydroxyalkyl C 10 -C 12 primary alcohol sulfate derive from undecylenic alcohol.
[0042] In some preferred compositions, the monounsaturated C 10 -C 12 primary alcohol sulfate has the structure:
[0000] R—O—SO 3 X
[0000] wherein R is a linear or branched C 10 -C 12 monounsaturated hydrocarbyl group, and X is a mono- or divalent cation or an ammonium or substituted ammonium cation. Preferably, R is a linear C 10 -C 12 monounsaturated hydrocarbyl group.
[0043] We found that falling-film sulfation with sulfur trioxide tends to scramble carbon-carbon double bond geometry. Thus, the product mixture frequently approaches a thermodynamically preferred mixture of cis- and trans-isomers, usually about 8:2 trans-/cis-, even if the unsaturation in the unsaturated C 10 -C 12 alcohol was predominantly or exclusively cis- or trans-.
[0044] In other preferred aspects, the secondary hydroxyalkyl C 10 -C 12 primary alcohol sulfate has the structure:
[0000] CH 3 —(CH 2 ) y —CHOH—(CH 2 ) z —O—SO 3 X
[0000] wherein y=0 to 8, z=0 to 8, y+z=8 to 10, and X is a mono- or divalent cation or an ammonium or substituted ammonium cation. Preferably, y+z=9.
[0045] The sulfate compositions are preferably made by sulfating a monounsaturated C 10 -C 12 alcohol with sulfur trioxide in a falling-film reactor, followed by neutralization, according to methods described earlier.
[0046] We also found that terminal unsaturation is not retained when sulfur trioxide is used to make monounsaturated C 10 -C 12 alcohol sulfates and ether sulfates. Instead, isomerization occurs to give more-substituted unsaturated products. Thus, in one inventive process, an internally monounsaturated C 10 -C 12 alcohol sulfate or ether sulfate is made. This process comprises reacting a terminally monounsaturated C 10 -C 12 alcohol or alkoxylate with sulfur trioxide in a falling-film reactor, followed by neutralization.
[0047] We also observed positional isomerization upon sulfation of internally unsaturated C 10 -C 12 alcohols. This may occur through the regeneration of an olefin when a dialkylsulfate eliminates in the “opposite” direction (or side of the chain) from which the addition had occurred. Whether or not the olefin can fully “zip” up and down the chain is unclear. Positional isomerization could occur by multiple addition/elimination, olefin migration prior to addition of the sulfuric acid ester, or some other mechanism.
[0048] The alkoxylate, sulfate, or ether sulfate-based surfactant compositions may be incorporated into various formulations and used as emulsifiers, skin feel agents, film formers, rheological modifiers, solvents, release agents, biocides, biocide potentiators, conditioners, dispersants, hydrotropes, or the like. Such formulations may be used in end-use applications including, among others: personal care; household, industrial, and institutional cleaning products; oilfield applications; enhanced oil recovery; gypsum foamers; coatings, adhesives and sealants; and agricultural formulations.
[0049] Thus, the alkoxylates, sulfates, or ether sulfates may be used in such personal care applications as bar soaps, bubble baths, liquid cleansing products, conditioning bars, oral care products, shampoos, body washes, facial cleansers, hand soaps/washes, shower gels, wipes, baby cleansing products, creams/lotions, hair treatment products, antiperspirants, and deodorants.
[0050] Cleaning applications include, among others, household cleaners, degreasers, sanitizers and disinfectants, liquid and powdered laundry detergents, heavy duty liquid detergents, light-duty liquid detergents, hard and soft surface cleaners for household, autodish detergents, rinse aids, laundry additives, carpet cleaners, spot treatments, softergents, liquid and sheet fabric softeners, industrial and institutional cleaners and degreasers, oven cleaners, car washes, transportation cleaners, drain cleaners, industrial cleaners, foamers, defoamers, institutional cleaners, janitorial cleaners, glass cleaners, graffiti removers, concrete cleaners, metal/machine parts cleaners, and food service cleaners.
[0051] In specialty foam applications (firefighting, gypsum, concrete, cement wallboard), the alkoxylates, sulfates, or ether sulfates function as foamers, wetting agents, and foam control agents.
[0052] In paints and coatings, the alkoxylates, sulfates, or ether sulfates are used as solvents, coalescing agents, or additives for emulsion polymerization.
[0053] In oilfield applications, the alkoxylates, sulfates or ether sulfates can be used for oil and gas transport, production, stimulation, enhanced oil recovery, and as components of drilling fluids.
[0054] In agricultural applications, the alkoxylates, sulfates, or ether sulfates are used as solvents, dispersants, surfactants, emulsifiers, wetting agents, formulation inerts, or adjuvants.
[0055] As demonstrated in the examples below, the inventive alkoxylate, sulfate, or ether sulfate-based compositions are exceptionally useful in applications requiring low irritation, agricultural dispersants, water-soluble herbicides, aqueous hard surface cleaner degreasers and glass cleaners, and surfactant applications that require high actives levels or improved solubility.
[0000] Preparation of Sulfates and Ether Sulfates from Undecylenic Alcohol
Undecylenic Alcohol Sulfate, Sodium Salt
[0056] A large-scale, water-jacketed (40° C.) batch reactor equipped with addition funnel, mechanical stirring, and nitrogen inlet (5 mL/min. flow rate) is charged with undecylenic alcohol (125.5 g, 0.737 mol). Sulfur trioxide (70.7 g, 1.2 eq.) is charged to the addition funnel, then added carefully to the vaporizer while maintaining the reaction temperature below 50° C. Initial fuming in the headspace is severe. Following the SO 3 addition, the reactor is purged with nitrogen for 5 min. Total addition time: 2 h, 15 min. The acid intermediate is dark brown with moderate viscosity.
[0057] A round-bottom flask equipped with mechanical stirring is charged with water (418.4 g) and sodium hydroxide solution (61.6 g of 50% aq. NaOH). The acid intermediate from above (160.0 g) is added to the aqueous base solution, and the resulting mixture is heated to and held at 70° C. for 1 h. The product is filtered to remove particulates. 1 H NMR analysis shows migration of the carbon-carbon double bond and about 44% of monounsaturated C 11 primary alcohol sulfate. Solids: 28.1%; unsulfated alcohol: 0.46%; inorganic sulfate: 0.24%; actives: 27.4%. Yield: 167.4 g (91%).
1-Undecanol Sulfate, Sodium Salt
[0058] The procedure described above is followed to prepare the saturated C 11 alcohol sulfate from 1-undecanol (125.1 g) and sulfur trioxide (71.9 g, 1.2 eq.). Total addition time for the sulfur trioxide: 1.5 h. The acid is dark brown with low viscosity.
[0059] Conversion to the sodium sulfate is performed using water (471.3 g), sodium hydroxide solution (68.7 g of 50% aq. NaOH), and the acid intermediate (180.0 g). The acid is added while keeping the reaction temperature below 50° C., and the resulting product is mixed for 1 h. The pH is adjusted to 8.6 with 10% aq. H 2 SO 4 solution, and the product is transferred to a jar. Solids: 24.9%; unsulfated alcohol: 1.27%; inorganic sulfate: 2.45%; actives: 21.2%. Yield: 190 g (100%).
Ethoxylation of Undecylenic Alcohol to Produce 1, 3, and 7 Mole Alcohol Ethoxylates
[0060] Ethoxylations are performed sequentially using one reactor to prepare undecylenic alcohol ethoxylates that have, on average, 1, 3, or 7 oxyethylene units.
[0061] Undecylenic alcohol (1796 g) is charged to a pressure reactor. Liquid KOH (45%, 17.6 g) is added. The reactor is sealed and heated to 100° C. under nitrogen with agitation. At ˜50° C., vacuum (20 mm) is applied to remove water. The contents are further heated to 105-115° C. under vacuum (20 mm) and held for 3 h with a nitrogen sparge.
[0062] The remaining dried catalyzed alcohol feed (1802 g) is heated to 145° C. The reactor is pressurized with nitrogen and vented three times. Ethylene oxide (460 g, 1 mole per mole of starter) is introduced to the reactor at 145-160° C. over 1 h. After the EO addition, the mixture digests for 1 h at 150-160° C. until the reactor pressure equilibrates. The mixture is cooled to 50° C. and partially drained (380 g removed) to provide the 1 mole ethoxylated unsaturated alcohol. Hydroxyl value: 259 mg KOH/g; iodine value: 149 g I 2 /100 g sample.
[0063] The reactor contents (1880 g) are re-heated to 145° C., and the reactor is vented with nitrogen as described earlier. Ethylene oxide (775 g, 2 additional moles per mole of starter; 3 moles of EO per mole of undecylenic alcohol charged) is added to the feed at 145-160° C. After digesting 1 h at 150-160° C., the mixture is cooled to 60° C. and partially drained (470 g removed) to recover the 3 mole ethoxylated unsaturated alcohol. Hydroxyl value: 183 mg KOH/g; iodine value: 149 g I 2 /100 g sample.
[0064] The reactor contents (2185 g) are re-heated to 145° C., and the reactor is vented with nitrogen as described earlier. Ethylene oxide (1265 g, 4 additional moles per mole of starter; 7 moles of EO per mole of undecylenic alcohol charged) is added to the feed at 145-160° C. After digesting 1 h at 150-160° C., the mixture is cooled to 60° C. and drained to recover the 7 mole ethoxylated unsaturated alcohol. Hydroxyl value: 116 mg KOH/g; iodine value: 52 g I 2 /100 g sample. Yield: 3450 g.
Ethoxylation of 1-Undecanol to Produce 1, 3, and 7 Mole Alcohol Ethoxylates
[0065] Ethoxylations are performed sequentially using one reactor to prepare 1-undecanol ethoxylates that have, on average, 1, 3, or 7 oxyethylene units.
[0066] 1-Undecanol (1715 g) is charged to a pressure reactor. Liquid KOH (45%, 18.0 g) is added. The reactor is sealed and heated to 100° C. under nitrogen with agitation. At ˜50° C., vacuum (20 mm) is applied to remove water. The contents are further heated to 105-115° C. under vacuum (20 mm) and held for 3 h with a nitrogen sparge.
[0067] The remaining dried catalyzed alcohol feed (1713 g) is heated to 145° C. The reactor is pressurized with nitrogen and vented three times. Ethylene oxide (440 g, 1 mole per mole of starter) is introduced to the reactor at 145-160° C. over 1 h. After the EO addition, the mixture digests for 1 h at 150-160° C. until the reactor pressure equilibrates. The mixture is cooled to 50° C. and partially drained (299 g removed) to provide the 1 mole ethoxylated saturated alcohol. Hydroxyl value: 257 mg KOH/g.
[0068] The reactor contents (1854 g) are re-heated to 145° C., and the reactor is vented with nitrogen as described earlier. Ethylene oxide (750 g, 2 additional moles per mole of starter; 3 moles of EO per mole of 1-undecanol charged) is added to the feed at 145-160° C. After digesting 1 h at 150-160° C., the mixture is cooled to 60° C. and partially drained (407 g removed) to recover the 3 mole ethoxylated saturated alcohol. Hydroxyl value: 184 mg KOH/g.
[0069] The reactor contents (2197 g) are re-heated to 145° C., and the reactor is vented with nitrogen as described earlier. Ethylene oxide (1275 g, 4 additional moles per mole of starter; 7 moles of EO per mole of 1-undecanol charged) is added to the feed at 145-160° C. After digesting 1 h at 150-160° C., the mixture is cooled to 60° C. and drained to recover the 7 mole ethoxylated saturated alcohol. Hydroxyl value: 116 mg KOH/g. Yield: 3472 g.
Preparation of Ether Sulfates
Undecylenic Alcohol, 1 EO Ether Sulfate, Sodium Salt
[0070] The procedure used for undecylenic alcohol is generally followed using undecylenic alcohol 1EO ethoxylate (123.5 g, 0.578 mol) and sulfur trioxide (55.5 g, 0.693 mol, 1.2 eq.). Total addition time: 1 h, 50 min. The acid intermediate (155.0 g) is combined with water (414.3 g) and aqueous sodium hydroxide solution (50.7 g of 50% NaOH) and heated 1 h at 70° C. 1 H NMR analysis indicates 57% internal olefin and 13% terminal olefin present. Solids: 28.0%; unsulfated alcohol: 0.97%; inorganic sulfate: 0.14%; actives: 26.9%. Yield: 162.0 g (95%).
1-Undecanol, 1EO Ether Sulfate, Sodium Salt
[0071] The procedure used for undecylenic alcohol is generally followed using 1-undecanol 1EO ethoxylate (123.2 g, 0.564 mol) and sulfur trioxide (53.9 g, 0.674 mol, 1.2 eq.). Total addition time: 1 h, 35 min. The acid intermediate (160.0 g) is combined with water (428.5 g) and aqueous sodium hydroxide solution (51.5 g of 50% NaOH) and heated 1 h at 70° C. Solids: 27.4%; unsulfated alcohol: 0.76%; inorganic sulfate: 0.52%; actives: 26.2%. Yield: 165.4 g (98%).
Undecylenic Alcohol, 3EO Ether Sulfate, Sodium Salt
[0072] The procedure used for undecylenic alcohol is generally followed using undecylenic alcohol 3EO ethoxylate (118.9 g, 0.393 mol) and sulfur trioxide (37.6 g, 0.469 mol, 1.2 eq.). Total addition time: 1 h, 30 min. The acid intermediate (140.0 g) is combined with water (384.8 g) and aqueous sodium hydroxide solution (35.2 g of 50% NaOH) and heated 1 h at 70° C. 1 H NMR analysis indicates 62% terminal olefin and 19% internal olefin present. Solids: 27.2%; unsulfated alcohol: 1.61%; inorganic sulfate: 0.13%; actives: 25.4%. Yield: 145.1 g (97%).
1-Undecanol, 3EO Ether Sulfate, Sodium Salt
[0073] The procedure used for undecylenic alcohol is generally followed using 1-undecanol 3EO ethoxylate (150.2 g, 0.493 mol) and sulfur trioxide (47.3 g, 0.591 mol, 1.2 eq.). Total addition time: 1 h, 25 min. The acid intermediate (180.0 g) is combined with water (495.1 g) and aqueous sodium hydroxide solution (44.9 g of 50% NaOH) and heated 1 h at 70° C. Solids: 26.8%; unsulfated alcohol: 1.09%; inorganic sulfate: 0.27%; actives: 25.5%. Yield: 186.4 g (98%).
Undecylenic Alcohol, 1 EO Ether Sulfate, Ammonium Salt
[0074] A four-neck flask equipped with overhead mechanical stirrer, condenser, nitrogen inlet, thermocouple, heating mantle, and temperature controller is charged with undecylenic alcohol 1EO ethoxylate (111 g, 0.520 mol) and 1,4-dioxane (250 mL). Sulfamic acid (53.0 g, 0.546 mol) and urea (1.64 g) are added. The mixture is heated to reflux (about 103° C.) for 4 h. Analysis by 1 H NMR (MeOD) indicates ˜99% conversion to sulfate. Upon cooling, the mixture becomes a slurry. Chloroform (500 mL) is added and the mixture is heated to 55° C. Upon cooling and standing overnight, very fine insolubles settle to bottom. The solution is vacuum filtered using filter aid and a coarse funnel, washing with fresh chloroform. The filtrate is concentrated by rotary evaporation. The dioxane-wet paste is then dissolved in methanol (500 mL), adjusted to ˜pH 7 with ammonium hydroxide, and then reconcentrated. This procedure is repeated 5X, with the last concentration stopped before the product becomes too thick. Material is transferred to glass baking dish, using MeOH to quantitatively transfer residue. The solids are allowed to dry in a hood over the weekend and then further dried in a vacuum oven (70° C., 5 h). The product is a yellow semi-solid. 1 H NMR analysis indicates 99% conversion to the ammonium sulfate.
1-Undecanol, 1 EO Ether Sulfate, Ammonium Salt
[0075] The procedure used above to convert undecylenic alcohol 1 EO ethoxylate to the ammonium sulfate is generally followed using 1-undecanol 1EO ethoxylate (109.5 g, 0.508 mol), sulfamic acid (51.8 g, 0.533 mol), 1,4-dioxane (250 mL), and urea (1.61 g). The product is a yellow semi-solid. 1 H NMR analysis indicates quantitative conversion to the ammonium sulfate.
Evaluation of Alcohol Sulfates and Ether Sulfates in Product Development Applications
Zein Test
[0076] The zein test is based on solubilization by surfactants of a yellow corn (maize) protein that is normally insoluble in water unless it is denatured. The test gravimetrically determines the amount of zein dissolved by a surfactant solution. The solubility of zein in surfactant solutions correlates well with skin irritation or roughness caused by the surfactant. The “zein number” is a value relative to a normalized control, i.e., a 1% actives solution of Stepanol® WA-Extra PCK (sodium lauryl sulfate) in water. A higher zein number corresponds to a greater degree of irritation.
[0077] A 1% actives solution of each test surfactant (120 mL) is prepared. The pH of each solution is adjusted to about 7.0 with dilute aq. sulfuric acid or dilute aq. sodium hydroxide. The surfactant solution is warmed to 45° C. Zein powder (1.50 g) is added to each of three jars. Surfactant (25.0 g of 1% actives solution) is added to each jar, and to one empty jar to be used as a blank. The solutions are mixed using magnetic stirring on a temperature-controlled hotplate at 45° C. for 60 min. Each mixture is then centrifuged (2500 rpm, 15 min.), and undissolved zein powder is isolated by vacuum filtration. The residue is washed with deionized water and dried (55° C., 24 h) to constant weight. The amount of undissolved zein protein is found gravimetrically, and the results from three runs are averaged to give the % of solubilized zein and zein number. Results appear in Table 1.
[0000]
TABLE 1
Results of Zein Test 1
% solubilized zein
zein number
comment
Stepanol ® WA-
49.6
100
control
Extra PCK (SLS)
Unsat. C 11 alcohol
9.6
19.3
Unsaturated
Na sulfate
derivative is much
Sat. C 11 alcohol
52.9
107
less irritating than the
Na sulfate
saturated analog
Unsat. C 11 alcohol
8.3
16.7
Unsaturated
1EO Na sulfate
derivative is much
Sat. C 11 alcohol
33.7
68.0
less irritating than the
1EO Na sulfate
saturated analog
Unsat. C 11 alcohol
16.5
31.6
Unsaturated
3EO Na sulfate
derivative is less
Sat. C 11 alcohol
22.3
44.9
irritating than the
3EO Na sulfate
saturated analog
1 Average of three runs
[0078] As shown in Table 1, the sulfate and ether sulfate derivatives made from undecylenic alcohol are less or much less irritating than their saturated analogs based on the test results. All of the unsaturated derivatives tested are far less irritating when compared with the control, Stepanol® WA-Extra PCK (sodium lauryl sulfate). There appears to be less of a difference in the zein number between the unsaturated derivative and its saturated analog when the degree of ethoxylation is greater.
Hard-Surface Cleaners: Glass Cleaner
[0079] Control:
[0080] Stepanol WA-Extra® SLS (sodium lauryl sulfate, 1.0 g, product of Stepan, 29.4% active) is combined with isopropyl alcohol (2.0 g) and diluted to 100 mL with deionized water.
[0081] Test Formulation:
[0082] Test sample (1.2 to 1.4 g) is combined with isopropyl alcohol (2.0 g) and diluted to 100 mL with deionized water.
[0083] Test Materials:
[0084] Saturated C 11 alcohol sulfate, Na salt, 21.2% actives
[0085] Unsaturated C 11 alcohol sulfate, Na salt, 27.4% actives
[0086] Saturated C 11 alcohol 3EO ethoxylate sulfate, Na salt, 25.5% actives
[0087] Unsaturated C 11 alcohol 3EO ethoxylate sulfate, Na salt, 25.4% actives
[0088] Formulations:
[0089] A: Saturated Na sulfate (1.4 g). Clear, pH 4-5
[0090] B: Unsaturated Na sulfate (1.1 g). Clear, pH 9-10
[0091] C: Saturated 3EO Na sulfate (1.2 g). Clear, pH 6-7
[0092] D: Unsaturated 3EO Na sulfate (1.2 g). Clear, pH 7-8
[0093] Method:
[0094] The test formulation is evaluated for clarity; only clear formulations are evaluated in the low film/low streak test. The test measures the ability of the cleaner to leave a streak and film-free surface on a test mirror. The test formula is applied to a mirror in a controlled quantity and wiped with a standard substrate back and forth, leaving the spread product to dry. Once dry, the mirrors are evaluated and rated by a two-person panel. Results appear in Table 2.
[0095] As shown in Table 2 (A versus B), the formulation based on the C 11 unsaturated alcohol sulfate, sodium salt (formulation B) outperforms formulation A, which is based on a C 11 saturated alcohol sulfate, sodium salt in terms of a reduced degree of streaking.
[0096] Comparing formulations C and D, both the unsaturated alcohol 3EO sulfate, sodium salt, and its saturated analog perform similarly and well in the test. Both perform nearly as well as the control in terms of a low degree of filming and streaking and both perform better when compared with the alcohol sulfate formulations (A & B).
[0000]
TABLE 2
Glass Cleaner Performance
Filming on
Streaking on
A versus B
Observations
mirror panel
mirror panel
Control
Clear; no film or streak
0%
0%
B-Unsat. C 11 alcohol
Slight streaking
0%
5%
Na sulfate
A-Saturated C 11 alcohol
Unacceptable
0%
30%
Na sulfate
streaking
Better of A and B
B
Filming on
Streaking on
C versus D
Observations
mirror panel
mirror panel
Control
Clear; no film or streak
0%
0%
D-Unsaturated C 11
Minimal spotting;
0%
1%
alcohol 3EO Na sulfate
almost equal to control
C-Saturated C 11 alcohol
Very minor
0%
3%
3EO Na sulfate
streaking/spotting
Better of C and D
D
Hard Surface Cleaners: Aqueous Degreasers
[0097] This test measures the ability of a cleaning product to remove a greasy dirt soil from a white vinyl tile. The test is automated and uses an industry standard Gardner Straight Line Washability Apparatus. A camera and controlled lighting are used to take a live video of the cleaning process. The machine uses a sponge wetted with a known amount of test product. As the machine wipes the sponge across the soiled tile, the video records the result, from which a cleaning percentage can be determined. A total of 10 strokes are made using test formulation diluted 1:32 with water, and cleaning is calculated for each of strokes 1-10 to provide a profile of the cleaning efficiency of the product.
[0098] Test Samples:
[0099] A neutral, dilutable all-purpose cleaner is prepared from propylene glycol n-propyl ether (4.0 g), butyl carbitol (4.0 g), sodium citrate (4.0 g), Bio-Soft® EC-690 ethoxylated alcohol (1.0 g, product of Stepan), test sample (1.1 to 1.4 g), and deionized water (to 100.0 g solution). The control sample for anionic testing replaces the test sample with Stepanol® WA-Extra PCK (sodium lauryl sulfate, Stepan, 1.0 g, 29.4% active).
[0100] Test Materials:
[0101] Saturated C 11 alcohol sulfate, Na salt, 21.2% actives
[0102] Unsaturated C 11 alcohol sulfate, Na salt, 27.4% actives
[0103] Saturated C 11 alcohol 3EO ethoxylate sulfate, Na salt, 25.5% actives
[0104] Unsaturated C 11 alcohol 3EO ethoxylate sulfate, Na salt, 25.4% actives
[0105] Formulations:
[0106] A: Saturated Na sulfate (1.4 g). Clear, pH 7.5
[0107] B: Unsaturated Na sulfate (1.1 g). Clear, pH 7.5
[0108] C: Saturated 3EO Na sulfate (1.2 g). Clear, pH 7.4
[0109] D: Unsaturated 3EO Na sulfate (1.2 g). Clear, pH 7.5
[0110] Soil Composition (from Gardner ASTM D4488-95 Method):
[0111] Tiles are soiled with a particulate medium (50 mg) and an oil medium (5 drops). The particulate medium is composed of (in parts by weight) hyperhumus (39), paraffin oil (1), used motor oil (1.5), Portland cement (17.7), silica (18), molacca black (1.5), iron oxide (0.3), bandy black clay (18), stearic acid (2), and oleic acid (2). The oil medium is composed of kerosene (12), Stoddard solvent (12), paraffin oil (1), SAE-10 motor oil (1), Crisco® shortening, product of J.M. Smucker Co. (1), olive oil (3), linoleic acid (3), and squalene (3).
[0112] Results appear in Table 3. As shown in the table, all of the test samples perform equal to the control within the limits of the test method.
[0000]
TABLE 3
Gardner Straight-Line Washability Test
Ave. % clean after 2,
4, 6, 8, or 10 swipes
Rat-
2
4
6
8
10
ing
WA-Extra (sat C 12
91.3
93.6
93.2
94.1
95.4
control
Na sulfate)
Unsat C 11 alcohol
92.5
94.4
94.9
95.2
96.2
equal
Na sulfate
Sat C 11 alcohol Na sulfate
91.4
94.5
96.4
98.2
97.5
equal
Unsat C 11 3EO Na sulfate
94.0
97.4
99.1
96.5
100
equal
Sat C 11 3EO Na sulfate
97.5
98.9
98.9
99.3
100
equal
Water-Soluble Herbicide Formulation Testing
[0113] Surfactant candidates for water soluble herbicide applications are examined as a replacement for the anionic, nonionic, or anionic/nonionic blend portion and compared to a known industry adjuvant standard for use in paraquat, a water soluble herbicide concentrate formulation. A standard dilution test is conducted whereby the concentrates are diluted in water to determine if solubility is complete.
[0114] Control:
[0115] Paraquat (9.13 g of 43.8% active material) is added to a 20-mL glass vial. A known industry paraquat adjuvant (2.8 g) is added and vigorously mixed for 30 s. Deionized water (8.07 g) is added, and mixing resumes for 30 s. Standard 342 ppm water (47.5 mL) is added to a 50-mL Nessler cylinder, which is stoppered and equilibrated in a 30° C. water bath. Once the test water equilibrates, the formulated paraquat (2.5 mL) is added by pipette into the cylinder. The cylinder is stoppered and inverted ten times. Solubility is recorded as complete or incomplete. Cylinders are allowed to stand and the amount (in mL) and type of separation are recorded after 30 min., 1 h, 2 h, and 24 h. Results of the solubility testing appear in Table 4 below.
[0116] Anionic Test Sample:
[0117] Paraquat (4.57 g of 43.8% active material) is added to a 20-mL glass vial. An eight to ten mole alkyl phenol ethoxylate surfactant (0.7 g) is added and vigorously mixed for 30 s. Test sample (0.7 g) is added and mixing resumes for 30 s. Deionized water (4.03 g) is added, and mixing resumes for 30 s. A 2.5-mL sample of the formulated paraquat is added to 47.5 mL of 342 ppm hardness water, and testing continues as described above for the control sample.
[0118] Nonionic Test Sample:
[0119] Paraquat (4.57 g of 43.8% active material) is added to a 20-mL glass vial. Test sample (0.7 g) is added and vigorously mixed for 30 s. Sodium linear alkylbenzene sulfonate (“NaLAS,” 0.7 g) is added and mixing resumes for 30 s. Deionized water (4.03 g) is added, and mixing resumes for 30 s. A 2.5-mL sample of the formulated paraquat is added to 47.5 mL of 342 ppm hardness water, and testing continues as described above for the control sample.
[0120] Adjuvant (Anionic/Nonionic) Test Sample:
[0121] Paraquat (4.57 g of 43.8% active material) is added to a 20-mL glass vial. Test sample (1.4 g) is added and vigorously mixed for 30 s. Deionized water (4.03 g) is added, and mixing resumes for 30 s. A 2.5-mL sample of the formulated paraquat is added to 47.5 mL of 342 ppm hardness water, and testing continues as described above for the control sample.
[0122] Test Materials:
[0123] Saturated C 11 alcohol sulfate, Na salt, 21.2% actives
[0124] Unsaturated C 11 alcohol sulfate, Na salt, 27.4% actives
[0125] Saturated C 11 alcohol 1 EO ethoxylate sulfate, Na salt, 26.2% actives
[0126] Unsaturated C 11 alcohol 1EO ethoxylate sulfate, Na salt, 26.9% actives
[0127] Saturated C 11 alcohol 1 EO ethoxylate sulfate, NH 4 salt, 97.5% actives
[0128] Unsaturated C 11 alcohol 1EO ethoxylate sulfate, NH 4 salt, 95.5% actives
[0129] Saturated C 11 alcohol 3EO ethoxylate sulfate, Na salt, 25.5% actives
[0130] Unsaturated C 11 alcohol 3EO ethoxylate sulfate, Na salt, 25.4% actives
[0131] Criteria for emulsion solubility: Test samples should be as good as or better than the control with no separation after one hour. All of the tested formulations perform well in comparison to the controls, particularly when the saturated or unsaturated C 11 alcohol derivative is used to replace the anionic portion of the formulation (left set of columns in Table 4). Overall, no significant difference is noted between the unsaturated C 11 alcohol derivatives and their saturated counterparts in this test. Results appear in Table 4.
[0000]
TABLE 4
Water Soluble Herbicide Formulation:
Emulsion stability, mL separation
Anionic
Nonionic
Adjuvant
Rat-
test sample
sol
1 h
24 h
sol
1 h
24 h
sol
1 h
24 h
ing
Unsaturated
S
0
0
I
0.25
0.4
D
0
0.25
good
Na sulfate
Saturated
S
0
0
I
0.2
0.3
I
0.2
0.4
good
Na sulfate
Unsat. 1EO
S
0
0
D
0.2
0.25
D
0
0.5
good
Na sulfate
Sat. 1EO
S
0
0
D
0.2
0.5
D
0
0.2
good
Na sulfate
Unsat. 3EO
S
0
0
D
0.2
0.5
D
0
Tr
good
Na sulfate
Sat. 3EO
S
0
0
D
0.1
0.5
D
0
Tr
good
Na sulfate
Unsat. 1EO
S
0
0
D
0
Tr
S
0
0
good
NH 4 sulfate
Sat. 1EO
S
0
0
S
0
0
S
0
0
good
NH 4 sulfate
D = dispersable; S = soluble; I = insoluble; Tr = trace
Control result: Solubility: D; 1 h: 0 mL; 24 h: 0.2
Agricultural Dispersant Screening:
[0132] The potential of a composition for use as an agricultural dispersant is evaluated by its performance with five typical pesticide active ingredients: atrazine, chlorothalonil, diuron, imidacloprid and tebuconazole. The performance of each dispersant sample is evaluated in comparison with two standard Stepsperse® dispersants: DF-200 and DF-500 (products of Stepan Company).
[0133] A screening sample is prepared as shown below for each active. Wetting agents, clays, and various additives are included or excluded from the screening process as needed. The weight percent of pesticide (“technical material”) in the formulation depends on the desired active level of the final product. The active level chosen is similar to other products on the market. If this is a new active ingredient, then the highest active level is used.
[0134] Samples are evaluated in waters of varying hardness, in this case 342 ppm and 1000 ppm. The initial evaluations are performed at ambient temperature. Other temperatures can be evaluated as desired. The 342 ppm water is made by dissolving anhydrous calcium chloride (0.304 g) and magnesium chloride hexahydrate (0.139 g) in deionized water and diluting to 1 L. The 1000 ppm water is made similarly using 0.89 g of calcium chloride and 0.40 g of magnesium chloride hexahydrate.
[0135] Technical material (60-92.5 wt. %), anionic wetting agent (0.5-1.0 wt. %), silica (0.5-1.0 wt. %), and clay (balance) are blended in a suitable container. The blend is milled to a particle size of at least a d(90) of <20μ using a hammer and air/jet mills as needed. Test dispersant (0.1 g) is added to test water (50 mL) in a beaker and stirred 1-2 min. Milled powder containing the technical material (1.0 g) is added to the dispersant solution and stirred until all powder is wet (2-5 min.). The mixture is transferred to a 100-mL cylinder using additional test water for rinsing the beaker and is then diluted to volume. The cylinder is stoppered and inverted ten times, then allowed to stand. Visual inspection is performed at t=0.5, 1.0, 2.0, and 24 hours, and the amount of sediment observed (in mL) is recorded. Trace of sediment=“Tr” (see Table 5).
[0136] Results appear in Table 5. As shown in the table, both the unsaturated C 11 alcohol 1EO ethoxylate sulfate, sodium salt, and its saturated analog perform equal to the controls in this test.
[0000]
TABLE 5
Agricultural Dispersants Testing: Anionic Wetting Agent
Sedimentation results at 1 h; 24 h (mL)
test water,
Unsaturated 1EO
Saturated 1EO sodium
ppm
DF-200
DF-500
sodium sulfate
sulfate
Diuron
342
1; 2
0.5; 1-1.5
0.5; 1
0.5; 1
1000
1; 2-2.5
0.5-0.75; 2
1, 2
1, 2 (flock)
Chlorothalonil
342
0.25; 1-1.25
0.25; 1-1.25
Tr.; 1
0.5; 1
1000
0.25-0.5; 1.25-1.5
2; 3
0.5; 1
0.5; 2
Imidacloprid
342
Tr; 1-1.5
0.5-1; 2
3, 4
1; 2
1000
Tr; 1-1.5
0.5-1; 2-2.5
3, 3
2.5, 2 (flock)
Tebuconazole
342
Tr; 1.25
Tr; 1.5
Tr.; 2
Tr.; 0.5
1000
Tr; 3
Tr; 3
flocked
5, 3 (flock)
Atrazine
342
Tr-0.25; 1-1.5
0.5; 1
Tr.; 1
Tr.; 1
1000
Tr-0.25; 1-1.5
6; 3
0.5; 1
0.5; 1
Rating
control
control
equal
equal
[0000]
TABLE 6
Comparison of Monounsaturated C 11 Derivatives v. Saturated Analogs:
Estimated Phase Region as a Function of % Actives Level 1
Isotro-
Solid/
Solid/
pic
Lamel-
Hexag-
Cu-
isotro-
gum/
Clear
lar
onal
bic
pic
paste
Unsaturated
0-68
68-100
Na sulfate
Saturated
0-33
33-43
43-100
Na sulfate
Unsat. 1EO
0-64
64-74
74-100
Na sulfate
Sat. 1EO
0-36
58-72
36-58
72-100
Na sulfate
Unsat, 1EO
0-31
58-91
31-58
91-100
NH, sulfate
Sat. 1EO
0-26
67-85
26-58
58-67
85-100
NH 4 sulfate
Unsat, 3EO
0-70
70-80
80-100
Na sulfate
Sat. 3EO
0-33
58-82
33-58
82-100
Na sulfate
Unsat. 7EO
0-38,
38-57
ethoxylate
57-98 2
Sat. 7EO
0-34,
63-78
34-63
ethoxylate
78-98 2
1 All microscopy examinations are performed at room temperature (20-22° C.). Phase boundaries are estimates.
2 At ~98-100% actives, a two-phase liquid results.
[0137] Surfactant Phase Behavior Study:
[0138] Phase behavior is observed using an Olympus BH-2 cross-polarized microscope at 100-400X and room temperature (20° C. to 22° C.). The monounsaturated C 11 alcohol derivatives (sulfates, ethoxylate sulfates, and alcohol ethoxylates) are compared with their saturated analogs.
[0139] Samples are prepared by diluting the most concentrated product gradually with deionized water. When the surfactant concentration approaches a phase transition, the concentration is varied at 2-4% intervals to estimate the phase boundary. The actives level reported in Table 6 for each phase boundary is within ±5% of the true boundary.
[0140] Samples are loaded between a microscope slide and cover glass and are allowed to equilibrate before observation. Microscopic texture is analyzed and used to determine the phase. For some samples, an AR 2000 rheometer (TA Instruments) is used to measure viscosity at 25° C. to further verify phase behavior.
[0141] At low surfactant concentrations, randomly oriented micelles (spheres or cylinders) generally predominate, resulting in a clear or isotropic liquid. As concentration increases, cylindrical micelles can arrange themselves into either hexagonal or cubic phases, both of which have very high viscosities (10-50K cP at 25° C. for the hexagonal phase, higher for the cubic phase). Thus, in the hexagonal and cubic phases, the surfactant is difficult to process or formulate. Increasing the surfactant concentration more can generate a lamellar phase, where micellar bilayers are separated by water. Because the lamellar phase is pumpable (1-15K cP at 25° C.), compositions having high levels of surfactant actives can be produced. Further concentration of the surfactant can lead to reverse micelles, in some cases generating an isotropic mixture. In sum, phase behavior is important for manufacture, processing, transportation, and formulation of compositions containing surfactants.
[0142] An ideal sample is isotropic and clear throughout the entire range of active levels with low viscosity, as this is most likely to avoid any processing issues related with gelling or precipitation during formulation. A lamellar phase is also considered favorable for processing and transportation. Less favorable gel phases include cubic, hexagonal, and solid/gum/paste. All of the samples tested had at least some gel/solid component. The presence of these phases at a particular actives level suggests that processing at or near that actives level will be very difficult.
[0143] As shown in Table 6, several of the unsaturated C 11 derivatives, notably the alcohol sulfate sodium salts and alcohol ether sulfate sodium salts, have isotropic clear phases at actives levels from 0 to 60 or 70 wt. %. This suggests that these surfactants will have wide latitude for formulating at relatively high actives levels. When compared with their saturated analogs, the unsaturated C 11 derivatives unexpectedly demonstrate favorable phase behavior (combination of isotropic clear and lamellar phases) over a much wider range of actives levels. The results indicate that the unsaturated derivatives will be easier to process than the saturated analogs in intermediate products or fully formulated end-use applications.
[0000] Synergy Study: Combining Derivatives with Cationic Surfactant
[0144] The surfactant blends tested are prepared at a 1:1 molar ratio without any pH adjustment. Dilutions are made using deionized water to the desired actives level. Actives amounts are wt. % unless indicated otherwise. Appearances are reported at ambient temperature for samples prepared within the last 24 h.
[0145] Interfacial tension (IFT) of all the individual components and their blends is measured at 0.1 wt. % active against light mineral oil at ambient temperature using a Kruss DSA-20 pendent drop tensiometer. The drop is blown out at 600 μL/min., and a video is recorded for 100 s. The video frames taken during the last 15 s are analyzed and used for the IFT calculation.
[0146] For blends having an IFT less than 0.5 mN/m, the IFT is determined using a spinning drop tensiometer (University of Texas 500) at 25° C. Oil density=0.877 g/cm 3 and surfactant density=0.997 g/cm 3 are used for the IFT calculation.
[0147] The expected IFT for a blend is calculated based on ideal mixing (non-synergistic) using the active component in each blend. The equation used is given as:
[0000] Expected IFT= X *IFT a +(1 −X )*IFT b
[0000] where X is the actives % of component A, IFTa is the IFT of component A, and IFTb is the IFT of component B. If the measured IFT for a blend is less than the expected IFT, then the blend is synergistic. If the measured IFT for a blend is higher than the expected IFT, the system is antagonistic.
[0148] As shown in Table 7, the unsaturated C 11 alcohol sulfate, sodium salt, when combined with Ammonyx® Cetac 30, exhibits very high synergy and improved solubility character compared with the saturated analog. Tables 8-10 confirm that the solubility improvement from the unsaturated derivatives is a general trend. Overall, the unsaturated derivatives display a high level of synergy, i.e., as much or more than the saturated analogs.
[0000]
TABLE 7
Blends of Unsaturated or Saturated C 11 Na Sulfate with Cationic Surfactants
Sample
Type
anionic
anionic
cationic
Name
Unsat C 11 Na
Sat C 11 Na sulfate
Ammonyx ® Cetac 30
sulfate
(cetrimonium Cl)
anionic:cationic (molar)
1:1
1:1
Appearance, 1.0%
homogeneous,
separated
clear liquid
hazy liquid
Appearance, 0.1%
slightly hazy liquid
separated
clear liquid
IFT at 0.1% actives
5.95
16.34
0.35
(single component)
IFT at 0.1%
0.17
2.67
actives/mineral oil (blend)
Calculated IFT
3.16
8.35
(no synergy)
Synergy?
very high
above average
Solubility
good
poor
[0000]
TABLE 8
Blends of Unsaturated or Saturated C 11 1EO Na Sulfate
with Cationic Surfactants
Sample
Type
anionic
anionic
cationic
Name
Unsat. C 11 1EO
Sat. C 11 1 EO
Ammonyx ®
Na sulfate
Na sulfate
Cetac 30
(cetrimonium Cl)
anionic:cationic
1:1
1:1
(molar)
Appearance, 1.0%
separated
separated
clear liquid
Appearance, 0.1%
slightly hazy liquid
hazy liquid
clear liquid
IFT at 0.1% actives
6.18
12.52
0.35
(single component)
IFT at 0.1%
0.13
0.23
actives/mineral oil
(blend)
Calculated IFT
3.27
6.44
(no synergy)
Synergy?
very high
very high
Solubility
good
fair-poor
[0000]
TABLE 9
Blends of Unsaturated or Saturated C 11 1EO NH 4 Sulfate
with Cationic Surfactants
Sample
Type
anionic
anionic
cationic
Name
Unsat. C 11 1EO
Sat. C 11 1 EO
Ammonyx ®
NH 4 sulfate
NH 4 sulfate
Cetac 30
(cetrimonium Cl)
anionic:cationic
1:1
1:1
(molar)
Appearance, 1.0%
homogeneous
separated
clear liquid
hazy liquid
Appearance, 0.1%
slightly hazy liquid
hazy liquid
clear liquid
IFT at 0.1% actives
17.22
12.40
0.38
(single component)
IFT at 0.1%
0.60
0.85
actives/mineral oil
(blend)
Calculated IFT
8.8
6.2
(no synergy)
Synergy?
very high
high
Solubility
good
fair-poor
[0000]
TABLE 10
Blends of Unsaturated or Saturated C 11 3EO Na Sulfate
with Cationic Surfactants
Sample
Type
anionic
anionic
cationic
Name
Unsat. C 11 3EO
Sat. C 11 3 EO
Ammonyx ®
Na sulfate
Na sulfate
Cetac 30
(cetrimonium Cl)
anionic:cationic
1:1
1:1
(molar)
Appearance, 1.0%
hazy liquid
separated
clear liquid
Appearance, 0.1%
slightly hazy liquid
hazy liquid
clear liquid
IFT at 0.1% actives
5.10
8.80
0.35
(single component)
IFT at 0.1%
0.17
0.03
actives/mineral oil
(blend)
Calculated IFT
2.73
4.58
(no synergy)
Synergy?
high
very high
Solubility
good
fair-poor
[0149] The preceding examples are meant only as illustrations; the following claims define the invention.
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Surfactant compositions comprising an alkoxylate, a sulfate, or ether sulfate of a C 10 -C 12 monounsaturated alcohol are disclosed. The alkoxylate, sulfate, or ether sulfate may derive from undecylenic acid or undecylenic alcohol. Compared with their saturated analogs, the monounsaturated alkoxylates, sulfates, and ether sulfates are less irritating, making them valuable for personal care, laundry, cleaners, and other household applications. Microscopy studies show that the alkoxylates, sulfates, and ether sulfates have favorable phase behavior over a wide range of actives levels, expanding opportunities for products with greater compaction. When combined with cationic surfactants, the alkoxylates, sulfates, and ether sulfates exhibit synergy, and they have improved solubility compared with their saturated analogs. The surfactants find value for the personal care, laundry and cleaning, emulsion polymerization, agricultural products, oilfield applications, and specialty foams industries.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. Ser. No. 14/111,925 filed Mar. 25, 2014, which is incorporated herein by reference and which is a National Phase of PCT/FR2012/50806, filed Apr. 12, 2012, which claims priority under 35 U.S.C. 119 from French Application No. 11 01177 filed Apr. 14, 2011.
BACKGROUND OF THE INVENTION
[0002] Field of the Invention
[0003] The invention relates to a high-voltage battery charging device, in particular for an electric-traction motor vehicle, on the basis of a single-phase power supply network.
[0004] In high-voltage battery recharging systems, the electrical power from the network is delivered to the battery successively via two converters: a voltage step-down or “buck” converter and a voltage step-up or “boost” converter. These two converters enable the voltage ratio between the output and input terminals thereof to be decreased or increased by successively opening and closing a series of switches, at a frequency controlled as a function of the output current and/or the desired output voltage.
[0005] Description of the Related Art
[0006] Such recharging systems are for example described in patent application FR 2 943 188, which relates to an on-board recharging system for motor vehicles enabling a battery of the vehicle to be recharged from a three-phase or single-phase circuit, the recharging circuit incorporating the coils of an electric machine that also provides other functions such as current generation or vehicle propulsion.
[0007] The chopping of the current drawn from the power supply network induces high-frequency components in the current drawn, i.e. harmonics of an order higher than the fundamental frequency of the distribution network, which is conventionally 50 Hz.
[0008] As the electricity distributor imposes a standard concerning the harmonics of the current drawn, such a recharge system also includes a resistive/inductive/capacitive (RLC) filter at the input of the voltage step-down converter. This filter induces a phase shift between the current and the voltage drawn from the network. This phase shift results in a reactive power flowing through the network that is not drawn by the user and that should ideally be minimized.
[0009] Furthermore, most domestic power supply networks are single-phase power supply networks. A vehicle including a device for recharging a battery from a single-phase power supply can therefore be recharged from a domestic power supply network, for example in a private parking spot or garage.
[0010] Recharging from a single-phase power supply network has some specific features. Depending on the topology thereof, it is not always possible to bring the input current into phase with the network voltage. Moreover, when the input sinusoidal voltage is close to zero, the system becomes momentarily uncontrollable, which is not very inconvenient if the storage inductance of the electric machine between the voltage step-down converter and the voltage step-up converter is high, because the current in the inductor does not have time to drop, but has the drawback of this inductor being voluminous.
[0011] Furthermore, for the power flow to be continuous, a non-zero current needs to be flowing through the storage inductor of the electric machine between the voltage step-down converter and the voltage step-up converter.
BRIEF SUMMARY OF THE INVENTION
[0012] The aim of the invention is to propose a device for controlling the voltage step-down converter and the voltage step-up converter of such a recharging device that enables a reduced phase angle to be maintained between the current and the voltage drawn from the single-phase power supply network, despite the presence of an RLC filter at the device input.
[0013] Another aim of the invention is to propose an on-board recharging device for a motor vehicle that can be connected to an external single-phase power supply network and that incorporates the winding of an electric machine of the vehicle in the circuit thereof.
[0014] According to one aspect, one embodiment proposes a device for charging a battery, in particular a battery of an electric-traction motor vehicle, from a single-phase power supply network, comprising a filtering stage intended to be connected to the single-phase network, a voltage step-down stage connected to the filtering stage, a voltage step-up stage intended to be connected to the battery and coupled to the voltage step-down stage via an inductive component such as an inductance coil, a control unit able to impose chopping duty cycles on the voltage step-down stage and the voltage step-up stage.
[0015] According to a general feature, the control unit includes means for compensating for the phase shift between the input current of the voltage step-down stage and the input voltage of the voltage step-down stage.
[0016] Advantageously, the control unit includes a first open-loop control module able to determine a chopping duty cycle of the voltage step-down stage as a function of the voltage of the single-phase power supply network, a setpoint power, and the intensity of the current flowing through the inductance coil, to compensate for the phase shift between the input current of the voltage step-down stage and the input voltage of the voltage step-down stage, and to control the power received by the battery as a function of the setpoint power.
[0017] The first control module may advantageously include a map providing the amplitude of the input current of the voltage step-down stage as a function of the amplitude of the input voltage and of the setpoint power.
[0018] Preferably, the control unit includes a second control module able to determine a chopping duty cycle of the voltage step-up stage as a function of the voltage at the output of the voltage step-down stage, the voltage of the battery, and the difference between the setpoint induction intensity and the intensity of the current flowing through the inductance coil, providing closed-loop control of the intensity of the current flowing through the battery.
[0019] The setpoint induction intensity is preferably always greater than the intensity flowing through the battery, and the intensity flowing through the inductance coil.
[0020] Advantageously, the second control module includes a proportional-integral controller to which is sent the difference between the intensity of the current flowing through the inductance coil and the setpoint inductance intensity, and overspeed protection means designed to deactivate the integral part of the controller if the chopping duty cycle determined by the second module is approximately equal to “0” or “1”.
[0021] According to another aspect, the invention proposes a motor vehicle with at least partial electrical traction including an electric machine coupled to the drive wheels and an inverter stage able to power the electric machine.
[0022] According to a general feature, said vehicle includes a device for charging a battery from a single-phase network as described above, the electrical connections and a switch of the voltage step-up stage of said device being included in the inverter stage, and the inductance coil of said device corresponding to the windings of said electric machine.
[0023] According to another aspect, one embodiment proposes a method for controlling the charging of a battery, in particular a battery of a motor vehicle, from a single-phase network, in which the input voltage is filtered, the electrical power is taken from the network to the battery via a voltage step-down stage and a voltage step-up stage coupled via an inductive component such as an inductance coil.
[0024] According to a general feature, the phase shift between the input current of the voltage step-down stage and the input voltage of the voltage step-down stage is compensated.
[0025] Preferably, the input current of the voltage step-down stage is controlled by means of the open-loop control of a chopping duty cycle of the voltage step-down stage as a function of the voltage of the single-phase power supply network, a setpoint power, and the intensity of the current flowing through the inductance coil, to compensate for the phase shift between the input current of the voltage step-down stage and the input voltage of the voltage step-down stage, and to control the power received by the battery as a function of the setpoint power.
[0026] The intensity of the current flowing through the battery can also be set to a reference battery intensity by setting, in a closed loop, a chopping duty cycle of the voltage step-up stage as a function of the voltage at the output of the voltage step-down stage, the voltage of the battery, and the difference between the setpoint induction intensity and the intensity of the current flowing through the inductance coil.
[0027] The integral part of a proportional-integral controller can advantageously be deactivated if the chopping duty cycle is approximately equal to “0” or “1”.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0028] Other advantages and features of the invention are set out in the detailed description of an embodiment of the invention, which is in no way limiting, and the attached drawings, in which:
[0029] FIG. 1 shows a recharging device according to an embodiment of the invention;
[0030] FIGS. 2 a and 2 b show respectively first and second embodiments of a first control module;
[0031] FIG. 3 is a schematic view of an embodiment of a second control module;
[0032] FIG. 4 is a graphical representation of the current flowing through the inductance coil.
DETAILED DESCRIPTION OF THE INVENTION
[0033] FIG. 1 shows a schematic view of a device for charging a battery of an electric-traction motor vehicle from a single-phase power supply network, according to one embodiment.
[0034] The recharging device 1 includes a filtering stage 2 , a voltage step-down stage 3 coupled to the filtering stage 2 , and a voltage step-up stage 4 coupled to the voltage step-down stage 3 via an electric machine 5 .
[0035] Since the device 1 can be coupled to a three-phase or single-phase power supply, it has three terminals B 1 B 2 , B 3 coupled to the input of the filtering stage 2 , and that can be coupled to a power supply network. In single-phase recharging, only the inputs B 1 and B 2 are coupled to a single-phase power supply network delivering an input voltage Ve and an input current Ie.
[0036] Each input terminal B 1 , B 2 and B 3 is coupled to a filtering branch of the filtering stage 2 . Each filtering branch includes two branches in parallel, one having an inductor of value L 2 and the other having an inductor of value L 1 and a resistor of value R in series.
[0037] The outputs of these two filtering branches are each coupled to a capacitor of capacitance C also coupled to ground, at a point respectively named D 1 , D 2 , D 3 for each of the filtering branches. The set of resistors of value R, inductors of value L 1 or L 2 , and capacitors of capacitance C form an RLC filter at the input of the voltage step-down converter 3 .
[0038] In single phase recharging, terminal B 3 is not coupled to the power supply network. Since the filtering branch coupled to terminal B 3 is not used, it is not taken into account in the remainder of the description and is shown using dotted lines. The other elements of the electrical circuit shown using dotted lines are elements that are only used when coupling to a three-phase power supply network.
[0039] The voltage step-down stage 3 is coupled to the filtering stage 2 at points D 1 and D 2 . When operating with a single-phase power supply, the voltage step-down converter 3 includes two parallel branches 6 and 7 , each having two switches S 1 or S 2 controlled by a control unit 15 .
[0040] Each input D 1 or D 2 of the voltage step-down converter is connected, respectively by a branch F 1 and F 2 to a connection point located between two switches S 1 or S 2 of a single branch 6 and 7 , respectively.
[0041] The common extremities of the branches 6 and 7 form two output terminals of the voltage step-down converter 3 . One of the terminals is linked to the “−” terminal of the battery 13 and to a first input 10 of a voltage step-up converter 4 . The other of these terminals is connected to a first terminal of an electric machine 5 , the other terminal of which is connected to a second input 11 of the voltage step-up converter 4 .
[0042] The voltage step-up converter 4 has two switches S 4 and S 5 that can be controlled by the control unit 15 independently. These two switches S 4 and S 5 are located on a branch connecting the first input 10 of the voltage step-up converter 4 and the “+” terminal of the battery 13 . The second input 11 of the voltage step-up converter 4 , to which the electric machine 5 is connected, is connected between the two switches S 4 and S 5 , the switch S 4 being connected between the second input 11 and the “+” terminal of the battery 143 , and the switch S 5 being coupled between the first input 10 and the second input 11 .
[0043] An electric machine 5 , similar to a resistor of value Rd placed in series with an inductance coil Ld, is connected between the output terminal of the voltage step-down converter 3 and the second input 11 of the voltage step-up converter 4 . The electric machine 5 may be replaced by a non-resistive inductance coil or a supplementary inductance coil may be connected in series with the electric machine 5 without moving outside the scope of the invention.
[0044] The terminals of the battery 13 are connected to a capacitor 12 intended to keep the voltage at the terminals of the battery 13 relatively stable, and a module 19 for monitoring the charge of the battery that is able to deliver a setpoint value I bat ref determining, as a function of the battery charge level, the optimal current intensity to inject via the “+” terminal of the battery 13 . The charge monitoring module 19 sends the setpoint value I bat ref to the control unit 15 over a dedicated connection.
[0045] Measurement means, built into the module 19 or otherwise, also send the control unit 15 a value I bat determining a measured current actually entering the battery, and a value V bat determining the voltage between the “−” terminal and the “+” terminal of the battery 13 .
[0046] Other current intensity measurement modules make it possible to measure and send to the control unit 15 the value Id of the current flowing through the electric machine 5 , the intensity Ie of the current of the power supply network entering the filtering stage 2 , and the input voltage value Ve of the power supply from the network.
[0047] The control unit 15 includes a first control module 16 determining the chopping duty cycle a of the voltage step-down stage 3 , and a second control module 17 determining a chopping duty cycle setpoint a s of the voltage step-up stage 4 .
[0048] For this, the control unit 15 includes two pilot modules (not shown), the first to impose a temporal opening and closing pattern for each of the switches of the voltage step-down converter 3 such as to obtain the chopping duty cycle a of the voltage step-down stage 3 , and the second to impose a temporal opening and closing pattern for each of the switches S 4 and S 5 of the voltage step-up converter 4 such as to obtain the duty cycle a s .
[0049] The switches are preferably transistors enabling rapid switching, for example insulated gate bipolar transistors (IGBT).
[0050] When used exclusively in single-phase mode, the switch S 4 between the second input 11 of the voltage step-up converter 4 and the “+” terminal of the battery 13 is always closed and may as a result be replaced by a diode enabling a flow from said second input 11 to the “+” terminal of the battery 13 . If the device 1 can be coupled to a single-phase power supply network as well as a three-phase power supply network, a diode can be connected in parallel with the switch S 4 coupled between said second input 11 and the “+” terminal of the battery 13 , the diode enabling a flow from said second input 11 to the “+” terminal of the battery 13 .
[0051] To assess the duty cycles a and a s , the control unit 15 receives as input the values of the power supply voltage Ve from the network, the intensity Id of the current flowing through the electric machine 5 , the voltage V bat across the battery 13 , the intensity I bat of the current flowing through the battery 13 , and the reference battery intensity I bat ref delivered by the charge monitoring module 19 .
[0052] By way of example, the characteristic values of the electrical elements of the charging device 1 are within the following ranges:
the capacitance values of the filter 2 represent several hundred pF, for example between 100 and 500 μF each, the capacitance 12 between the terminals of the battery 13 used to stabilize the voltage of the terminals is around mF, for example between 1 and 10 mF, the resistance values R of the filtering circuit 2 are around one ohm, for example between 1 and 10Ω, the resistance Rd of the rotor of the electric machine Me is around several tens of mΩ, for example between 0.01Ω and 0.1Ω, the inductance values L1, L2, Ld corresponding respectively to the inductors of the filtering stage 2 and the winding of the electric machine 5 , have values of around several tens of μH, for example between 10 μH and 100 μH.
[0058] Using the first control module 16 and the second module 17 , the control unit prepares chopping duty cycle setpoint values a and a s for the voltage step-down converter 3 and for the voltage step-up converter 4 , satisfying the following three objectives:
controlling the amplitude of the input current If of the voltage step-down stage 3 and ensuring that this current If is in phase with the input voltage Ve (this control minimizes the phase shift between the input current If of the voltage step-down stage 3 and the input voltage V c of the voltage step-down stage 3 ), thereby controlling the power drawn as a function of the power supply network, obtaining a measured input current I bat at the “+” terminal of the battery 13 , corresponding to the power supply needs of the battery 13 , these needs being determined by the charge monitoring module 19 and delivered as the I bat ref function to the control unit 15 , preventing elimination of the current Id flowing through the inductance coil Ld of the electric machine 5 so as not to generate unwanted harmonics in the current drawn from the network.
[0062] Since the voltage drop in the filtering stage 2 is negligible for the power range used, the equations of the input filter need not be described.
[0063] The voltage Vc at the input of the voltage step-down stage 3 is deemed to be equal to the input voltage Ve of the power supply network.
[0064] The output voltage Vkn of the voltage step-down stage 3 is a·Ve. As it is equal to a·Ve, the equation of the branch bearing the electric machine 5 can be written in the following form:
[0000] Rd·Id+Ld·s·Id=a·Ve−a s ·V bat (equation 1)
[0000] where s is the derivative operator in relation to time “t”, or
[0000]
t
=
s
,
[0000] a is the chopping duty cycle of the voltage step-down stage 3 , a s the duty cycle of the voltage step-up stage 4 .
[0065] The chopping duty cycle a of the voltage step-down stage 3 can also be written a=If/Id, where If is the input current in the voltage step-up stage 3 , and the chopping duty cycle a s of the voltage step-up stage 4 is given by a s =I batt /Id.
[0066] The equation (1) can therefore also be written in the following form:
[0000]
Rd
·
Id
+
Ld
·
s
·
Id
=
(
If
·
Ve
-
I
bat
·
V
bat
)
/
Id
or
:
(
equation
2
)
Rd
·
Id
2
+
Ld
2
·
s
·
Id
2
=
If
·
Ve
-
I
bat
·
V
bat
(
equation
3
)
[0067] According to equation 3, the intensity If of the input current of the voltage step-down stage 3 can therefore be used as a control variable to lock the current Id flowing through the electric machine 5 to a setpoint value Id ref prepared such as to prevent the elimination of the current in the inductance coil Ld.
[0068] If the input voltage Ve approaches zero, the system becomes uncontrollable, even if it is locked. According to the equations, during these uncontrollable phases, the current Id in the coil Ld of the electric machine 5 can only drop, as shown in FIG. 4 .
[0069] Dividing the value of the intensity If of the input current of the voltage step-down stage 3 by the value of the intensity Id of the current measured through the electric machine 5 by definition gives the value of the chopping duty cycle a of the voltage step-down stage 3 . Controlling the voltage step-down stage 3 using the chopping duty cycle setpoint a makes it possible to lock the power supply current Ie of the network to a zero reference, in order to eliminate the phase shift between the current and the voltage at the input of the voltage step-down stage 3 , and to lock the current Id flowing through the electric machine 5 to the desired setpoint value, i.e. the setpoint induction intensity Id ref .
[0070] The input voltage Vc of the voltage step-down stage 3 , equal to the input voltage Ve of the power supply network, takes the form Vc=Ve=Vm sin(ωt).
[0071] The command guarantees that If is in phase with the input voltage. The input current Ie is given by Ie=If+Ic, i.e. I e =I fm sin(ωt)+C/2 V m cos(ωt).
[0072] The current If is therefore an image of the active power taken from the network. This latter is given by the relationship P active =I fm V m /2, where I fm =2 P active /V m .
[0073] If the input current Ie is controlled by the input current If of the voltage step-down stage 3 to eliminate the phase shift, and the current Id flowing through the electric machine 5 is controlled by the input current If of the voltage step-down stage 3 to prevent elimination of current in the coil Ld of the electric machine 5 , then the third objective of the control provided by the control unit 15 relating to locking the input current in the battery I bat to the setpoint value I bat ref delivered by the charge monitoring module 19 remains to be fulfilled.
[0074] To do so, a chopping duty cycle a s can for example be applied to the voltage step-up converter such as to satisfy the relationship a s =I bat ref /Id.
[0075] The relationship determining the dynamic of the current through the electric machine 5 , given by the equation (1), directly links the duty cycle a s of the voltage step-up stage 4 and the current Id flowing through the electric machine 5 .
[0076] It is therefore possible to control a s directly from the error between the reference value Id ref and the measured value Id flowing through the electric machine 5 .
[0077] FIG. 2 a is a schematic view of a first embodiment of the first control module 16 . The first control module includes open-loop control of the input current If of the voltage step-down stage 3 . The input current If of the voltage step-down stage 3 is controlled by calculating the chopping duty cycle a of the voltage step-down converter 3 .
[0078] The chopping duty cycle a of the voltage step-down stage 3 is determined as a function of the setpoint power P bat ref , determined from the voltage of the battery V bat and the setpoint battery intensity I batt ref , the input voltage Ve of the single-phase power supply network and the intensity Id of the current flowing through the inductance coil Ld.
[0079] The first control module 16 receives the battery intensity setpoint I bat ref at a first input and the voltage measured at the terminals of the battery V bat at a second input. The setpoint intensity of the battery T bat ref and the voltage V bat of the battery are inputted to a first multiplier 21 which then outputs the setpoint power P bat ref .
[0080] At a third input, the control module 16 receives the input voltage Ve from the power supply network. The module 16 includes a signal analyzer 22 enabling the standardized amplitude signal V m proportional to the input voltage Ve of the single-phase power supply network to be extracted. The amplitude signal V m is delivered to a first reversing switch 23 that outputs the reverse of the amplitude V m . The reverse V m of this amplitude is delivered to a second multiplier 24 that also receives as an input the setpoint power P bat ref .
[0081] The second multiplier 24 then outputs the amplitude If m of the input current of the voltage step-down stage 3 to a third multiplier 25 , which also receives as an input the phase signal sin(Ωt) of the input voltage V e of the single-phase power supply network.
[0082] The third multiplier 25 then outputs the input current If of the output voltage step-down stage 3 , firstly to the second control module 17 and secondly to a fourth multiplier 26 . The module 16 receives, via a fourth input, the value Id of the intensity of the current flowing through the coil Ld of the electric machine 5 . The value Id of the current flowing through the coil Ld is delivered to a second reversing switch 27 that outputs the reverse of the intensity Id of the current flowing through the coil Ld to the fourth multiplier 26 .
[0083] The fourth multiplier 26 then performs the calculation If/Id and outputs the value of the chopping duty cycle a of the voltage step-down stage 3 , enabling the input current If of the voltage step-down stage 3 to be controlled.
[0084] FIG. 2 b shows a second embodiment of the first control module 16 .
[0085] In this module 16 , the second multiplier 24 has been replaced by a map 28 delivering the amplitude If m of the input current If of the voltage step-down stage 3 as a function of the amplitude V , of the input voltage Ve and of the setpoint power P bat ref .
[0086] FIG. 3 shows an embodiment of the second control module 17 .
[0087] In the charging device 1 , the current I bat flowing through the battery 13 is controlled by the voltage step-up stage 4 . Indeed the current I bat of the battery is given by the relationship I bat =a s I d .
[0088] Thus, the current I bat in the battery 13 can simply be locked to the related reference value with a s =I bat ref /Id.
[0089] It is also possible to add a correction loop if the current measurement of the battery is available. In this case, the following is obtained:
[0000]
a
s
=
1
Id
·
{
I
bat
ref
+
α
·
(
I
batt
ref
-
I
bat
)
]
(
equation
4
)
[0000] where α is a setting parameter.
[0090] The second control module 17 includes closed-loop control of the intensity Id of the current flowing through the inductance coil Ld of the electric machine 5 .
[0091] The second control module 17 receives, at a first input, a value Ie of the input intensity of the power supply network. This intensity value Ie is delivered to a module 31 determining the value of the setpoint induction intensity Id ref . The second control module 17 receives, at a second input, the value Id of the intensity of the current flowing through the coil Ld of the electric machine 5 . The value Id of the intensity is delivered to a negative input of a first subtracter 32 that receives at a positive input the value Id ref of the setpoint induction intensity.
[0092] The first subtracter 32 then outputs the difference between the intensity Id of the current flowing through the inductance coil Ld and the setpoint inductance intensity I d ref to a proportional/integral controller 30 .
[0093] The proportional/integral controller 30 includes two branches in parallel, the first of which includes a proportional control module K p and the second includes an integral control module K i and an integration module i.
[0094] The second control module 17 receives, at a third input, the value If of the intensity of the input current of the voltage step-down stage 3 delivered by the first control module 16 . The intensity If is delivered to a first multiplier 33 , which also receives as input the input voltage V e of the single-phase network received at a fourth input of the second control module 17 .
[0095] The first multiplier 33 thus outputs a value P active of the active power. This value P active is inputted to a second multiplier 34 that also receives as input the reverse of the current Id, the current Id having previously been delivered to a first reversing switch 35 .
[0096] The second multiplier 34 performs the calculation P active / Id and outputs a value Vkn of the output voltage of the voltage step-down stage 3 . The voltage Vkn of the voltage step-down stage 3 is delivered to a positive input of a second subtracter 36 that receives on a negative input the output from the proportional/integral controller 30 .
[0097] The second subtracter 36 then outputs the sum of the difference between the intensity Id of the current flowing through the inductance coil Ld and the setpoint inductance intensity I d ref corrected by the proportional/integral controller 30 , with the output voltage Vkn of the voltage step-down stage 3 at the input of a third multiplier 37 . The third multiplier 37 also receives as input the reverse of the battery voltage V bat , the battery voltage V bat having been received at a fifth input of the second control module and delivered in advance to a second reversing switch 38 .
[0098] The third multiplier 37 then outputs the setpoint value of the chopping duty cycle a s of the voltage step-up stage 4 .
[0099] The second control module 17 also includes a feedback loop between the output of the third multiplier 37 and the input of the branch of the proportional/integral controller 30 containing the integral control module K.
[0100] If the value of the chopping duty cycle a s of the voltage step-up stage 4 is approximately 0 or 1, the integral control branch is deactivated.
[0101] This feedback loop is an overspeed protection technique used to overcome the loss of control of the device when the input voltage Ve approaches zero. Indeed during uncontrollable phases, control is saturated, i.e. the duty cycles of the switches, or IGBT transistors, are at 1, as it is not able to reduce the difference. To prevent this error from continuing to be integrated, the feedback loop is used. Accordingly, once the device can be controlled, the current Id flowing through the coil Ld of the electric machine 5 is brought to the reference value Id ref .
[0102] The use of this feedback loop also makes it possible to control a system that has a very-low-inductance coil Ld. The use of a low-inductance coil makes it possible to reduce the volume of the charger.
[0103] The invention provides an on-board charging device for a motor vehicle designed to be connected to an external single-phase power supply network, incorporating within its circuit the winding of an electric machine of the vehicle, and making it possible to control the voltage step-down converter and the voltage step-up converter such as to maintain a reduced phase shift between the current and the voltage drawn from the single-phase power supply network.
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A device for charging a battery, in particular a battery of an electric traction motor vehicle, on the basis of a single-phase power supply network, including a filtering stage intended to be connected to the single-phase network, a voltage step-down stage connected to the filtering stage, a voltage step-up stage intended to be connected to the battery and coupled to the voltage step-down stage via an inductive component such as an induction coil, a regulating unit able to impose chopping duty ratios on the voltage step-down stage and on the voltage step-up stage. The regulating unit includes means for compensating for the phase shift between the imput current of the voltage step-down stage and the imput voltage of the voltage step-down stage.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention is generally related to bottom-founded offshore platforms and more particularly to such platforms wherein a compliant response to design environmental forces is desirable.
2. General Background
The oil and gas industry has developed a variety of structures, floating vessels, and sub-sea installations to assist with and support drilling and production operations. One of the more common structures used for this purpose is a fixed offshore platform. These platforms have been constructed in an assortment of structural configurations. The term fixed offshore platform in the more general sense is known within the industry to mean any structure founded on the seafloor and extending from the seafloor through the water surface and may support facilities for either drilling and production equipment or both. The portion of the platform housing drilling and production equipment is typically referred to as the platform topsides or deck. The portion of the platform extending from the seafloor through the water surface and supporting the topsides is typically of a type referred to as a jacket (tubular space frame), guyed platform, or tension leg platform. The most common type being the jacket or tubular space frame.
Platforms located in shallow waters are designed for static wind and wave loadings plus dynamic amplification of these loads with little effort directed towards controlling the magnitude of dynamic amplification of these loadings. A platform designed in this manner is generally known within the industry as a ‘fixed’ or ‘non-compliant’ platform. Alternatively, the design of the platform may include measures to limit the degree of dynamic amplification of the applied loads. These structures are generally known within the industry as compliant structures. Platform designs include various techniques and means to introduce compliant behavior. The primary objective of a compliant platform is to provide a structure with natural periods of vibration that are substantially different than the period of the waves containing maximum energy within the design wave spectrum. For offshore platforms located in the Gulf of Mexico, the period of vibration to be avoided is typically 13 to 14 seconds. Most compliant structures are configured to have a period of the first mode of vibration (sway mode) in excess of 25 seconds. It is generally desirable for the second mode of vibration (bending mode) to be less than 8 seconds. These values may vary depending on platform location. Platforms with these vibration characteristics avoid design problems associated with resonance and minimize dynamic amplification of the design loads.
Compliant platforms founded on the seafloor and containing a support structure extending from the seafloor to above the water for the support of topside facilities can generally be grouped into one of the two following groups.
The first of these groups consists of several platform designs wherein a sufficiently long period of the first mode of vibration is provided through some form of articulation of a rigidly framed support structure. This articulation may be located at either the platform base or at some intermediate location between the seafloor and the water surface. Some platforms may also include the addition of a mass trap near the top of the structure to assist with obtaining desired first mode periods of vibration.
One such structure is a guyed platform. Guyed platforms are typically supported vertically and laterally at the base while free to rotate out of vertical about the base. Stability is supplied to the platform by an array of guy lines attached towards the platform top and anchored to the seafloor some distance away from the platform base. The platform is restored to a vertical position after being deflected horizontally by tension forces within the attached guys.
Other compliant platforms of this first group include rigidly framed jackets with a point of minimal rotational restraint at either the seafloor or at some intermediate point typically in the lower half of the support structure. Various spring elements, buoyancy, guys, or a combination of these features provide stability and the capacity to return to a vertical position after being deflected laterally. One platform of this type is disclosed in U.S. Pat. No. 4,696,603. Another similar compliant platform of this type was disclosed in the article entitled “Composite Leg Platforms for Deep U.S. Gulf Waters”, Ocean Industry, March 1988. The use of a flex pile was disclosed by these designs as one method of providing the required spring characteristics and restoring forces necessary for stability while providing the flexibility required to obtain compliant first mode vibration characteristics. These flex piles are typically rigidly connected to the platform near the platform mid-height and extend into the seafloor or are connected directly to piling extending from the seafloor. At intermediate locations between the seafloor and the upper end of the flex piles, the flex piles pass through guides providing relative axial movement while restraining the flex piles laterally. These guides are necessary to provide shear force transfer between the platform and the foundation and to also increase the compressive buckling strength of the flex piles. These flex piles may be located within the interior of the platform framing or exterior to the platform framing and are generally always framed to the platform legs by guides and an upper rigid connection. Another similar design incorporating a type of flex pile for a compliant concrete structure is disclosed in U.S. Pat. No. 4,793,739.
Also included within this first group of compliant platform structures is a compliant platform disclosed in U.S. Pat. No. 4,797,034 wherein the articulation point is located between a lower platform portion secured to the seafloor and an upper portion supporting the platform topsides. The lower platform section is secured to the seafloor by piling and is without any compliant features. Tubular members secured to both the upper and lower platform section by rigid connections and guides in a manner similar to the flex piles as previously described provide the required flexibility and stability for a compliant structure. Installation considerations will generally dictate that the platform be fabricated in sections different than those delineated by the point of articulation.
A platform disclosed in U.S. Pat. No. 4,738,567 also makes use of a long flexible piling to achieve a period of first mode vibration suitable for a compliant platform. For this platform the flexible pilings are installed through the diameter of large jacket legs. Each leg may contain several piles, which in turn may contain well conductors and casings. Another compliant offshore platform disclosed in U.S. Pat. No. 5,431,512 provides flexible tubular members located within the jacket legs. For this platform each leg contains a single flex tube member which extends beyond the lower end of an upper jacket section leg and is installed into a pre-installed fixed base section secured to the seafloor with piling using conventional offshore methods. These structures provide a compliant platform that pivots at or near the platform base to obtain required sway mode characteristics. The tubular members located within the platform legs provide platform stability and flexibility.
Compliant platforms of this first group achieve compliant characteristics through articulation about the base or at specific locations where hinge devices have been located. The amount of rotation is controlled by the addition of vertical spring elements normally taking the form of elongated vertical tubulars or flex piles. The use of axial flex tubes spanning across the location of a hinge or pivot point as used by some of the disclosed platforms normally requires a platform to pile rigid connection at each end of the axial flex tubes in addition to the normal foundation pile to platform connections. Flex piles as disclosed in U.S. Pat. No. 4,696,603 and the referenced CCLP platform only require one flex pile to platform connection located at the upper end of each flex pile. However, the combined length of foundation pile and the flex pile requires that the pile section below the seafloor be installed prior to platform installation and then spliced with a pre-installed flex pile section extending to the upper flex pile rigid connection. Alternatively it is required that the combined flex pile and foundation pile be spliced during installation and that the rigid flex pile to platform connection be field installed. If the flex piles are not pre-installed on the jacket structure, the location of anodes for cathodic protection from corrosion will be less than optimal. Platforms, which include flex tubes or flex piles require intermediate slip guides each equipped with wear surfaces. Similar wear surfaces are required at corresponding locations on each of the flex tubes or flex piles. Each of these elements increases the complication of the structure and is generally expensive. Typically flex piles, flex tubes, and slip guides are fabricated from materials with higher than normal strength properties. These materials are expensive and may present unnecessary welding difficulties. Non-traditional erection and installation procedures are required for both the hinge elements and flex piles or flex tubes. The concentration of buoyancy provided by pre-installed flex piles can be problematic during the installation launch operation and tends to inhibit design optimization for platform installation.
A second group of compliant platforms consist of structures that are designed to deflect laterally along the length of the structure as opposed to articulation about a designated point or points. These platforms rely on the global shear stiffness properties of the structure to provide a sway mode period of vibration consistent with the requirements of a compliant offshore platform. Internal forces generated by lateral displacement and buoyancy generally provide stability and restoring forces.
The offshore platform disclosed in U.S. Pat. No. 4,117,690 is an example of a compliant platform of the second type. Traditional framing and jacket legs are replaced with large diameter tubulars through which the foundation piling is installed. The platform legs are connected by horizontal framing members at selected levels. The disclosed platform employs a rigid connection between the platform piling and the bottom of the platform legs at the seafloor. These features distinguish the disclosed platform from the first group of structures that provide a point of articulation in order to obtain the required compliant characteristics of the first mode of vibration. The diagonal bracing normally provided within a platform structure to prevent buckling of the platform legs when subjected to compression loads has been eliminated so as to produce a more flexible structure. Local buckling strength of the legs is increased by pile and well conductor guides attached along the inside of the platform legs that serve as longitudinal stiffeners. The disclosed platform also assumes that the platform will be designed to have sufficient buoyancy such that there will exist at least some tension at the bottom of the platform legs. The disclosed platform also provides various techniques and vibration-influencing means in order to achieve compliant characteristics. One such technique is a provision for adjustable ballast compartments located within both braces and legs whereby both the buoyancy and mass of the platform can be varied. Vibration-influencing means such as the use of added stiffness provided by the introduction of X-bracing at selected levels was also disclosed.
The offshore platform disclosed in U.S. Pat. No. 4,117,690 does not require the added components associated with the compliant platforms disclosed in the first group to achieve compliant periods of vibration but does include features which are non-traditional and difficult to construct and maintain over the life of the structure. The extreme lack of diagonal bracing between the platform legs requires the incorporation of features such as the requirement that there be at least some tension at the bottom of the legs and that the legs be large diameter to achieve required buckling strength. The requirement that there be tension at the bottom of the platform legs imposes weight control restrictions and limitations to future platform modifications normally associated with floating structures. The use of ballast compartments throughout the legs and braces imposes costs and risks related to the construction of piping systems, manifolds, and pumps not normally required for conventional platform construction. These features must be maintained throughout the life of the structure. As disclosed in U.S. Pat. No. 4,117,690 stiffeners may be required to provide sufficient local bucking strength to the large diameter legs. The disclosed platform has assumed that the piling will be installed through guides located internally to the legs that will also serve to stiffen the leg's walls. Pile installation through guides attached to the interior of the leg walls may not be practical for any of the platform embodiments that incorporate variable diameter legs. All of the preferred embodiments of the disclosed platform impose further difficulties regarding pile and well string installation through a reduction in leg diameter below the water line. For these conditions platform piles could be pre-driven allowing the platform to be installed by stabbing over pre-driven piles. However, a stab-over procedure would impose fit-up and alignment costs associated with mating to pre-driven piles. All of these pile installation scenarios would incur the risk and uncertainty of completing the rigid connection of the platform leg to the internally located pile without ready access for contingencies. The inclusion of well strings and risers within the platform legs imposes added operational expenses and introduces the hazard of possible explosive gas accumulations within the platform legs.
SUMMARY OF THE INVENTION
Compliant platforms are generally considered as a reasonable alternative for water depths ranging from 1,400 feet to above 2,500 feet. For the deeper water depths, compliant characteristics may be obtained without the need to artificially increase the period of the sway mode of vibration. Considerable effort has been directed towards development of technology to achieve compliant characteristics in platforms installed in the shallower water depths representing a transition between non-compliant and compliant platforms. The present invention has significant advantages for water depths between 1,000 feet and 2,000 feet. The present invention discloses a technology enabling a compliant offshore platform in which the period of the sway mode of vibration is extended by restriction of diagonal bracing at selected locations within the platform framing. Maintaining a diagonally braced jacket structure throughout the majority of the platform height provides stability for the platform. In the preferred embodiments all of the platform foundation support is obtained through a plurality of skirt piles located about the base of the platform. These skirt piles are rigidly connected to the platform base and extend vertically only as necessary to complete the connection at the platform base. The skirt piles may be pre-installed or installed through sleeves attached to the platform framing. The platform supports topsides for drilling and production facilities. The platform framing is conducive to the support of drilling strings, risers, and pull tubes external to the platform legs.
The current invention does not rely on hinges, points of articulation, pivoting devices, vertical spring elements such as flex piles or flex tubes, or components for providing righting forces such as guys or supplemental buoyancy tanks to provide periods of the sway mode of vibration required to obtain compliant behavior. Normal requirements are that the period of the sway mode of vibration be greater than approximately 25 seconds but may vary depending on the environment of the intended platform location. Preferred embodiments of the current invention limit the areas in which unbraced portal framing is substituted for traditional diagonally braced jacket framing to those that are actually required to achieve compliant behavior. Additionally, the current invention does not sacrifice all of the inherent advantages of a totally braced space frame jacket. This feature is useful regarding the installation of piles, well strings, risers, and pull-tubes. The current invention does not require the use of guy lines nor is it required that the platform provide buoyancy to the extent that the platform legs will be loaded in tension. As a consequence of the use of skirt piles rigidly connected near the platform base as opposed to flex piles extending to near mid-platform height, relative motions between the platform base and the seafloor are reduced as is the exposed steel surface area requiring protection from corrosion.
BRIEF DESCRIPTION OF THE DRAWINGS
For a further understanding of the nature and objects of the present invention reference should be made to the following description, taken in conjunction with the accompanying drawings in which like parts are given like reference numerals, and wherein:
FIG. 1 is an elevation view of a compliant platform according to the present invention.
FIG. 2 is a plot of lateral platform displacements illustrating the advantage of the present invention.
FIG. 3 is a view taken along lines 3 — 3 in FIG. 1 .
FIG. 3A is a view taken along lines 3 A— 3 A in FIG. 3 .
FIG. 3B is a view taken along lines 3 B— 3 B in FIG. 3 .
FIGS. 4A and 4B are elevation views of one of the possible installation scenarios.
FIGS. 5A and 5B are elevation views near the platform base wherein the foundation piles are installed taking advantage of a shallow platform base section utilized as a template.
FIG. 6 illustrates means of providing temporary support and leveling of the jacket section.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates an embodiment of a compliant platform according to the present invention as seen in elevation. The platform jacket 13 is shown to support a deck 12 some distance above the water line 10 . The platform jacket 13 extends to a location near the seafloor 11 where it is supported by a plurality of skirt piles 20 rigidly connected to the jacket. These skirt piles are installed through skirt pile sleeves 21 and rigidly connected with the skirt pile sleeves by grouting or by mechanical means, which are well known within the industry. Well conductors 22 normally extend downward from the platform deck 12 into the seafloor 11 . Conductor guides 25 (better seen in FIG. 3) are normally provided at each horizontal framing level for lateral conductor support. The jacket legs 14 extend the length of the structure and are normally extended above the water line 10 to support the deck 12 . Additional deck support may be provided by false legs 15 . Horizontal braces 16 , diagonal braces 17 , and horizontal diagonal braces 19 (better seen in FIG. 3) interconnect the jacket legs. Additional vertical bracing 18 may be used at various locations to strengthen horizontal braces 16 . These components are typically constructed from tubular members and framed together in such a fashion as to form a rigid tubular space frame as is well known within the industry. Typically, platform jackets are constructed in this fashion.
In accordance with the present invention, selected areas of the jacket are intentionally left void of any diagonal bracing 17 that traditionally prevents shearing or sway displacements between levels of horizontal bracing 16 . This omission of diagonal braces is illustrated to occur at three locations in FIG. 1 . This feature of the present invention provides additional flexibility as is required to obtain a period of the sway mode of vibration necessary for compliant response to environmental loadings. This added flexibility can be seen by comparing the two curves of FIG. 2 . Curve A depicts the lateral displacement of a traditional, completely braced structure. Curve B depicts the lateral displacement of a platform of the present invention. Shear displacements are introduced at the location of the unbraced jacket levels. These added displacements provide additional flexibility and increase the period of the platform sway mode of vibration. Additional platform leg steel required due to additional leg bending will generally minimize any effects regarding the period of the platform bending mode of vibration. The number and location of unbraced panels is determined by design and is a function of water depth at the site, the weight and mass of the deck, and the environmental forces associated with the platform location.
As is the case for all offshore structures, consideration must be given to seawater pressure on the various tubulars. Likewise, the buoyancy and flotation characteristics of the jacket must be considered for platform installation. These considerations will normally dictate that most of the tubular members remain void and buoyant. However, various installation operations will also necessitate that some of the members be flooded during certain installation sequences. The present invention does not require a particular buoyant configuration once fully installed.
FIG. 3 illustrates typical framing, which may be present within a horizontal plane at each level of horizontal bracing. Horizontal diagonal bracing 19 is provided to prevent racking of the jacket cross-section. These braces also provide support for conductor guides 25 , riser supports 26 , and pull tube supports 27 . These are traditional means of supporting this necessary equipment and are well known within the industry. The present invention may accommodate the typically less desirable placement of these items internal to the platform legs in the event that unusual conditions exist.
One possible embodiment of the present invention and an associated example installation scenario is illustrated in FIGS. 4A and 4B. An assembled platform including the skirt pile foundation, jacket, and platform deck is shown in FIG. 4 A. Because compliant platforms are generally intended for installation at deepwater sites, in excess of one thousand feet, installation by sections is normally desirable. The embodiment shown in FIG. 4B is intended to minimize installation equipment requirements and seeks to also minimize risk from unexpected storms while platform installation is in progress. The initial jacket section is lowered to the seafloor where it is leveled and placed on temporary supports such as mudmats or other temporary supports that are well known within the industry.
One such means of providing temporary support and leveling means is illustrated in FIG. 6 . The jacket section is brought to rest on temporary support piles 31 . Each temporary support pile is engaged by a support bracket assembly 32 . The support bracket assemblies 32 are rigidly attached to the jacket leg 14 and all components are of such a capacity as to provide a support interface on which the temporary support piles 31 can bear thereby supporting the weight of the jacket 13 during installation. The support bracket assembly is comprised of a leveling device 34 and a support bracket 33 . The support bracket 33 is comprised of a bracket rigidly connected to the jacket leg 14 , which in turn supports the leveling device 34 . The leveling device 34 provides an interface between the support bracket 33 and the temporary support piles 31 and provides a means of adjusting the landing elevation and thereby the verticality or levelness of the structure. For the example illustrated in the drawings, the leveling device 34 has been shown as a large hydraulic cylinder.
As the initial jacket section is placed on the seafloor, alignment means not shown may be used to locate and stab the jacket over pre-driven wells. Skirt piles are then lowered and driven using conventional methods. Once driven, these skirt piles are rigidly connected to the jacket by grouting or by mechanical means, which are well known in the industry. A second jacket section is then lowered to within close proximity to the previously installed section. Extensions to the lower end of the jacket legs serve as grout pins 28 which are aligned with the upper end of the jacket legs of the previously installed initial jacket section. The legs on the initial jacket section serve as grout sleeves 29 . Once aligned, the second jacket section is stabbed into the first section and lowered to a pre-determined elevation where it may be supported on various permanent or temporary support devices. The jacket sections are then aligned vertically and rigidly connected by grouting or mechanical means. This procedure is then repeated with additional jacket sections until the complete platform has been installed. At this point, the platform deck 12 is installed on the jacket support structure. The number of unbraced jacket panels, the number of jacket sections, and the lengths of the various jacket sections will vary depending on the particular requirements of a given platform. It is not necessary that the areas of the jacket where the diagonal bracing is excluded be located adjacent to the rigid connections between jacket sections. Each of the connections between jacket sections are configured as grouted connections wherein the grout pins 28 extend downward and are received by grout sleeves 29 located in a lower jacket section. The position of the pins may be reversed wherein the grout pins extend upward from a lower jacket section and are received by grout sleeves located at the lower end of legs of the adjacent upper jacket section. Further, it is understood that the grouted connection may extend for a length less than the distance between horizontal bracing levels and may also extend across a plurality of horizontal bracing levels and in effect form a composite member in addition to providing a rigid connection between platform sections.
FIG. 5 illustrates an additional embodiment of the invention wherein a truncated section of the jacket is installed and functions as an installation template 30 . The use of a template 30 may be beneficial for a variety of reasons related to conductor installation, pre-drilling of wells, or pre-driving of skirt piles. The template section 30 is lowered to the seafloor where it is leveled and placed on temporary supports such as mudmats or other temporary supports that are well known within the industry. As the template section is placed on the seafloor, alignment means not shown may be used to locate and stab the template over pre-driven wells. Skirt piles are then lowered and driven using conventional methods. Once driven, these skirt piles are rigidly connected to the jacket by grouting or mechanical means well known within the industry. At this point well conductors may be pre-installed and initial drilling may be commenced with the use of a floating drilling vessel. The remainder of the platform may then be installed at some later time as described above and illustrated in FIG. 4 . These procedures offer the advantage that an early installation of the platform foundation, installation of conductors, and pre-drilling of wells may be accomplished while the design and fabrication of the remainder of the platform and platform deck is being completed. The capacity of the foundation piles will benefit from the additional set-up period provided between actual driving of piles and completion of the platform.
There are several advantages to the present invention, which include, but are not limited to, all the advantages of compliant platforms in general when compared to non-compliant platforms. Of primary importance is the ability to produce oil and gas in the dry using above-water manned faculties based on a bottom-founded platform in water depths beyond those that are economical for non-compliant platforms. The present invention does not rely on hinges or pivoting devices. It is not necessary that the installed platform be positively buoyant. The present invention does not require that the platform foundation piles, well strings, or risers be installed internally to the platform legs. Avoiding the installation of well strings and risers through the interior of the platform legs eliminates the hazard associated with gas accumulations inside platform legs.
All of the platform foundation piles may be traditional skirt piles taking advantage of existing pile installation technology. This existing technology includes the use of grouting hardware such as pile grippers and grout seals. Skirt piles as described in the various embodiments of the present invention only require one pile to platform connection for each pile. The use of skirt piles rigidly connected to the platform as disclosed in the present invention eliminates the requirement for intermediate flex pile guides, the additional framing required to integrate the flex pile guides into the platform, and eliminates the need for slip guides and wear surfaces on either the piles or guides. Installation and fabrication complications associated with the use of a hinge within the platform jacket are eliminated. The present invention eliminates the problems sometimes associated with the sudden addition of buoyancy as pre-installed flex piles or axial flex tubes initially enter the water during platform launch. The elimination of flex piles or axial tubes from the structure significantly reduces the exposed surface area that must be protected from corrosion. The method of obtaining the required vibration characteristics necessary to obtain compliant behavior as disclosed in the present invention facilitates the inclusion of structural support for well strings, j-tubes and risers as in traditional jackets. The rigid connection of the platform piles near the base of the platform serves to reduce relative displacements between the platform and the seafloor when compared to prior art platform designs employing flex piles that are secured to the platform near mid-platform. These reduced relative displacements are beneficial to the design of well strings, risers, and pull-tubes. Additionally, since the base of the platform is rigidly connected to the foundation piles and since the present invention does not rely on large displacements and rotations about the base for compliant behavior, it is not necessary to decouple the jacket from temporary installation supports after platform installation.
Because many varying and differing embodiments may be made within the scope of the inventive concept herein taught and because many modifications may be made in the embodiment herein detailed in accordance with the descriptive requirement of the law, it is to be understood that the details herein are to be interpreted as illustrative and not in a limiting sense.
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A compliant offshore platform wherein the sole foundation support for platform loads not provided by seawater buoyancy is provided by traditional skirt piles rigidly attached to the platform base near the ocean floor. Lateral flexibility of the platform is enhanced by the introduction of unbraced portal frames located throughout the platform framing in such a way as to facilitate lateral shearing displacements within the platform framing to the extent that the required compliant characteristics are obtained for the sway mode (first structural mode) of vibration while at the same time allowing the overturning moments generated by wind, wave, and current loads to be resisted by the vertical forces within the platform legs and platform foundation. The addition of these portal framed sections at selected locations into an otherwise traditional jacket provides a framing system with improved fundamental modes of vibration as are required for compliant structural behavior. In the preferred embodiment the platform skirt piles are rigidly attached to the jacket near the lowest levels of the jacket framing but somewhat above the seafloor. The skirt piles provide lateral restraint for the base of the platform.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is based on Japanese Patent Application No. 2009-227949 filed with the Japan Patent Office on Sep. 30, 2009, the entire content of which is hereby incorporated by reference.
BACKGROUND
1. Technical Field
The present invention relates to a cornea shape measurement apparatus for measuring a shape of a cornea of an examinee's eye.
2. Related Art
There has been known a cornea shape measurement apparatus for projecting an index for cornea shape measurement onto a cornea and capturing an image of the index reflected from the cornea to measure a shape of the cornea (e.g., refer to JP 2003-169778 A). A cornea shape obtained by such an apparatus has been used for determining a dioptric power of an intraocular lens (IOL), for example.
As an example of IOLs, recently, there has been proposed a TORIC-IOL for astigmatism correction. In a case of injecting a TORIC-IOL into a patient's eye (an examinee's eye), an operator (an examiner) previously measures an astigmatic axis of the patient's eye by use of a cornea shape measurement apparatus. Then, the operator places a first mark on the patient's eye in a direction of a horizontal axis by use of a dedicated member. Further, the operator places a second mark on the patient's eye in a direction of the astigmatic axis with respect to the first mark, and then injects the IOL into the patient's eye so as to align the second mark with an axis of the IOL.
However, when a posture of the patient varies at the time of measuring the cornea shape and at the time of placing the mark, the operator fails to properly place the mark on the patient's eye in the direction of the astigmatic axis. Consequently, there is a possibility of deviation of a position where the IOL is to be injected.
SUMMARY
An object of the present invention is to provide a cornea shape measurement apparatus capable of outputting data useful for prescription as well as injection and installation of a TORIC-IOL.
In order to accomplish this object, the present invention provides the following configurations.
That is, a cornea shape measurement apparatus includes: a projecting optical system that includes a first light source, and projects an index for cornea shape measurement onto a cornea of an examinee's eye; an illuminating optical system that includes a second visible light source which is different from the first light source, and illuminates an anterior segment of the eye, on which a reference mark for intraocular lens operations is placed, with visible light; an imaging optical system that includes an imaging device, and captures an anterior segment image containing the reference mark and an image of the index reflected from the cornea; a memory that stores therein the anterior segment image containing the reference mark and the index image, based on an output signal from the imaging device; a calculator that determines a direction of an astigmatic axis of the cornea, based on the index image in the memory; an image processor that overlays an astigmatic axis mark indicating the direction of the astigmatic axis on the anterior segment image in the memory, in accordance with a calculation result by the calculator; a display; and a controller that displays the anterior segment image, which is subjected to the image processing by the image processor so as to contain the astigmatic axis mark, on the display.
Preferably, the image processor overlays angle information for determining an angle between the reference mark and the direction of the astigmatic axis, on the anterior segment image.
Preferably, the illuminating optical system and the imaging optical system are each configured such that the imaging device receives light which is reflected from the anterior segment and has a wavelength characteristic of satisfying a complementary relation with a color of ink to be used for the reference mark.
Preferably, the illuminating optical system and the imaging optical system are each configured such that the imaging device receives light which is reflected from the anterior segment and has a wavelength characteristic that a center wavelength falls within a range from 500 nm to 600 nm.
Preferably, in a case where the color of ink to be used for the reference mark is one of blue and purple, the illuminating optical system and the imaging optical system are each configured such that the imaging device receives light which is reflected from the anterior segment and has a wavelength characteristic that a center wavelength falls within a green range.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features, aspects and advantages of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings, in which:
FIG. 1 illustrates a schematic configuration of an optical system and a control system in a cornea shape measurement apparatus according to one embodiment of the present invention;
FIGS. 2A and 2B each illustrate an observation screen on which an anterior segment image is displayed;
FIG. 3 illustrates luminance distribution in the anterior segment image;
FIG. 4 illustrates anterior segment image data for use in injection of an intraocular lens for astigmatism correction;
FIG. 5 illustrates an example of a wavelength characteristic of a filter arranged in an imaging optical system; and
FIG. 6 illustrates a wavelength characteristic of a filter for taking an image of a reference mark and a wavelength characteristic of a filter for taking an image of an index for cornea shape measurement and an image of an alignment index.
DESCRIPTION OF EMBODIMENTS
Preferred embodiments of the present invention will be described below with reference to the accompanying drawings, in which like reference characters designate similar or identical parts throughout the several views thereof. FIG. 1 illustrates a schematic configuration of an optical system and a control system in a cornea shape measurement apparatus according to one embodiment of the present invention. In this apparatus, the optical system includes a cornea shape measuring index projecting optical system 20 , an illuminating optical system 80 , an alignment index projecting optical system 50 , an imaging optical system 30 , a measuring optical system 60 and a fixation index projecting optical system 40 . The projecting optical system 20 projects a ring index for cornea shape measurement onto a cornea Ec of an examinee's eye E. The illuminating optical system 80 illuminates an anterior segment of the examinee's eye E with visible light. The projecting optical system 50 projects a ring index for alignment status detection onto the cornea Ec. The imaging optical system 30 captures a front image of the anterior segment. The measuring optical system 60 measures an eye characteristic other than a cornea shape. The fixation index projecting optical system 40 is used for fixation of the examinee's eye E (i.e., fixes a line of sight). Herein, each optical system is incorporated in a housing (not illustrated). Moreover, the housing is shifted in a three-dimensional direction with respect to the examinee's eye E by a well-known shifting (moving) mechanism for alignment including an operating member (e.g., a joystick).
The projecting optical system 20 includes a ring-shaped light source 21 arranged about a measurement optical axis L 1 . The projecting optical system 20 is used for measuring a shape (e.g., a curvature, an astigmatic axis angle and the like in a direction of a strong principal meridian and a direction of a weak principal meridian) of the cornea Ec by projecting a ring index R 2 onto the cornea Ec. Herein, examples of the light source 21 include an LED (Light Emitting Diode) that emits visible light or infrared light, and the like. Preferably, the light source of the projecting optical system 20 is at least three or more point light sources arranged on a single circumference about the optical axis L 1 . In other words, this light source may be an intermittent (discontinuous) ring-shaped light source. Furthermore, the projecting optical system 20 may be an optical system for projecting a plurality of ring indexes.
The illuminating optical system 80 includes a plurality (four in this embodiment) of green light sources (e.g., LEDs that emit green light) 81 arranged outside the light source 21 about the optical axis L 1 . The light source 81 illuminates the anterior segment with green light, and is used for capturing an anterior segment image (see FIG. 2B ) containing a blue or purple mark M.
The mark M is placed with ink on a white portion of the examinee's eye E in order to carry out operations for injection of an intraocular lens for astigmatism correction (a TORIC-IOL). This mark M corresponds to a first mark (a reference mark) which is placed on the examinee's eye E in a direction of a horizontal axis. As the light source 81 , for example, there is used a green light source that emits green light which has a center wavelength of 525 nm and falls within a wavelength range from 500 nm to 550 nm. However, the light source 81 is not limited to such a green light source. For example, the light source 81 may be a white light source. In such a case, a filter having a characteristic of allowing only green light to transmit therethrough may be provided forward the light source 81 .
The projecting optical system 50 includes an infrared light source 51 (e.g., an LED that emits infrared light having a center wavelength of 970 nm) arranged inside the light source 21 about the optical axis L 1 . The light source 51 is used for projecting an alignment index onto the cornea Ec. The alignment index projected on the cornea Ec is used for alignment (positioning) of the apparatus with respect to the examinee's eye E. In this embodiment, the projecting optical system 50 is an optical system for projecting a ring index R 1 onto the cornea Ec. Moreover, the projecting optical system 50 (the light source 51 ) also serves as an illuminating optical system (a light source) for illuminating the anterior segment with infrared light in an oblique direction.
The imaging optical system 30 is used for capturing the front image of the anterior segment. The imaging optical system 30 includes a dichroic mirror (a beam splitter) 33 , an objective lens 47 , a total reflection mirror 62 , a filter 34 , an imaging lens 37 and a two-dimensional imaging device (a light receiving device) 35 .
Each of the reflected light from the anterior segment based on the light from the projecting optical system 20 (the light source 21 ), the reflected light from the anterior segment based on the light from the illuminating optical system 80 (the light source 81 ) and the reflected light from the anterior segment based on the light from the projecting optical system 50 (the light source 51 ) is reflected by the dichroic mirror 33 , transmits through the objective lens 47 , is reflected by the total reflection mirror 62 , and transmits through the filter 34 . Based on each reflected light, an image is formed on the imaging device 35 through the imaging lens 37 . In other words, the imaging device 35 has a sensitivity range from visible light to infrared light.
The imaging optical system 30 captures an image of the anterior segment by use of the light emitted from the light source 21 . Thus, the imaging optical system 30 can capture an anterior segment image A that contains the ring index R 2 (i.e., a cornea reflection image) formed on the cornea Ec. In the case where the mark M is placed on the examinee's eye E, moreover, the imaging optical system 30 captures an image of the anterior segment by use of the light emitted from the light source 81 . Thus, the imaging optical system 30 can capture an anterior segment image A that contains the mark M.
The filter 34 is used for allowing the visible light or infrared light from the light source 21 , the green light from the light source 81 , and the infrared light from the light source 51 to transmit therethrough, but blocking light other than the light mentioned above.
The measuring optical system 60 includes a measuring optical unit 61 and a dichroic mirror 45 . The measuring optical unit 61 has such a configuration as to project infrared measurement light onto the examinee's eye E and receive the reflected light from the examinee's eye E. The dichroic mirror 45 has a characteristic of allowing infrared light to transmit therethrough, but reflecting visible light.
Examples of the measuring optical system 60 may include an axial length measuring optical system (e.g., a center wavelength of a measurement light source is 830 nm) for measuring an axial length by receiving interference light of infrared measurement light, which is projected onto and then reflected from a fundus, with infrared reference light, an eye refractive power measuring optical system (e.g., a center wavelength of a measurement light source is 870 nm) for measuring an eye refractive power by receiving infrared measurement light which is projected onto and then reflected from a fundus, and the like.
The projecting optical system 40 that includes a visible light source is arranged in a direction of reflection by the dichroic mirror 45 .
The following description is given about the control system. A calculation control part 70 performs various operations, e.g., controls the entire apparatus, and calculates a result of measurement. The light source 21 , the light source 81 , the light source 51 , the imaging device 35 , the measuring optical unit 61 , the fixation index projecting optical system 40 , a monitor (a display) 71 , a memory 75 and the like are connected to the calculation control part 70 . An output signal (a signal of an anterior segment image) from the imaging device 35 is input to the calculation control part 70 , and then is subjected to image processing. An image obtained by this processing is displayed as an anterior segment image on the monitor 71 . Moreover, the calculation control part 70 detects an alignment status of the apparatus with respect to the examinee's eye E, based on a result of image processing for an output signal (a signal of an alignment index) from the imaging device 35 .
The following description is given about operations of the apparatus configured as described above. FIGS. 2A and 2B each illustrate an observation screen on which an anterior segment image captured by the imaging device 35 is displayed. Upon alignment, the light source 21 and the light source 51 each emit light. As illustrated in FIG. 2A , the examiner conducts alignment of the apparatus in an up-to-down direction and a left-to-right direction with respect to the examinee's eye E such that an electrically displayed reticle LT is aligned concentrically with the ring index R 1 from the light source 51 . Moreover, the examiner conducts alignment of the apparatus in a forward-to-backward direction (a working distance direction) with respect to the examinee's eye E such that the ring index R 1 is brought into focus (i.e., the ring index R 1 is displayed clearly).
Subsequent to the alignment described above, a predetermined trigger signal is generated. Then, the calculation control part 70 causes the light source 81 to emit light, and causes the imaging device 35 to capture an anterior segment image. Based on an output signal from the imaging device 35 (i.e., a signal of the anterior segment image), the calculation control part 70 acquires, as a still image, an anterior segment image that contains the ring index R 1 , the ring index R 2 and the mark M, and stores the still image in the memory 75 (see FIG. 2B ). In FIG. 2B , four bright spots G each represent a cornea reflection image based on the light from the light source 81 . Herein, the operation of measuring the cornea shape and the operation of taking the image of the mark M are conducted simultaneously. However, these operations may be conducted at different timings, respectively.
Next, the calculation control part 70 determines the cornea shape, based on the ring index R 2 in the anterior segment image stored in the memory 75 , and stores the result of determination in the memory 75 . In a case of a corneal astigmatism eye, such a ring index R 2 has an oval shape. With regard to this ring index R 2 , therefore, the calculation control part 70 detects a direction of a longer diameter and a direction of a shorter diameter to determine an angle of an astigmatic axis. Herein, the cornea shape may be determined based on the ring index R 1 in addition to the ring index R 2 .
Moreover, the calculation control part 70 detects a position of the mark M in the anterior segment image stored in the memory 75 , and stores the result of detection in the memory 75 . More specifically, the calculation control part 70 detects a position of a ring-shaped boundary between an iris and a white portion in an eye, based on image processing, and then determines luminance distribution at a position located outward by a predetermined amount with respect to the boundary (see a dotted line T in FIG. 2B ). As illustrated in FIG. 3 , then, the calculation control part 70 detects a portion, where a luminance level is lowered maximumly with respect to a luminance level Ma, in the white portion of the eye, (a luminance level Mi) from the luminance distribution, and specifies the position C of the mark M, based on the result of detection. Thus, the calculation control part 70 detects positions of two marks M which are symmetrical with each other with respect to a center of a pupil (or a center of the cornea).
FIG. 4 illustrates anterior segment image data for use in injection of the intraocular lens for astigmatism correction into the examinee's eye E. The calculation control part 70 prepares the anterior segment image data illustrated in FIG. 4 , based on the results of measurement and the results of detection, and then displays the data on the monitor 71 .
In FIG. 4 , a line K 1 and a line B 1 are each displayed electrically in such a manner that the anterior segment image stored in the memory 75 is subjected to image processing. The line K 1 is a mark indicating the direction of the astigmatic axis of the cornea with respect to the mark M. The line B 1 is a mark indicating a reference axis for conducting marking in the direction of the astigmatic axis, and corresponds to the mark M. That is, the line B 1 passes the two marks M.
Herein, the calculation control part 70 determines an angle of the line K 1 , based on the angle of the astigmatic axis calculated as described above. Then, the calculation control part 70 displays the line K 1 combinedly on the anterior segment image such that the line K 1 passes the center of the ring index R 2 in the anterior segment image. Based on the positions of the two marks M detected as described above, moreover, the calculation control part 70 displays the line B 1 , which connects between the two marks M, combinedly on the anterior segment image.
Based on the result of calculation of the angle of the astigmatic axis and the result of detection of the mark M, further, the calculation control part 70 calculates an angle between the mark M (the line B 1 ) and the direction of the astigmatic axis (the line K 1 ). The result of calculation may be displayed combinedly as an angle RE on the anterior segment image (see FIG. 4 ).
The calculation control part 70 stores the anterior segment image data prepared by the image processing in the memory 75 . The calculation control part 70 causes the monitor 71 to display the anterior segment image data. In addition, the calculation control part 70 causes a printer to output the data as printed matter. The anterior segment image data (the output data) illustrated in FIG. 4 is used for placing a second mark (an astigmatic axis mark) on a position of the eye corresponding to the astigmatic axis of the cornea.
Based on the anterior segment image data illustrated in FIG. 4 , the operator can ascertain the direction of the astigmatic axis relative to the first mark M indicating the reference axis. Therefore, the operator can place the second mark corresponding to the direction of the astigmatic axis on an appropriate position on the cornea. Thus, the operator can easily inject the TORIC-IOL into an appropriate position of the patient's eye.
According to the configuration described above, the anterior segment image containing the mark M is captured using the light from the green light source 81 , so that a contrast between the anterior segment image (e.g., the anterior segment image illustrated in FIG. 2A ) and the mark M becomes clear in the anterior segment image data illustrated in FIG. 4 . Thus, the operator can visually identify the mark M with ease. The reason therefor is as follows. That is, the mark M is placed with blue ink or purple ink in general, and the green light which is emitted from the light source 81 is not reflected because of the ink since the green light does not interfere with blue light or purple light in view of the principle of three primary colors (red, blue, green). Thus, a contrast between the mark M and the white portion of the eye becomes more remarkable. Herein, purple is a mixed color of red with blue. The present inventors have conducted experiments using different colors other than green. As the results of experiments, the present inventors have found out that in the case of using blue light, the blue mark M becomes poor in visibility whereas in the case of using red light, the purple mark M becomes poor in visibility.
In the foregoing description, the illuminating optical system 80 illuminates the anterior segment with the green light. However, the configuration of the illuminating optical system 80 is not limited to that described above. For example, the illuminating optical system 80 may be configured to illuminate the anterior segment with light which falls within such a wavelength range as to hardly interfere with the color of ink to be used for the mark M (e.g., light having a center wavelength in a range from 500 nm to 600 nm). In other words, the illuminating optical system 80 may illuminate the anterior segment with light having a wavelength characteristic of satisfying a complementary relation with the color of ink to be used for the mark M. Preferably, the light source to be used herein is excellent in monochromaticity.
In the foregoing embodiment, the illuminating optical system 80 adopts one type light source in order to take an image of the mark M. However, the configuration of the illuminating optical system 80 is not limited to that described above. For example, the illuminating optical system 80 may include at least two type light sources which are different in center wavelength from each other, and switches between the light sources in accordance with the color of the mark M in order to prevent light emitted from the light source from interfering with the color of the mark M.
Further, the configuration of the illuminating optical system 80 and the configuration of the imaging optical system 30 are not limited to those described above as long as the imaging device 35 receives light which is reflected from the anterior segment and has a wavelength characteristic of satisfying a complementary relation with the color of the mark M. For example, the illuminating optical system 80 may include a white light source. Further, a filter that allows green light and infrared light to transmit therethrough, but absorbs light other than the green light and infrared light may be arranged on an optical path of the imaging optical system 30 .
In the foregoing description, moreover, the result of detection (i.e., the angle RE between the mark M (the line B 1 ) and the direction of the astigmatic axis (the line K 1 )) is output. However, the present invention is not limited to this configuration as long as angle information for determining the angle between the mark M and the direction of the astigmatic axis is displayed together with the anterior segment image. For example, an angle scale (e.g., a protractor) for determining an angle between the mark M (the line B 1 ) and the line K 1 may be displayed combinedly with the anterior segment image. In such a case, preferably, scales are drawn with the position of the mark M being defined as 0 degree.
Moreover, the configuration of the calculation control part 70 is not limited to that described above. For example, the calculation control part 70 may rotate the line K 1 displayed on the screen of the monitor 71 , based on an operating signal from a predetermined switch which is actuated manually by the examiner. In such a case, the calculation control part 70 may measure a rotation angle of the line K 1 which matches with the mark M. Alternatively, the calculation control part 70 may rotate the line B 1 displayed on the screen of the monitor 71 and may measure a rotation angle of the line B 1 .
FIG. 5 illustrates an example of a wavelength characteristic of a filter 34 . The filter 34 is subjected to coating to allow the green light (500 nm to 550 nm) from the light source 81 and the infrared light from the light sources 21 and 51 to transmit therethrough.
Herein, the green light range is set to be considerably smaller in transmittancy than the infrared light range in order to deal with variations in sensitivity characteristics among imaging devices 35 which are usable herein and to intercept (cut) visible disturbance light (e.g., light from a fluorescent lamp). Preferably, an output from, i.e., a luminance of the light source 81 is large since the transmittancy in the green light range is small.
In place of the filter 34 , a filter 34 G for taking an image of the mark M and a filter 34 R for taking images of the ring indexes R 1 and R 2 may be arranged in a switchable manner (see FIG. 6 ).
While the invention has been illustrated and described in detail, the foregoing description is in all aspects illustrative and not restrictive. It is therefore understood that numerous modifications and variations can be devised without departing from the spirit and scope of the invention.
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A cornea shape measurement apparatus outputs data useful for prescription as well as injection and installation of a TORIC-IOL. This apparatus includes: a projecting optical system projecting an index for measurement onto a cornea; an illuminating optical system illuminating an anterior segment on which a reference mark is placed; an imaging optical system capturing an anterior segment image containing the reference mark and an image of the index reflected from the cornea; an image processor overlaying an astigmatic axis mark indicating a direction of an astigmatic axis of the cornea, which is calculated based on the index image, on the anterior segment image; and a controller displaying the anterior segment image, which contains the astigmatic axis mark, on a display.
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This is a division of application Ser. No. 432,742, filed Jan. 11, 1974, now U.S. Pat. No. 3,948,149.
BACKGROUND OF THE INVENTION
The present invention relates generally to a piston machine, and more particularly to a piston machine wherein a piston is connected with a piston-reciprocating element by a glide shoe articulated to the piston and in gliding contact with a glide surface of the piston-reciprocating element.
Piston machines are known of the type having a housing, a reciprocable piston in the housing, and provided with an axial end portion, and a piston-reciprocating element having a glide surface located opposite to and movable with reference to the end portion of the piston for effecting reciprocation of the latter. It is also known to provide a glide shoe which is connected with the axial end portion of the piston and has a glide face which is in gliding contact with the glide surface of the piston-reciprocating element. Such arrangements are known both in axial piston machines and in radial piston machines, the present invention being particularly concerned with the latter type. Such a radial piston machine is disclosed e.g. in the U.S. Pat. No. 3,663,125.
It is known to construct the glide shoe with an annular recess in its glide face, the recess being surrounded by a relatively broad sealing rim, and the glide face being further provided on its corners with approximately triangular supporting face portions. This prior-art construction assures, due to the presence of the broad sealing rim, that there will be low leakage losses of fluid and that the glide face will be relatively resistant to wear. However, this construction has the disadvantage that the hydrostatic relief of the glide shoe is relatively poor because the supporting face portions are too small to allow the development of significant hydrodynamic pressure fields between themselves and the juxtaposed glide surface of the piston-reciprocating element. This means that this type of glide shoe is not useable for radial piston machines which are operated at high pressures or at high speeds of revolution.
SUMMARY OF THE INVENTION
Accordingly, it is a general object of the present invention to overcome the disadvantages of the prior art.
More particularly, it is an object of the present invention to provide, in a piston machine of the type under discussion, an improved glide shoe which is relieved both hydrostatically and hydrodynamically, and which is therefore particularly well suited for piston machines operating at high rotary speeds or at high pressures.
In keeping with the above objects, and with others which will become apparent hereafter, one feature of the invention resides in a piston machine of the type having a housing, a reciprocable piston in the housing and having an axial end portion, and a piston-reciprocating element having a glide surface located opposite and movable with reference to the end portion for effecting the reciprocation of the piston, in a combination which comprises a glide shoe articulately connected to the end portion of the piston and having a glide face in gliding contact with the glide surface. The glide face has a recess which communicates via a passage with a source of pressure fluid, a sealing rim of substantially constant width surrounding the recess, and a plurality of face portions which are located outwardly of the sealing rim and are configurated so that hydrodynamic pressure fields develop between the face portions and the respectively juxtaposed surface portions of the glide surface.
The supporting capability of the hydrodynamic pressure fields depends upon the rotary speed of the machine, so that if the speed of rotation varies, an excellent accommodation is obtained to the forces which are to be absorbed by the glide shoe and which vary with the variations in the speed of rotation.
It is particularly advantageous if the recess is in form of a rectangle the longitudinal sides of which extend normal to the direction of relative movement between glide shoe and piston-reciprocating element, and if it is located between two grooves which extend transverse to the direction of movement and intersect the edges of the glide face which extend in the direction of relative movement. With such a construction rectangular glide face portions are provided at the opposite ends of the glide face which have longitudinal sides that extend transversely to the direction of movement. In such a construction the bending stress upon the glide face is low because the hydrodynamic pressure field extends transversely to the elongation of the glide face.
The novel features which are considered as characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a fragmentary axial section through a piston, glide shoe and piston-reciprocating element in a machine of the type according to the present invention;
FIG. 2 is a bottom plan view of the glide face on the shoe in FIG. 1, as seen from the line II--II; and
FIGS. 3-14 are all views similar to FIG. 2 but illustrating further embodiments of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Discussing firstly the embodiment in FIGS. 1 and 2, it will be seen that reference numeral 1 identifies a glide shoe having a shaft 2 which is provided with a spherical head 3. The latter is received in a spherical socket 4 formed in a stepped bore 6 which extends axially through a piston 5. The invention is being described with reference to a rotary piston machine, such machines being already well known to those skilled in the art. The piston 5 is reciprocably accommodated in a bore 7 formed in a cylinder body 8. A spring ring or circlip 9 is provided to maintain the glide shoe 1 on the piston 5 as shown.
A cylindrical portion 10 of the stepped bore 6 is located above or inwardly of the head 3 and accommodates a valve plate 11 which can close a throttling gap 12 forming a part of the bore 6, with which throttling gap 12 the valve plate 11 forms a non-return valve.
The glide shoe 1 has a glide face 13 which is in gliding contact with a glide surface 14 of a piston-reciprocating element 15 of the radial piston machine, that is an element which resembles in its function the swash plate of an axial piston machine. The element 15 is accommodated in the interior of the housing that is not illustrated because it is well known in the art.
FIG. 2 shows details of the configuration of the glide face 13. It will be seen that the latter is provided with a circular recess 16 into which a bore 17 opens which is formed in the shaft 2, so that pressure fluid can enter the recess 16 through the bore 17 from the cylinder bore 7. The bore 17 communicates with the cylindrical portion 10 of the stepped bore 6, and from there it communicates with the cylinder bore 7 via the throttling gap 12. The recess 16 is surrounded by an annular sealing ring 18, the outer diameter of which corresponds to the transverse width of the glide face 13. The term transverse width refers to the dimension of the glide face 13 in direction normal to the relative movement between the shoe 1 and the element 15, which relative movement is identified with the double-headed arrow A in FIG. 2. It is appropriate at this point to state that the same direction of movement is identified in the remaining Figures by the double-headed arrow A if the direction of movement between glide shoe 1 and element 15 can be reversed, whereas a single-headed arrow B is used if the movement between glide shoe 1 and element 15 can be in only one direction. By the same token, the longitudinal direction of the glide shoe 1 refers of course to the dimension of the glide shoe 1 in the direction of the arrows A or B in all Figures.
The sealing rim 18, which is of substantially constant width, is surrounded by an annular groove 19 which is evidently of larger diameter than the rim 18 and which thus intersects the longitudinally extending edges 13a of the glide face 13. At the opposite ends of the glide face 13 as seen with respect to the direction of movement A, there are provided glide surface portions 20, 21 which extend over the entire transverse width of the surface 13 and in longitudinal direction of the glide surface 13 are delimited by respective opposite ends of the glide surface on the one hand, and the grooves 19 on the other hand.
The forces exerted by the piston 5 upon the glide shoe 1 are compensated for by the hydrostatic pressure field which develops as the result of the inflow of pressure medium through the bore 17 in and above the recess 16, that is between the recess 16 and the corresponding portion of the glide surface 14 of the element 15, and also by the hydrodynamic pressure fields which develop during the movement of the glide shoe between the glide surface portions 20, 21 and the respectively juxtaposed portions of the surface 14. The provision of the groove 19 assures an exact positioning of the hydrodynamic pressure field which develops in the recess 16, and the symmetrical arrangement of the glide face portions 20, 21 makes this particular glide shoe 1 suitable for movement in two opposite directions, as indicated by the double-headed arrow A.
The provision of the valve 11, 12 assures that pressure medium can flow into the recess 16, but prevents the flow of pressure medium from the interior of the housing via the recess 16 and the bore 17 into the cylinder bore 7 in the event that the pressure in the hydrodynamic pressure field opposite the face portion 20 or 21 is greater than the pressure in the cylinder bore 7. The groove 19 operates in the same sense, because pressure medium which during relative movement of the surfaces 13 and 14 is drawn into the gap between the surface 14 and the face portions 20 and 21, is largely guided back into the interior of the housing along the longitudinal edges 13a where it escapes from the groove 19.
This particular glide surface with its various recesses and face portions can be produced very readily, for instance by milling, casting or flow-molding, and the fact that the recess 16 is circular reduces the susceptibility of the face 13 to interference from accumulating contaminants.
In FIG. 3 we have shown a glide face 23. In this Figure, as in FIGS. 4-14, it should be understood that the basic construction corresponds to that shown in FIG. 1, except that the glide surface in each instance differs from that in FIGS. 1 and 2.
The glide face 23 in FIG. 3, wherein like reference numerals identify like components as before, is provided at the opposite ends with surface portions 24, 25, having the form of respective rectangles the longitudinal sides of which extend normal to the direction of movement A. In other respects the embodiment of FIG. 3 corresponds to that of FIG. 2, and in operation it will also behave approximately in the same manner as that of FIG. 2.
FIG. 4 shows an embodiment wherein the glide face 27 is provided with two grooves 28, 29 extending normal to the direction A and being arranged symmetrically with respect to the center of the glide face. They delimit glide face portions 30, 31 located at the opposite ends of the glide face 27 and being of rectangular outline, the longitudinal side of the respective rectangle extending transverse to the direction A. A rectangular recess 32 is here provided instead of the circular recess 16 of FIGS. 2 and 3, and is surrounded by a similarly rectangular sealing rim 33 of approximately constant width. The inner corners of the recess 32 are rounded, and the elongation of the rectangle formed by the recess 32 extends transversely to the direction A.
In this embodiment, the forces acting upon the glide shoe having the glide face 27, are absorbed by the hydrostatic pressure field which develops in the recess 32, and the hydrodynamic pressure fields which develop during the relative movement of glide shoe and element 15 between the glide face portions 30, 31 and corresponding surface portions of the glide surface 14. The grooves 28 and 29 delimit the hydrodynamic pressure fields which develop opposite the face portions 30, 31 and at the same time prevent pressure fluid from being dragged during gliding movement into the region of the recess 32, a feature which is important because it would adversely influence the precalculated relationship of forces which act upon the glide face 27. The rounding of the corners of the recess 32 reduces the danger that groove might be worn in the glide face 27 due to the presence of contaminants which otherwise would be deposited in those corners. The symmetrical arrangement of the face portions 30, 31 makes the glide shoe suitable again for movements in two opposite directions, as indicated by the arrow A. Because the hydrodynamic pressure field in the recess 32 extends transversely to the elongation of the glide face 27, the bending stresses acting upon the glide shoe having the face 27 are reduced.
FIG. 5 shows an embodiment wherein the glide face identified with reference numeral 35 is provided with a recess 36 of approximately oval configuration. The longitudinal sides of this recess extend transversely to the direction of the arrow A and are connected by semi-circles having the radius R. In other respects the embodiment of FIG. 5 corresponds to that of FIG. 4 and the same reference numerals are used to designate like elements. The oval configuration of the recess 36 makes the glide face 35 particularly resistant to the formation of grooves due to the presence of contaminants. In operation and in characteristics the embodiment of FIG. 5 corresponds to that of FIG. 4.
FIG. 6 shows an embodiment wherein the glide face 38 is intended for only movement in one direction, namely the direction indicated by the arrow B. Hence, the left-hand transverse edge of the glide face 38 is the leading edge, and the right-hand transverse edge is the trailing edge. In the region of the leading edge, the glide face 38 is subdivided by a longitudinally extending groove 39 into two face portions 40, 41, whereas in the region of the trailing edge, the face 38 is again subdivided by a longitudinally extending groove 42 into two face portions 43, 44. However, the groove 42 is substantially wider in transverse direction than the groove 39, so that the face portions 43, 44 are substantially narrower than the face portions 40, 41. The face portions 40, 41, 43 and 44 are all rectangles, the longitudinal sides of which, that is the major dimension of which, extends in the direction of the arrow B. In other respects, the embodiment of FIG. 6 corresponds to the embodiment of FIG. 5, and the recess being oval, and the grooves 28 and 29 being provided as in FIG. 5, with these grooves communicating with the recesses or grooves 39 and 42, respectively.
Because the hydrodynamically effective face portions 40, 41 at the leading edge region of the face 38 are larger than the face portions 43, 44, the relief is greater at the leading end region and the region of the narrowest gap between the glide face 38 and the glide surface 14 moves towards the rear or trailing edge, so that the glide shoe will lift off the glide surface 14 more strongly in the region of its leading edge with the result that the hydrodynamic supporting force and thereby the relief effect will be further improved.
The construction of FIGS. 2-4 can be modified analogously to the embodiment of FIG. 6, in that the glide surfaces 20, 21, 24, 25 and 30, 31 are subdivided by grooves corresponding to the grooves 39, 42 of FIG. 6. In that case the effect would be approximately the same as in the embodiment of FIG. 6.
FIG. 7 shows a glide face 46 wherein the recess located at the center of the glide face is approximately quadratic and is identified with reference numeral 17. Separated from the recess 47 by surface portions 48, 49 which are substantially strip-shaped and form a part of the sealing rim, there are provided rectangular recesses 50, 51 each of which extends from one of the ends (the leading end and the trailing end, respectively) to the respective surface portions 48, 49. The major dimension of each of the recesses 50, 51 extends transversely to the direction of movement A and their lengths corresponds to the length in the same direction of the recess 47. The recesses 5, 51 are each open over their entire length to the leading and trailing end, respectively, so that they communicate with the interior of the housing which was mentioned earlier. The corners of the recesses 47, 50 and 51 are rounded for the reasons which have been previously discussed, and the longitudinal edges of the glide face 46, that is the edges which extend parallel to the direction A, are formed with surface portions 52, 53, which are strip-shaped and extend over the entire length of the glide face 46, in part constituting the rim surrounding the recess 47, in conjunction with the surface portions 48 and 49. The width of the surface portions 52, 53 is substantially constant.
In this embodiment, the recesses 50, 51 reduce the dimensions of the glide face portions so that, while sufficient hydrodynamic supporting force is retained, the losses resulting from viscous friction over the respective glide face portions are reduced. The necessary hydrodynamic relief is obtained by the hydrodynamic pressure fields which develop between the surface portions 52, 53 and the corresponding surface portions of the surface 14. This configuration is particularly suitable for machines which operate at high rotary speed.
FIG. 8 shows an embodiment which is a modification of the embodiment shown in FIG. 7, like reference numerals again identifying like elements, except that here the face portions 52, 53 are replaced with face portions 52', 53'. The face portions 52', 53' extend at opposite sides of the recess 47' and are each formed with a longitudinal slot 56, 57, respectively, which extend parallel to the adjacent edges of the recess 47' and have the same length as these edges. These slots 56, 57 are in communication with the interior of the housing via respective bores 58, 59.
In this embodiment, the slots 56, 57 serve to provide an exact delimitation of the hydrostatic pressure field which develops in the recess 47', that is a delimitation along the sides of the recess 47' which are adjacent the slots 56, and 57. In other respects, this embodiment corresponds to the embodiment of FIG. 7.
FIG. 9 shows a glide face 61 wherein the longitudinal edges extending in the direction of movement are formed with surface portions 62, 63 which are strip-shaped and extend over the entire length of the glide face 61. Intermediate the surface portion 62, 63 and separated from the same by respective longitudinally extending grooves 64, 65, is provided a rectangular sealing rim 67 which surrounds a rectangular recess 66. The inner corners of the recess 66 are rounded for the reasons discussed earlier, and the length of the recess 66 in parallelism with the surface portion 62, 63 is substantially shorter than the length of the surface portions 62, 63. At the opposite ends of the glide face 61, intermediate these ends and the rim 67, there are formed recesses 68, 69 which communicate with the grooves 64, 65 and also with the interior of the housing.
The grooves 64, 65 delimit the hydrostatic pressure field in the recess 67 along the surface portions 62, 63. Hydrodynamic pressure fields develop over the surface portions 62, 63, and the surface area of these surface portions is so selected that the viscous friction losses are small, but that on the other hand, the desired relief of the glide shoe is obtained.
FIG. 10 shows an embodiment which is somewhat reminiscent of FIG. 9 and is intended for direction of movement in direction of B only. The glide surface is here identified with reference numeral 71 and the leading edge 72 of the glide face 71 is provided with glide face portions 73, 74 which merge into strip-shaped surface portions 75, 76. The face portions 73, 74 are separated from one another by a groove 77 extending in direction of the arrow B, and they are separated from the sealing rim 67 surrounding the recess 66 by a transverse groove 78 which merges with the groove 77 as well as with the grooves 64 and 65, that have been described with reference to FIG. 9.
In this embodiment, the glide face portions 73, 74 cause an increase of the hydrodynamic pressure field in the region of the leading end 72, so that in this region the glide shoe will be lifted off the surface 14 more strongly, thus obtaining an improvement in the hydrodynamic relief of the glide shoe. This makes the glide shoe particularly suitable for machines which operate at high rotary speeds and at high pressures.
The embodiments of FIGS. 7 and 8 could be modified analogously to the embodiment of FIG. 10, in which case the effect in these embodiments would be the same as that obtained in FIG. 10.
FIG. 11 shows a glide face 80 which is formed by three parallel recesses 83, 84 and 85 which are each of rectangular configuration. They are located one behind the other with respect to the direction of movement A and their major dimension extends transversely to this direction of movement. The length of the major dimension of each of the recesses 83, 84 and 85 is identical and the corners of the recesses are all rounded. In the direction A the size of the center recess 84 is substantially greater than that of the recesses 83, 85, the latter being connected by relief bores 86, 87, with the interior of the housing. Substantially strip-shaped surface portions 88, 89 extend along the longitudinal edges of the glide face 80 in parallelism with the direction A, and over the entire length of the glide face 80. Portions of these surface portions 88, 89 form, together with transversely extending portions 81 and 82, the sealing rim which surrounds the recess 84. The recesses 83 and 85 are separated from the leading and trailing ends (the definition of these ends is interchangeable, depending on the direction of movement) by strip-shaped face portions 90, 91, respectively.
The arrangement of the recesses 83, 85 reduces the glide face portions and thereby the friction. Hydrodynamic pressure fields for relief of the glide shoe can develop over the face portions 88, 89 and this makes this glide shoe particularly suitable for machines which operate at high revolutions. The hydrodynamic relief of the glide shoe results from the pressure field which develops in the recess 84.
FIG. 12 shows an embodiment wherein the glide face 93 is provided at its center with a rectangular recess 94 the longitudinal sides of which extend in parallelism with the direction of movement indicated by the arrow B. The corners are again rounded. At the leading end of the glide face 93 the latter is provided with glide face portion 95 of rectangular outline, the major dimension of which extends transverse to the direction B. The glide face portion 95 is provided with a slot-shaped groove or recess 97 which communicates via a relief bore 96 with the interior of the housing, and is separated from the recess 94 by a face portion 98. The length of the groove 97 corresponds to the dimension of the recess 94 in direction normal to the direction B. In the region of the trailing end, the glide face 93 is provided with a recess 100 which is separated from the recess 94 by a sealing portion 99. The recess 100 is rectangular and has a major dimension transversely to the direction B, being open over this entire major dimension to the interior of the housing in that it intersects the trailing end 101. Face portions 102 and 103 merge with the face portion 95.
This embodiment is particularly suitable for glide shoes used in machines with a uniform direction of rotation, as indicated by the arrow B. The glide face 95 causes the development of the hydrodynamic pressure field which relieves the glide shoe, and the groove 97 prevents the pressure fluid from being dragged out of this hydrodynamic pressure field into the recess 94, because this would disadvantageously influence the pressure distribution and the force relationships acting on the glide shoe. The recess 100 supplements and increases the effect of the glide face portion 95, in a sense assuring that particular hydrodynamic relief becomes available at the leading end for the glide shoe. Furthermore, the provision of the recess 100 in the region where the gap between the glide face 93 and the glide surface 14 is narrowest, causes a reduction in the viscous friction.
The glide face 105 in the embodiment of FIG. 13 is formed with a centered recess 106 having the form of a trapezoid the large side of which, as seen in the direction of movement indicated by the arrow B, is the trailing side. The length of the recess 106 is substantially smaller than the length of the glide face 105, and the recess is surrounded by a sealing rim 107 which is separated by grooves 108, 109 from glide face portions 110, 111 which extend in the direction indicated by the arrow B along the longitudinal edges of the glide face. These face portions 110, 111 extend over the entire length of the glide face 105 and each have the form of a trapezoid the larger side of which, as seen in the direction of the arrow B, is located at the leading end of the glide face. This construction is provided with the recesses 112 and 113, which communicate with the interior of the housing.
The hydrostatic pressure field which develops in the recess 106 compensates for a part of the forces which act on the glide shoe. The configuration of the face portions 110, 111 assures that at the leading ends (the left-hand ends in FIG. 13) thereof, they develop two hydrodynamic pressure fields which further relieve the glide shoe so that the latter is particularly suitable for a machine wherein the direction of rotation is unchanging and wherein the machine operates at high revolutions, because the glide face portions and therefore the frictional losses are relatively small.
Coming, finally to the embodiment illustrated in FIG. 14, it will be seen that the glide face 115 illustrated therein is provided with a centered recess 116 of trapezoidal configuration. The large side of the trapezoid, as seen with reference to the direction indicated by the arrow B, is the trailing side. The recess 116 is surrounded by a sealing rim 117 which is separated by grooves 118, 119 from glide face portions 120, 121 which each are substantially of triangular configuration, but the base of each triangle being located at the leading end 122 of the glide face 115. At the trailing end of the glide face there are provided two rectangular glide face portions 123, 124 which act as supporting faces and which are separated from the sealing rim 117 by two transversely extending grooves 125, 126, respectively. The major dimension of the face portions 123, 124 extend parallel to the direction indicated by the narrow B. The length of the recess 116 is substantially less than the overall length of the glide face 115, so that a recess 128 is located between the rim 117 and the trailing end of the glide face and a similar recess 127 is located between the rim 117 and the leading end 122 of the glide face 115. The recesses 127, 128 each are open to and communicate with the housing.
In this embodiment a hydrostatic pressure field develops in the recess 116 and partially relieves the forces acting upon the glide shoe. Further, hydrodynamic pressure fields develop over the face portions 120, 121 and further relieve the forces acting upon the glide shoe. Because of the small length of the face portions 123, 124 only insignificant hydrodynamic pressure fields can develop over these face portions, which means that the glide shoe is more strongly relieved at the region of its leading edge 122. Grooves 118, 119 prevent pressure fluid from being pulled or dragged into the recess 118 during the movement of the glide shoe and out of the hydrodyanmic pressure fields which develop over the face portions 120, 121, so that an undesired interference with the pre-computed force relationships is avoided.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the types described above.
While the invention has been illustrated and described as embodied in a glide shoe for a radial piston machine, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention and, therefore, such adaptations should and are intended to be comprehended within the meaning and range of equivalence of the following claims.
What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims.
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In a piston machine of the type having a housing, a reciprocable piston in the housing and provided with an axial end portion and a piston-reciprocating element having a glide surface located opposite and movable with reference to the end portion for effecting the reciprocation of the piston, the invention provides for a glide shoe which is articulately connected to the end portion of the piston and which has a glide face in gliding contact with the glide surface of the piston-reciprocating element. The glide face has a recess which communicates via a passage with a source of pressure fluid, a sealing rim of substantially constant width surrounding the recess, and a plurality of face portions which are located outwardly of the sealing rim and configurated so that hydrodynamic pressure fields develop between the face portions and the respectively juxtaposed surface portions of the glide surface.
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TECHNICAL FIELD
[0001] This invention relates to pre-manufactured concrete building structures, and more particularly, to building structures which can be attached to and removed from existing structures for repeated use.
BACKGROUND
[0002] For background, reference is made to U.S. Pat. Nos. 4,171,596, 4,275,533, 4,573,292, 4,745,719, 5,265,384, 5,727,353, 5,845,441, and 6,330,771.
SUMMARY
[0003] There is a need to provide portable structures to function as school classrooms, office spaces, and/or apartments in a economical and expeditious way. Readily adaptable and configurable building facilities are required to meet the rapidly changing requirements for facilities such as school classrooms. Structures according to the invention are formed from pre-manufactured modules which can be joined in many configurations for serving temporary or long term building needs.
[0004] Structures according to the invention can be readily attached to an existing building or serve as a standalone structure. In addition, the structure can be used for a number of years after being delivered to the site. If and when the demographics again change and the additional space afforded by the structure is no longer needed, the structure can be detached and moved to a new site for expansion of a new school facility.
[0005] Specifically in school applications, the total lead time from planning through commissioning, to building operation can take more than six years. With typical school expansion projects, an architectural firm will spend substantial efforts to develop and plan structures fitting the classrooms to the particular needs of the school. However, when specifying building modules according to the invention, the time required to plan and build the additional space is minimized. The necessity for numerous site specific shop drawings is also reduced because the specifications of the structure according to the invention are predefined. Through application of structures according to the invention, the delivery time and the costs of construction can be greatly reduced. Architects, engineers and school officials know building dimensions, specifications and costs in advance. Therefore, site specific planning and variability is vastly reduced. The total construction time is reduced because precasting of the building modules can be done concurrent with preparation of the existing school facility and adjacent construction site.
[0006] In one aspect according to the invention, a building structure includes at least one building module for providing a temporary or permanent dwelling space, the module including wall, floor and ceiling members formed from reinforced precast concrete. The members are detachably coupled to one another to form an enclosed space, with adjacent members being spaced apart from each other a predetermined distance. A compliant pad spans this distance and couples adjacent members to accommodate relative movement between the members during transport and once the structure is located on the site.
[0007] In one embodiment, the compliant pad is a synthetic rubber. In another embodiment, the structure includes a concrete form attached to the ceiling to accommodate fixtures, electrical conduit or suspending ceiling materials. The concrete form can include a channeled layer, such as a composite floor deck ceiling system, including EPICORE® (Epic Metals Corporation, Rankin, Pa.), for example. In another embodiment, the members of the structure are further adapted to detachably engage a second additional building module, comparable to the first module, to form a single larger structure. The modules can be arranged vertically to form a multiple-story building or connected along a horizontal orientation to form a larger single-story structure.
[0008] The structure can also include a conduit extending through the members for accommodating building utilities including at least one of plumbing, electrical, heating, ventilating, and air conditioning. The structure can also be adapted for attachment to an preexisting structure. The structure can also include any of number of exterior facade surfaces, such as brick, stone, stucco, or any combination thereof.
[0009] According to another aspect, of the invention, a portable pre-manufactured building includes a generally parallelepipal structure for releasable attachment to a pre-existing structure having vertical walls, a horizontal floor, and a horizontal ceiling. The walls and ceilings are formed from cast concrete including reinforcing steel rebar and include a connecting layer disposed between the top of the walls and the ceilings. Wall members can also include at least one conduit for uninterrupted passage of utilities.
[0010] In a various embodiments, the connecting substrate is a synthetic rubber, such as neoprene, for example. A channeled layer, such as EPICORE® or equivalent, can be attached to the floor and ceiling members. The members of the structure can be further adapted to detachably engage a second additional structure, comparable to the first structure, to form a single larger structure. The structure can also include a conduit extending through the wall members for accommodating building utilities, including, for example, at least one of plumbing, electrical, heating, ventilating, and air conditioning.
[0011] The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the detailed description, which refers to the following drawings, in which:
DESCRIPTION OF DRAWINGS
[0012] FIG. 1 is a perspective view of a pre-manufactured concrete building module according to the invention;
[0013] FIG. 2 is a perspective view of two of the building modules shown in FIG. 1 , arranged in a vertical configuration;
[0014] FIG. 3 is a floor plan view of a pre-manufactured concrete building module attached to an existing building;
[0015] FIG. 4 is a section view of the building module of FIG. 3 through line A-A;
[0016] FIG. 5 is a floor plan view of the structure of FIG. 1 ;
[0017] FIG. 6 is a cross-section elevation view of the typical wall and foundation construction;
[0018] FIG. 7 is a cross-section elevation view of wall, floor, and foundation construction;
[0019] FIG. 8 is a detail cross-section view of the junction between ceiling and wall members and floor and ceiling members;
[0020] FIG. 9 is another detail cross-section view of the junction between ceiling and wall members and floor and ceiling members;
[0021] FIG. 10 is a detail cross-section view of the junction between floor, ceiling, and wall members which depicts the attachment to the building foundation;
[0022] FIG. 11 is a detail cross-section view of a junction between adjacent floor members and a wall member;
[0023] FIG. 12 is a detail cross-section view of a window installed in a wall member; and
[0024] FIG. 13 is a detail view of an exterior door and an attached folding stair.
[0025] Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
[0026] This invention relates to a system of pre-manufactured concrete modules that can serve as a freestanding school classroom, expand a preexisting school, apartment units, small office of other commercial space. Construction details permit the option of readily adding exterior facades such as brick, stucco, stone or lapboard, for example, to architecturally blend the new structure with the existing structure. Individual modules can be connected horizontally and/or vertically stacked to form multi-story structures. The room sizes may vary as to need and desire so that the rooms can be versatile and the only thing that will be required is that the room sizes can be engineered economically and safely. The modules forming the building structure can be constructed to withstand hurricanes, rainstorms, windstorms, snowstorms, and if geographic conditions warrant, seismic activity.
[0027] For classroom applications, the modules can readily provide additional student capacity when demographic changes require it. The modules can be attached to and integrated with the existing school and not an isolated “portable” style classroom. The modules can be delivered to the construction site and furnished with interior features, desks, chalkboards. The modules can be located to form hallways and bathrooms, for example. In commercial applications, the modules can be arranged in various horizontal and vertical configurations to meet the particular building requirements.
[0028] With reference now to the drawings and more particularly to FIG. 1 , there is shown a concrete building module 20 according to the invention. The module 20 can be pre-manufactured in a factory to desired specification and include all building facilities, such as bathrooms, closets, hallways, interior wall furnishings, and lighting fixtures, for example, and ready for use after placement and installation at the construction site. Alternatively, if practical, the module can be cast onsite. The module 20 is a single story building having a generally rectangular floor plan and is formed from steel reinforced concrete floor member 22 , wall members 24 and roof member 26 . Other floor plan dimensions are contemplated to meet individual building requirements. The floor, wall, and roof member 22 , 24 , 26 can be formed from reinforced concrete slab having a thickness of six inches. In one embodiment, the roof member 26 extends beyond an exterior wall member 24 in one direction to form an overhang 28 . The concrete roof member 26 can be coated with a waterproof layer or membrane, such as a thoroseal material, for example. The roof member 26 can also be flat or pitched along the lateral dimension of the module 20 at a suitable pitch, such as ¼-inch per foot for improved drainage.
[0029] The module 20 can also include preinstalled windows 30 and doors 32 . Cutouts 34 in wall members 24 adjacent the roof members 26 form conduits for continuous piping 36 from one module 20 to another adjacent module, comparable to module 20 , or to a preexisting building. The floor, wall, and roof members 22 , 24 , 26 are cast individually in appropriately sized forms and then joined together as described below. The interior surfaces of the wall members 24 can be covered with drywall or painted plywood. Optional facings 38 can be attached to the exterior surfaces of the wall members 24 , such as brick, stone, stucco, or lapboard for example, to conform the building module 20 to the preexisting building to which it can be attached.
[0030] Referring to FIG. 2 , the modules 20 can be stacked to form the two-story structure 40 as shown. Up to the three modules can be stacked vertically. The modules can also be attached horizontally (not shown), to form a larger, single-story structure. Junctions (discussed below) disposed between adjacent members of the modules 20 connect the first and second modules together. The structure 40 is supported by concrete pilings 42 or concrete footings spaced along the underside of the floor member 22 of the first-story module. Along the mating surfaces between the modules, filler strips 44 consisting of elongate decorative metal or plastic panels, can be attached.
[0031] The structure 40 can serve as a standalone classroom, with interior facilities including blackboards/whiteboards, clocks, closets and cabinetry and desks, for example. As shown in FIGS. 3 and 4 , the structure 40 can function as an addition to an existing school building. Preferably, the structure 40 is attached to the existing school building and integrated into the design of the school. FIG. 3 depicts an aggregation of structures 40 to form a wing 41 extending from an existing building 43 . In this example, the wing 41 includes two sets of two structures 40 a, 40 b, 40 c and 40 d, connected by a hallway section 45 spanning the adjacent units. The wing 41 is attached to the building 43 by vestibules 47 extending therebetween. As shown in FIG. 4 , floor member 49 extends from a first structure 40 a to a second structure 40 c, 40 d. One end of the member 49 bears on notch unit 51 . A roof extension member 53 spans the roof members of structures 40 a and 40 c. In one example, the roof is arcuate and includes a skylight (shown in phantom). Alternatively, the structure 40 is located proximate to the school for ready accessibility. In the classroom application, the structure 40 can also be assembled and installed on site to meet the needs of increased enrollment at a particular school and later, if enrollment drops, detached and reinstalled for use in a different school district. The structure 40 can also serve individually or collectively, as apartment units, office space, or commercial retail space.
[0032] A representative floor plan shown in FIG. 5 , shows exterior dimensions of about 20 by 30 feet. Although the floor plan shown is rectangular, other dimensions, as dictated by the site, the specifications, and the existing structure (if an expansion), are contemplated. The floor member 22 is formed from one or more slabs of reinforced concrete, similar to roof member 26 , with a thickness of six inches. Flat beams 46 extend beneath the floor member 26 to support the module 20 on pilings and/or footings 42 ( FIG. 2 ). Interior spaces such as closets 50 are formed with internal, non-load bearing walls 52 , framed with metal or wood studs, having a thickness of six inches.
[0033] As shown in FIG. 6 , steel rods 52 extend vertically between upper and lower horizontal steel beams 52 , 54 , respectively, for reinforcing the wall member 24 . The module 20 is supported by pilings 42 positioned along the span of floor member 22 and corresponding to the flat beams 46 ( FIG. 5 ). The ceiling height is nominally 9 feet.
[0034] Referring now to FIG. 7 , the floor, wall, and ceiling members 22 , 24 , 26 are joined together along wall-to-roof member junctions 60 , wall-to-single floor member junctions 62 , wall-to-two floor member junctions 64 , a and floor-to-floor junctions 66 . The wall and roof members in junction 60 , the wall and floor members in junction 62 , and the wall and floor members in junction 64 are separated a vertical gap or distance D 1 . This distance is filled by a compliant pad 70 disposed between the concrete members. The pad 70 can be formed from a commercial available synthetic rubber compound, such as neoprene. A sealant 72 is applied along the peripheral edges of the pad 70 to substantially seal the connection against infiltration of weather and debris. Adjacent floor members 22 at junctions 64 and 66 are separated by a horizontal gap of distance D 2 filled with sealant 72 to bridge the gap. The vertical and horizontal gaps defined by D 1 and D 2 , respectively, in junctions 60 , 62 , 64 , and 66 , spanned by pad 70 or filled with sealant 72 , permit relative movement between wall, floor, and roof members during transport and after installed at the site to accommodate building settling, while also mitigated cracking and other damage to concrete members 22 , 24 , and 26 of the structure 40 ( FIG. 2 ).
[0035] FIGS. 8, 9 , and 10 show the junctions 60 , 62 , 64 and 66 in greater detail. Generally the detailed view of a typical joint, depicted in FIG. 11 , shows the ends of adjacent floor members 22 positioned proximate one another and separated by a horizontal gap of distance D 2 filled with sealant 72 . A compliant pad 70 is interposed between the wall member 24 and the two floor members 22 , spanning the vertical distance D 1 . A layer of sealant 72 also extends along the periphery of the compliant pad 70 to substantially seal the connection against infiltration of weather and debris. Reinforcing steel rebar 52 extends vertically through the wall members 24 to strengthen the wall members in tension, as is commonly known in the art. For those areas of steel rebar 52 which are exposed, a layer of anticorrosive paint can be applied to resist oxidation of the rebar. A channeled layer 78 is attached to the lower surface of the floor members 22 . The channeled layer 78 can include metal decking for supporting ceiling fixtures, containing insulation or concealing pipes and ventilation components, for example. A second complaint pad 80 , spanning a vertical distance D 3 , is disposed between the channeled layer 78 and the flat beam 24 .
[0036] The compliant pads 70 , 80 can be made from commercially available synthetic rubbers, such as neoprene, for example. Collectively, pad 70 , extending along the distance D 1 , second pad 80 extending between the layer 78 and the flat beam 24 , and horizontal gap of distance D 2 , filled with sealant 72 , prevent direct contact between the wall and floor members 22 , 24 , which accommodates relative moment therebetween for transport and settling while still maintaining sufficient dimensional stability and rigidity of the structure. Referring to FIG. 10 , the wall section 24 is supported by piling 42 . The flat metal beam 46 is rigidly connected to the concrete pile 42 (or footing) beneath it, by a steel strap 82 , for example.
[0037] FIG. 12 shows a typical window section. A window 100 , bounded by a window frame 102 , is installed within corresponding open of wall member 24 , according to standard, accepted installation techniques. A concrete teat 104 or 1-inch pressure-treated wood beam is positioned along the top of the window 100 . About all sides, the window frame 102 is secured in place with screws fastened to lead shields 106 which are attached to the opening in the wall member 24 . Pressure treated wood trim 108 and window sealant 110 are attached along the outside perimeter of the opening in the wall section 24 along the window 100 . The decorative facade 38 , attached to the exterior surface of the wall member 34 can extend proximate the lowest edge of the window 100 to form a window sill 112 . The sill 112 can be pitched downward away from the window 100 to facilitate drainage of rain water. An interior wall 114 , attached to the inside surface of the wall member 24 , can be ⅝-inch drywall or painted plywood 112 , for example.
[0038] FIG. 13 shows a detailed view of the lower edge of door 32 . The door can be solid wood, fiber glass-composite heavy-gauge, galvanized steel over a core of rigid foam, for example. If the doors 32 open to the outside, an exterior door sill 118 extends from the floor member 22 to engage the lower edge of the door 32 and provide a tight seal. Folding stairs 120 can be attached to the inside of the door 32 for emergency egress from the structure 40 . The stairs 120 can include a rope 122 , attached to the stairs, for extending the stair 120 away from the door 32 .
[0039] A number of embodiments have been described herein. Other embodiments are within the scope of the following claims.
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A pre-manufactured building structure including at least one building module for providing a temporary or permanent dwelling space. The module includes wall, floor and ceiling members formed from precast concrete and configured for detachable engagement to one another to form an enclosed space. Adjacent wall, floor and ceiling members are spaced apart from each other by a predetermined distance. A compliant pad spans this distance to couple adjacent members and accommodate relative movement between the members during transport and after installation of the structure.
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FIELD OF THE INVENTION
[0001] The invention involves reticulated foam structures comprised of polymer, metal, metal alloys, metal oxides, carbon and glass, and the method for making such structures.
BACKGROUND OF THE INVENTION
[0002] Reticulated (or “open-cell”) foam is used in a variety of applications, including non-conductive applications such as filters, heat dissipation, rigid mechanical structures and catalysts, and conductive applications such as electrodes.
[0003] Reticulated foam can be polymer-based or made of other materials such as carbon allotropes, metals, metal alloys, metal oxides and glass. Polymer-based reticulated foams can be made from polypropylene, polyurethane, polyethylene, polyester, polyether, acrylonitrile butadiene styrene, fluropolymers, polyvinyl chloride, cellulose, latex, etc., including co-polymers, such as ethylene vinyl acetate
[0004] Reticulated polymer foams can also be used as templates to create foams made of other materials. For example, Inco Limited, Toronto, Canada, uses reticulated polyurethane foam as a template to make high purity nickel foam (see Vladimir Paserin, Sam Marcuson, Jun Shu and David S. Wilkinson, Advanced Engineering Materials, 2004, 6, No. 6, 454459, DOI: 10,1002/adem.200405142) as disclosed in U.S. Pat. No. 4,957,543. The nickel foam is produced in large quantity by decomposing nickel carbonyl gas and depositing the nickel onto an open-cell polyurethane foam substrate. The primary application for this material is for battery electrodes, especially for nickel metal hydride batteries. U.S. Pat. No. 5,296,261 teaches a method for making nickel, copper or lead tarn using a reticulated polymer foam (i.e. polyurethane, polyester or polyether) as a template, where the template is impregnated with a nitrate or sulphate solution of nickel, copper or lead. The impregnated foam construct is subsequently heated to burn off the polymer template.
[0005] The use of a polymer as the base material for the template foam is attractive as polymers are low cost and widely available in a variety of open cell sizes and porosities. Prior art foamed materials consisting of non-polymer foam templates such as for example carbon or aluminum generally have limitations due to the high cost of producing such materials in commercial quantities, or having relatively small pore sizes between connecting cells, thereby creating high back-pressures for fluids flowing through such materials to create the intended final product.
[0006] Techniques such as melt processing, powder processing and vapour deposition for making foamed materials have been developed over past decades (see L. J. Gibson, “Mechanical Behavior of Metallic Foams”, Annu, Rev. Mater. Sci. 2000, 30:191-227) resulting in many commercial enterprises producing a variety of foamed materials.
[0007] “Metal Foams: A Design Guide” by M. F. Ashby, A. G. Evans, N. A. Fleck, L. J. Gibson, J. W. Hutchinson and H. N. G. Wadley, published in 2000 by Elsevier, provides a detailed description of various techniques for forming metal foams.
[0008] ERG Materials and Aerospace Corporation, Oakland, Calif. makes ceramic, metal and glassy carbon foams using the “directional solidification of material from a super-heated liquidous state in an environment of overpressure and high vacuum”. It appears that this is essentially an investment-casting process. Such metallic and metallic-based foams have utility as structural sandwich panels (allowing for energy absorption), heat dissipation devices (due to high internal surface area and thermal conductivity), and as porous electrodes.
[0009] The fabrication of porous metal foams for use in orthopaedic applications is described by G. Ryan, A. Pandit and D. P. Apatsidis in Biomaterials 27 (2006) 2651-2670. They coated polyurethane foams with a slurry of Ti—Al—V powder in a water and ammonia solution, with thermal removal of the polyurethane scaffold and binder to create a titanium alloy with an 88% porosity.
[0010] Researchers at the Fraunhofer Institute for Manufacturing and Advanced Materials IFAM in Dresden, Germany have developed a reticulated porous titanium foam for use as load-bearing bone implants (Science Daily, Sept. 22, 2010). They saturated polyurethane foam with a solution containing a binder and fine titanium powder, which are subsequently heated, leaving behind a titanium-based semblance of the original foam structure.
[0011] Low-density metal foams have been made by impregnating polymer foam (i.e. polyurethane) with plaster, heating the resulting construct to pyrolyze the polymer and then injecting molten metal (such as aluminum or magnesium) into the pores, and subsequently removing the plaster with water, leaving behind a reticulated metal foam (see Y. Yamada, K. Shimojima, Y. Sakaguchi, M. Mabuchi, M. Nakamura, T. Asahina, T. Mukai, H. Kanahashi and K. Higashi, Mater. Sci. and Eng. A272 (1999) 455-458).
[0012] Poco Graphite, Inc., Decatur, Tex., USA has licensed U.S. Pat. No. 6,033,506 for making carbon and graphite foam by inert gas expansion of mesophase or isotropic pitch.
[0013] Various groups have published other methods for producing reticulated carbon foam. For example, Kelly, et al, in U.S. Pat. No. 6,979,513 B2 teaches the pyrolization of different types of wood (which contain a natural open pore cellular structure) for use as a carbon foam battery current collector.
[0014] M. Inagaki, T. Morishita, A. Kuno, T. Kito, M. Hirano, T. Suwa and K. Kusakawa in Carbon, 42 (2004) 497-502 describe a process to create a reticulated graphite foam by first impregnating (and imidizing) polyurethane foam to create a composite polyurethane/polyimide, followed by pyrolysis.
[0015] S. M. Manocha, K. Patel and L. M. Manocha in Indian J. of Engineering & Material Science, Vol. 17, 2010, 338-342 describe a method of making reticulated vitreous carbon by impregnating open-cell polyurethane foam with thermosetting phenolic resin and heating this construct in an inert atmosphere.
[0016] Microporous carbon polymers have also been produced using esoteric processes such as heat treating hyperbranched conjugated polymers having thermally degradable alkoxyl groups (see N. Kobayashi and M. Kijima, J. Mater. Chem. 2007, 17, 4289-296).
[0017] A review of some of the prior art, including methods for making glass-based foamed structures, is provided by Berrang in PCT Application PCT/CA2010/001809.
[0018] In many contemplated applications it would be advantageous to achieve a structure with lower cost, higher porosity and higher effective contact surface area without a large back-pressure for the passage of fluids or gases through the foam structure, than is offered by many of the prior art reticulated foams.
[0019] The production of reticulated polymer foams, such as polyurethane foam, usually requires the use of chemical or physical blowing agents to generate gas bubbles, where adjacent bubbles need to connect to create a contiguous path. Too much gas expansion causes “foam collapse”. Too little gas expansion creates closed-cell foam where adjacent cells do not connect. Accordingly, the process for producing open-cell polymer foam with substantially 100% open-cell ligament (sometimes called “strut”) skeletons with no membranes between cells is limited to a cell diameter from about 200 microns to about 4 millimeters. Pores between the cells are generally about 200 microns for cell diameters of about 300 microns.
[0020] Smaller cell diameters in a reticulated foam structure can be created, to a limited extent, by compressing the open-cell polymer foam template. Although reticulated polyurethane foam is an excellent template for making metal, metal alloy, metal oxide, carbon and glass foamed constructs, the cell diameter range is inherently limited by the foam-formation and curing process, and is thereby not suitable for applications requiring pore sizes less than about 200 microns.
[0021] A process for making low density nanoporous monolithic transition-metal foams (such as iron, cobalt, copper and silver) using a self-assembly combustion synthesis has been published (see B. C. Tappan, M. H. Huynh, M. A. Fliskey, D. E. Chavez, E. P. Luther, J. T. Mang, and S. F. Son, J. Am. Chem. Soc. 2006, 128, 6589-6594). Additional information on this process is provided by Tappan, et al. in U.S. Pat. No. 7,141,675. The Tappan product is made via an esoteric approach, using expensive materials to fabricated nanoporous structures (pore size of 20-200 nm). This process is limited to metals, and in final construct size, as it requires pressing the precursor material into pellets using a die, and firing in an inert atmosphere at high temperatures (i.e. 800° C.) to remove the carbon and nitrogen impurities. The small pore size would also create a large back-pressure for some applications, e.g. use as filters, and would be difficult to use as a porous electrode since fluid infusion therein would be impractical.
[0022] Generally speaking, the prior art polymer foam-making techniques suffer broad dimensional limitations. A certain size of cell and of shared cell wall must be achieved before the shared cell walls will readily open to create pores and a resulting reticulated structure. However, expanding the cells too much results in collapse of the foam structure. As a result, most reticulated (open-cell) foam structures have minimum cell diameters of about 200-300 microns and for such material, minimum pore sizes, i.e. openings between adjacent cells, in the range of about 100-200 microns. Using such reticulated polymer foam structures as templates to produce foam structures made of other materials imposes inherent limitations on the surface area and pore size available in the so-formed reticulated foam, for example to catalyze chemical reactions or to act as a conductive matrix.
[0023] The doping of rigid closed-cell (as opposed to open-cell) polyurethane foam with carbon nanomaterials so as to enhance the mechanical properties of the foam has been described. For example, Md. E. Kabir, M. C. Saha, and S. Jeelani in Mat. Sci. and Eng. A 459 (2007) 111-116 discuss doping of rigid closed-cell polyurethane to strengthen it with carbon nanofibers 5-10 nanometers long using a sonification technique. Similarly, L. Zhang, E. D. Yilmaz, J. Schjodt-Thomsen, J. C. Rauhe, and R. Pyrz in Composites Science and Technology 71 (2011) 877-884 describe the doping of rigid closed-cell polyurethane with multi-walled carbon nanotubes using a high-shear mixing procedure. The small size of the nanofibers and nanotubes suggests that they will be bound to individual cell ligaments and accordingly it is unlikely to significantly affect the overall porosity of the resulting structure or the contact surface area available in the foam.
[0024] It is an object of the present invention to provide a reticulated or “open cell” foam structure that provides a lower cost, a lower back-pressure, a lower density and a greater contact or reaction surface area in the foam than is provided by most prior art reticulated foams, particularly those used as templates to produce foams comprised of other materials, while also avoiding the problems that characterize prior art reticulated foams and reticulated foam-making techniques.
[0025] It is a further object of the invention to provide methods of producing non-polymer reticulated foams having such advantageous characteristics, using the polymer reticulated foam as a template.
[0026] Other objects of the invention will be appreciated by reference to this disclosure as a whole, including to the claims to which the reader is also referred.
SUMMARY INVENTION
[0027] The present invention seeks to address the foregoing limitations by providing a reticulated foam wherein a primary open-cell foam structure is supplemented by a plurality of fibers within the cells and extending through inter-cell pores.
[0028] The incorporation of fibers into the foam modifies its effective porosity, increases the surface contact area and enhances its intrinsic mechanical support. The reticulated foam containing the fiber additives has utility in a number of applications such as for filtration, heat dissipation, or strong, lightweight mechanical structures. A fiber-enhanced reticulated polymer foam according to the invention is particularly useful as a template to fabricate fine-structure micro-porous reticulated foams made of metal, metal alloy, metal oxide, carbon-based or glass, some of which are particularly suited as battery electrodes.
[0029] A primary polymer foam according to the invention can be of one or more of polyurethane, polypropylene, polyethylene, polyester, polyether, acrylonitrile butadiene styrene, fluoropolymers, polyvinyl chloride, cellulose or latex, preferably polyurethane, or other suitable polymers including co-polymers.
[0030] The fibers introduced into the primary foam matrix extend across cells and inter-cell pores into adjacent cells. Accordingly, the fibers have an average length of between 2 and 10 times the average cell diameter, with the preferred range being from 2-5 times the average cell diameter.
[0031] The fibers may be of metal, a metal alloy, a metal oxide, a carbon material or glass. More specifically, the fibers can be made from metal such as tin, titanium, aluminum, chromium, vanadium, copper, nickel, iron or zinc, metal alloys such as titanium-nickel, titanium-aluminum-vanadium, iron-carbon, aluminum-copper-zinc-magnesium or eutectic alloys, metal oxides such as aluminum dioxide or titanium dioxide, or polymers such as nylon, polyacrylonitrile, polystyrene, polyamide, polyimide, PAN, PET, polycarbonate, polyurethane and polyvinyl esters for example. Additionally, the fibers can be made from an allotrope of carbon, for example, carbon material such as amorphous carbon, glassy carbon or graphite, or glass such as quartz, pyrex, or glasses doped with aluminum, sodium, lead or boron.
[0032] In one aspect, the invention comprises a reticulated open-cell foam having cells defined by a skeletal structure of ligaments and further comprising a plurality of fibers distributed substantially throughout said foam and extending across and between said cells of said foam.
[0033] In another aspect, the ratio of the average length of the fibers to the average diameter of said cells is at least 2:1. In another aspect, the average length of the fibers is between 400 microns and 40 millimeters.
[0034] In a further aspect, the invention comprises a reticulated foam construct composed substantially of a single non-polymer material and comprising a primary reticulated open-cell skeletal structure of ligaments, said ligaments defining cells, and a secondary structure of fiber-like elements distributed substantially throughout said primary structure, said fiber-like elements extending through and between adjacent cells.
[0035] The invention also comprises methods of producing the reticulated foam with fiber additives according to the invention.
[0036] According to the preferred embodiment, an additive comprised of thin-diameter, short-fibers made from a polymer, carbon material, metal, metal alloy, metal oxide or glass is added to the mix of chemicals used to prepare the reticulated polymer foam, prior to foam formation. During the foam-making process the fiber additive will then become randomly incorporated within, and bridge across the open cells, and through and across adjacent cells. Additionally, the fibers will then become rigidly incorporated into, and held within, the open-cell network of the final foam product, forming a porous fibrous web within each cell of the foam construct.
[0037] In another embodiment of the invention an additive comprised of thin diameter, short fibers made from metal, metal alloy, metal oxides, glass, carbon or any polymer is incorporated into reticulated polymer foam, preferably reticulated polyurethane foam, subsequent to foam formation. The reticulated foam is first soaked in an organic solvent, such as chloroform, which solvent causes the foam to expand in all dimensions, increasing the volume of the foam by double or more. This process expands both the cell diameter and pore size (i.e. openings between adjacent cells). By adding one or more fiber additives of metal, metal alloy, metal oxides, polymer, carbon material or glass to the solvent, and dispersing such additive within the solvent, it is then possible to disperse the added fibers within the cells of the expanded reticulated polymer. The solvent is then evaporated, causing the foam to shrink back to its original size, leaving the fiber additive entrained and held within the reticulated foam cells.
[0038] In one method aspect, the invention comprises a method for making a reticulated open-cell foam having cells defined by a skeletal structure of ligaments and further comprising a plurality of fibers distributed substantially throughout said foam and extending across and between the cells of the foam comprising the steps of adding the fibers to foam reactants used to make said skeletal structure of ligaments, and mixing the reactants including the added fibers.
[0039] In another aspect, the invention comprises a method for making a reticulated open-cell foam having cells defined by a skeletal structure of polymer ligaments and further comprising a plurality of fibers distributed substantially throughout said foam and extending across and between said cells of said foam comprising the steps of:
providing a starting reticulated open-cell foam having cells defined by a skeletal structure of polymer ligaments; soaking the starting foam in an organic solvent containing a dispersion of one or more fiber additives substantially made of fibers of a material selected from among the group comprising polymer, metal, metal oxide, carbon, glass, so as to expand the cell diameters of the primary foam; allowing said solvent to cause the starting foam to expand such that the average expanded cell diameter is at least the average length of the fibers; and, causing or allowing said solvent to evaporate and the starting foam to shrink so as to entrain and retain the fibers across and between the cells.
[0044] According to the invention, the primary fiber-supplemented reticulated foam may be used as a template for making foam of a similar structure but in a different material than the primary foam.
[0045] According to one aspect, the invention comprises a method of making a reticulated foam construct composed substantially of a single non-polymer material and comprising a primary reticulated open-cell skeletal structure of ligaments and a secondary structure of fiber-like elements extending across and through the primary skeletal structure, comprising the steps of:
providing a starting reticulated foam comprising an open-cell skeletal structure of polymer ligaments and further comprising a plurality of fibers distributed substantially throughout the structure and extending across and between cells defined by the ligaments; preparing a slurry comprising one or more materials selected front among the group comprising metal, metal alloy, metal oxide, carbon material, glass, silicon dioxide, silicon carbide, silicon nitride; coating all surfaces of the starting foam with the slurry; and, pyrolizing the polymer ligaments.
[0050] According to another aspect, the slurry may comprises nanomaterials. In another aspect, the method may comprises the further step of heating to sinter the slurry materials.
[0051] In another aspect, the invention comprises a method of making a reticulated foam construct composed substantially of a single non-polymer material and comprising a primary reticulated open-cell skeletal structure of ligaments and a secondary structure of fiber-like elements extending across and through the primary skeletal structure, comprising the steps of:
providing a starting reticulated foam comprising an open-cell skeletal structure of polymer ligaments and further comprising a plurality of fibers distributed substantially throughout the structure and extending across and between cells defined by the ligaments; directly depositing a metal or metal alloy unto the surfaces of the starting foam; pyrolizing the polymer ligaments; and, sintering the metal or metal alloy.
[0056] In a further aspect, the invention comprises a method of making a reticulated foam construct composed substantially of a single non-polymer material and comprising a primary reticulated open-cell skeletal structure of ligaments and a secondary structure of fiber-like elements extending across and through the primary skeletal structure, comprising the steps of:
preparing a mixture of foam reactants designed to produce a reticulated open-cell skeletal structure of polymer ligaments, and a fiber additive, the fiber additive comprising chopped or milled fibers 600 microns to 1.5 millimeters long; mixing the mixture; adding to the mixed mixture a nanopowder, nanoparticles or nanofibers of a material selected from among the group comprising metal, metal alloy, metal oxide, carbon material, glass, silicon dioxide, silicon carbide, silicon nitride; curing the resulting product; and, heating the resulting product to burn off the polymer.
[0062] In a further aspect, the invention comprises the foregoing method wherein the nanopowder, nanoparticles or nanofibers are of carbon and further comprising the step of heating the resulting product to about 3000° C. to graphitize the carbon.
[0063] In yet a further aspect, the invention comprises a method of making a reticulated foam construct composed substantially of carbon and comprising a primary reticulated open-cell skeletal structure of ligaments and a secondary structure of fiber-like elements extending across and through the primary skeletal structure, comprising the steps of:
providing a starting reticulated foam comprising an open-cell skeletal structure of polymer ligaments and further comprising a plurality of fibers distributed substantially throughout the structure and extending across and between cells defined by the ligaments; impregnating and imidizing the starting foam with poly(amide acid); pyrolyzing to remove the polymer; and, heating to about 3000° C. to graphitize the carbon,:
[0068] In another aspect, the invention comprises a method of making a reticulated foam construct composed substantially of a non-polymer and comprising a primary reticulated open-cell skeletal structure of ligaments and a secondary structure of fiber-like elements extending across and through the primary skeletal structure, comprising the steps of:
providing a starting reticulated foam comprising an open-cell skeletal structure of polymer ligaments and further comprising a plurality of fibers distributed substantially throughout the structure and extending across and between cells defined by the ligaments; immersing the starting foam in an organic solution containing poly(hydridocarbyne) and a solvent; evaporating the solvent to leave a coating of poly(hydridocarbyne) on the ligaments and fibers; pyrolyzing to remove the polymer and fibers; heating to about 1,000° C. to convert the poly(hydridocarbyne) to diamond or diamond-like carbon.
[0074] In another aspect, the invention comprises a method of making a reticulated foam construct composed substantially of a non-polymer and comprising a primary reticulated open-cell skeletal structure of ligaments and a secondary structure of fiber-like elements extending across and through the primary skeletal structure, comprising the steps of:
providing a starting reticulated foam comprising an open-cell skeletal structure of polymer ligaments and further comprising a plurality of fibers distributed substantially throughout the structure and extending across and between cells defined by the ligaments; immersing the starting foam in an organic solution containing poly(hydridocarbyne) and a solvent; evaporating the solvent to leave a coating of poly(hydridocarbyne) on the ligaments and fibers; pyrolyzing to remove the polymer and fibers; converting said poly(hydridocarbyne) to diamond by immersion in liquid ozone.
[0080] In yet another aspect, the invention comprises the use of the foam and foam constructs made according to the methods of the invention.
[0081] More specific aspects of the invention are disclosed in the claims, which should be deemed to be incorporated into this Summary of the Invention section and to which the reader is expressly referred.
[0082] The foregoing was intended as a broad summary only and of only some of the aspects of the invention. It was not intended to define the limits or requirements of the invention. Other aspects of the invention will also be appreciated by reference to the detailed description of the preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0083] The invention will be described by reference to the detailed description of the preferred embodiment and to the drawings thereof in which:
[0084] FIG. 1 is an illustration of a prior art reticulated polyurethane foam;
[0085] FIG. 2 is an illustration of a reticulated foam according to the preferred embodiment of the invention;
[0086] FIG. 3 is a process flow chart for a slurry-based process of making a reticulated foam construct according to a preferred embodiment of the invention;
[0087] FIG. 4 is a process flow chart for a slurry-based process of making an aluminum foam construct according a preferred embodiment of the invention;
[0088] FIG. 5 is a process flow chart for making a nickel-titanium alloy construct according to a preferred embodiment of the invention;
[0089] FIG. 6 is a process flow chart for a direct metallization process for making an electroless nickel construct according to a preferred embodiment of the invention;
[0090] FIG. 7 is a process flow chart for an in-situ fabrication process for a metal, metal alloy, metal oxide, carbon material or glass construct according to an alternative embodiment of the invention;
[0091] FIG. 8 is a process flow chart for an in-situ fabrication process for a graphite construct according to an alternative embodiment of the invention;
[0092] FIG. 9 is a process flow chart for an in-situ fabrication process for a nickel construct according to an alternative embodiment of the invention;
[0093] FIG. 10 is a process flow chart for an imidization process for making a graphite construct according to an alternative embodiment of the invention; and,
[0094] FIG. 11 is a process flow chart for a diamond fabrication process via direct coating with poly(hydridocarbyne) according to a preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0095] FIG. 1 is a three-dimensional sketch of commercially available reticulated polyurethane foam 10 , having open cells 11 and ligaments or struts 12 . Diameters of the open cells 11 can be in the range of 200 microns to 4 millimeters, which dimensions can be set by the production parameters. Pores 13 are in the range of 200 microns to about 3 millimeters across, which dimension is determined by the physical process of expanding bubbles during foam formation having common walls resulting from contact, which walls open, thereby forming a pore opening between adjacent cells.
[0096] FIG. 2 illustrates a reticulated polyurethane foam 20 according to the preferred embodiment of the invention. The primary polymer foam structure characterized by ligaments 14 in FIG. 2 is preferably of the same dimensions as the finer-structured commercially producible prior art foams having cell diameters of about 200 microns to 4 millimeters (depending on the production process used to make the foam). In the preferred embodiment, the primary polyurethane foam has an average cell diameter of about 300 microns with an average ligament diameter of about 100 microns.
[0097] Foam 20 contains thin diameter, elongated but relatively short fibers 21 randomly incorporated within the primary structure provided by the reticulated polyurethane foam formed by the ligaments 14 . The fibers generally bridge across cells, and generally through and across adjacent cells. Upon curing or otherwise making the foam, the fibers 21 remain held within the primary open cell polymer foam structure.
[0098] The average length of fibers 21 is 2-10 times the average diameter of open cells and preferably 2-5 times. That specification allows for the fibers to generally extend into at least one adjacent cell, thereby promoting a finer overall structure and smaller effective inter-cell porosity. Accordingly, the average fiber lengths would be at least 400 microns to 40 millimeters depending on the primary foam. The preferred embodiment uses an average fiber length of 600 microns (twice the average cell diameter of 300 microns).
[0099] The cross-section of the fibers can be any shape but in the preferred embodiment is round. The ratio of the average cross-sectional area of the fibers to the reticulated foam ligament cross-sectional area is less than 1 and preferably between 0.01 and 0.1 such that in the preferred embodiment, the average diameter of such a cross-sectional area would give a fiber with a diameter of about 1 to 10 microns.
[0100] The addition of the fibers to the primary reticulated foam structure reduces the effective pore size through the matrix of foam and fibers. The number of fibers per volume, and the average fiber diameter and length will determine the effective pore density and the effective pore size and hence the porosity of the resulting composite foam structure.
[0101] In the preferred embodiment, a sufficient number of fibers are added to the primary polymer foam to result in a plurality of fibers traversing and intersecting in most of the cells of the foam. The web of fibers thus created provides a micro-porous matrix in addition to that provided by the inter-cell pores with effective inter-fiber pore sizes of as low as 50 nanometers. The matrix of fibers also increases the contact surface area of the foam construct and enhances the structural rigidity and mechanical support provided by the foam. The effective pore size taking into account the fibers and the underlying ligand structure can be made very dense, from 50-100 nanometers, to 1-2 millimeters, depending upon the intended application. In this context, the “pore size” refers to the diameter of the largest particle that is able to just penetrate and pass through such randomly intersecting fibers and ligands. For example, if a particle with a diameter of 3 micron is just able to pass through a planar section of space bounded by one or more fibers or/and one or more foam ligands, then the pore size of such opening within the planar section of space would be 3 microns. The density, volume/volume or weight/weight (v/v or w/w) of the entrained fiber additive within the polyurethane foam can be in the range of 0.5% to 85%, preferably 10% to 30%, the narrower range being preferred for battery electrodes for example.
[0102] Many fiber additives such as metal, metal alloys or metal oxides, or polymers such as nylon, polyacrylonitrile, polystyrene, polyamide, polyimide, PAN, PET, polycarbonate, polyurethane and polyvinyl esters, can be made via a nanospinning process, which process is known to those skilled in the art. Carbon-based material and glass fibers of various diameters and lengths (i.e. chopped or milled) are also commercially available.
[0103] The preferred embodiment of a process for making the fiber-enhanced reticulated foam according to the invention will now be described. An additive comprised of suitably thin-diameter, short-fibers made from a polymer, carbon material, metal, metal alloy, metal oxide or glass is added to the reactants that would normally be used to prepare the reticulated polymer foam. The reactants including the fiber additive(s) are then mixed to create the foam. During the foam-making process the fibers will become randomly incorporated within, in and bridge across the open cells, and through and across adjacent cells. Upon curing of the foam, the fibers will be rigidly incorporated into, and held within, the open-cell network of the final foam product, forming a porous fibrous web extending across throughout the skeletal structure of ligaments that also define the cells of the foam.
[0104] In an alternative method of making the foam, the fibers are added subsequent to the formation of the primary foam structure. This method is particularly well suited to primary foam structure made of polyurethane. The primary reticulated foam is first soaked in an organic solvent, such as chloroform, which solvent causes the foam to expand in all dimensions, increasing the volume of the foam by a factor of two or more and in any event to an extent that the expanded cell diameters are generally more than the length of the fibers (by reference to the average of each). The solvent expansion process expands both the cell diameter and the inter-cell pore size. By adding one or more fiber additives of metal, metal alloy, metal oxides, polymer, carbon material or glass to the solvent, and dispersing such additive within the solvent, it is then possible to entrain the additive fibers within the cells of the expanded reticulated polymer. The solvent is then allowed to evaporate or caused to evaporate, causing the foam to shrink back to about its original size, leaving the fiber additive entrained and held within and between the reticulated foam cells.
[0105] The primary fiber-enhanced foam construct according to the invention can then be used as a template to create a structurally similar foam of metal, metal alloy, metal oxide, carbon material or glass. Metal foam ligaments fabricated using a polymer foam as a template can be of one or more of nickel, titanium, iron, aluminum or copper. Metal alloy foam ligaments can be comprised of one or more of nickel-titanium, titanium-aluminum-vanadium, iron-carbon, aluminum-copper-zinc-magnesium. Metal oxide foam ligaments can be titanium dioxide or aluminum oxide. Carbon material foam ligaments can be comprised of any allotrope of carbon. Glass foam ligaments can be comprised of one or more of glass, such as quartz, pyrex, or glasses doped with aluminum, sodium, lead and/or boron.
[0106] A preferred embodiment of the fiber-enhanced reticulated (i.e. open cell) polymer foam that is subsequently used as a template to produce a nickel-foam construct for use as a battery electrode is as follows:
Polymer template: polyurethane average cell diameter: 300 microns average ligament diameter: 100 microns fiber additive: carbon average fiber length: 600 microns to 1.5 millimeters average fiber diameter: 10 microns fiber shape: round fiber density: 10-30% v/v or w/w
[0115] As discussed above, an important use of the fiber-enhanced reticulated polymer foam according to the invention is as a template to produce a fine-structured, microporous reticulated foam of metal, metal alloy, metal oxide, carbon or glass. The following describes the preferred processes for creating such constructs according to the invention. In summary they include:
(a) A slurry process as described by reference to FIGS. 3 , 4 and 5 . (b) A direct metallization process such as nickel carbonyl deposition, metal sulphate (or nitrate) deposition, or electroless nickel deposition. The electroless nickel process is described by reference to FIG. 6 . (c) An in-situ process as described by reference to FIGS. 7 , 8 , and 9 . (d) An imidization process as described by reference to FIG. 10 . (e) An direct coating process with poly(hydridocarbyne) as described by reference to FIG. 11 .
[0121] In the following descriptions, the term HPOCF (an acronym for “hybrid-porosity open cell foam”) will sometimes be used to refer to the fiber-enhanced reticulated foam according to the invention, whether it is a fiber-enhanced reticulated polymer foam, or a reticulated foam made using the fiber-enhanced reticulated polymer foam as a template.
[0122] Slurry Process
[0123] FIG. 3 is a flow chart for a metal, metal alloy, metal oxide, carbon material or glass HPOCF fabrication process using a slurry approach. Starting ( 30 ) with unmixed reactants for producing reticulated polymer foam having an average cell diameter of about 300 microns, chopped or milled fibers of average length between 600 microns and 1.5 millimeters are added ( 31 ) to the unmixed reactants, and thoroughly mixed ( 32 ) therein using, for example, mechanical stirring and/or sonification. The fiber-entrained polymer HPOCF is then allowed to cure.
[0124] All surfaces of the polymer HPOCF are then coated ( 33 ) with a slurry comprised of one or more metal, metal alloy, metal oxide, carbon material or glass, in the form of nanopowder, nanoparticles or nanofibers, including, optionally, a binder. In one embodiment, the slurry can also contain silicon dioxide, silicon carbide or silicon nitride. Nanopowder and nanoparticle diameters are preferably 10 to 1,000 nanometers. Nanofiber lengths are preferably 20 nanometers to 50 microns, with diameters ranging from 10 nanometers to 20 microns. In one embodiment, the nanopowder can be in the form of hollow spheres.
[0125] Metal nanopowder, nanoparticles or nanofibers can be made from, for example, nickel, titanium, iron, aluminum or copper. Metal alloys in the form of nanopowder, nanoparticles or nanofibers can be of nickel-titanium, titanium-aluminum-vanadium, iron-carbon, aluminum-zinc-copper-magnesium, etc. Metal oxide in the form of nanopowder, nanoparticles or nanofibers can be comprised of titanium dioxide or aluminum oxide. Carbon nanopowder, nanoparticles or nanofibers can be comprised of any allotrope of carbon. Glass nanopowder, nanoparticles or nanofibers can be comprised of any type of glass, such as quartz, pyrex, or aluminum, sodium, lead and/or boron doped glasses.
[0126] The slurry coated construct is subsequently heated ( 34 ) to burn-off the polymer, foaming agents, catalysts and any binder, and heated further ( 35 ) at higher temperature to sinter the additives, producing a final product 36 that is a metal, metal alloy, metal oxide, carbon or glass HPOCF construct that has substantially the same form as the fiber-entrained polymer HPOCF template.
[0127] In the case where the final HPOCF construct is comprised of an oxide such as TiO 2 or Al 2 O 3 , such construct can be further treated to reduce the oxides to their pure metal form using, preferably, the known FCC Cambridge Process (developed in 1997 at the University of Cambridge), which process uses an electrochemical method to remove the oxygen from, for example, TiO 2 in a solution of molten CaCl 2 (see also U.S. Pat. No. 6,921,473 B2). The resulting pure titanium foam construct has great utility for use in medical implants as it is biocompatible, ductile, strong and light. Applications include use as a porous-walled stent which allows for cell growth into the stent wall, as a scaffold for bone and tissue support, and as dental support structures.
[0128] A similar reduction process using molten LiCl can be used to reduce Al 2 O 3 to Al (see U.S. Pat. No. 6,921,473 B2),
[0129] FIG. 4 is a flow chart for a slurry approach for making hybrid-porosity open cell aluminum foam using a polyurethane foam template having an average cell diameter of about 300 microns.
[0130] Starting with unmixed reactants ( 40 ) for producing reticulated polyurethane foam (i.e. liquid isocyanate and liquid polyols, containing a catalyst and other additives) having an average cell diameter of about 300 microns, chopped or milled fibers 600 microns to 1.5 millimeters long are added ( 41 ) to the unmixed reactants, and thoroughly mixed therein using, for example, mechanical stirring and/or sonification, The fiber-entrained polyurethane HPOCF so is then allowed to cure ( 42 ).
[0131] All surfaces of the fiber-entrained polyurethane HPOCF are then coated ( 43 ) with a slurry comprised of aluminum in a form of nanopowder, nanoparticles and/or nanofibers, including, optionally, a binder.
[0132] The aluminum slurry-coated construct is subsequently heated ( 44 ) to burn-off the polymer, foaming agents, catalysts and any binder, and heated further at higher temperature to sinter the aluminum, producing a final aluminum HPOCF construct 45 that has substantially the same form as the fiber-entrained polyurethane HPOCF template.
[0133] FIG. 5 is a flow chart for a slurry approach for making a nickel-titanium alloy HPOCF using a polyurethane foam template.
[0134] Starting with unmixed reactants ( 50 ) for producing reticulated polyurethane foam i.e. liquid isocyanate and liquid polyols, containing a catalyst and other additives) having an average cell diameter of about 300 microns, chopped or milled fibers 600 microns to 1.5 millimeters long are added ( 51 ) to the unmixed reactants, and thoroughly mixed ( 52 ) therein using, for example, mechanical stirring and/or sonification. The fiber-entrained polyurethane HPOCF is then allowed to cure.
[0135] All surfaces of the fiber-entrained polyurethane HPOCF are then coated ( 53 ) with a slurry comprised of a nickel-titanium alloy in a form of nanopowder, nanoparticles and/or nanofibers, including, optionally, a binder.
[0136] The nickel-titanium alloy slurry-coated construct is subsequently heated ( 54 ) to burn-off the polymer, foaming agents, catalysts and any binder, and heated further ( 55 ) at higher temperature to sinter the nickel-titanium alloy, producing a final nickel-titanium alloy HPOCF construct 56 that has substantially the same form as the fiber-entrained polyurethane HPOCF template.
[0137] In one embodiment, the ratio of the nickel/titanium is 55/45, which alloy is know as “nitinol” which has a memory shape at a specific temperature, and is both strong and biocompatible, making such an alloy useful, especially in medical applications such as implants and stents,
[0138] Direct Metallization Process
[0139] A direct metallization process such as nickel carbonyl deposition, metal sulphate (or nitrate) deposition, or electroless nickel deposition can be used to metallize hybrid-porosity open cell polyurethane foam.
[0140] (a) Electroless Nickel Deposition
[0141] A flow chart for an electroless nickel process is shown in FIG. 6 .
[0142] Starting with unmixed reactants ( 60 ) for producing reticulated polyurethane foam (i.e. liquid isocyanate and liquid polyols, containing a catalyst and other additives) having an average cell diameter of about 300 microns, chopped or milled fibers 600 microns to 1.5 millimeters long are added ( 61 ) to the unmixed reactants, and thoroughly mixed ( 62 ) therein using, for example, mechanical stirring and/or sonification. The fiber-entrained polyurethane HPOCF is then allowed to cure.
[0143] All surfaces of the polyurethane HPOCF are then electroless nickel plated ( 63 ). The nickel coated construct is subsequently heated ( 64 ) to burn-off the polymer, catalysts and any foaming agents, and heated further ( 65 ) at higher temperature to sinter the nickel, producing a final nickel HPOCF construct 66 that has substantially the same form as the fiber-entrained polyurethane HPOCF template.
[0144] (b) Metal Sulphate and Metal Nitrate Impregnation
[0145] A similar direct metallization process can be used by impregnating polyurethane foam with a solution of nickel, copper or lead sulphate, or nickel, copper or lead nitrate.
[0146] Starting with unmixed reactants for producing reticulated polyurethane foam (i.e. liquid isocyanate and liquid polyols, containing a catalyst and other additives) having an average cell diameter of about 300 microns, chopped or milled fibers 600 microns to 1.5 millimeters long are added to the unmixed reactants, and thoroughly mixed therein using, for example, mechanical stirring and/or sonification. The fiber-entrained polyurethane HPOCF is then. allowed to cure.
[0147] All surfaces of the polyurethane HPOCF are then impregnated with a solution of nickel, copper or lead sulphate, or nickel, copper or lead nitrate.
[0148] The impregnated construct is subsequently heated to burn-off the polymer, catalysts and any foaming agents, and additives producing a final nickel, copper or lead HPOCF construct that has substantially the same form as the fiber-entrained polyurethane HPOCF template.
[0149] (c) Nickel Carbonyl Deposition
[0150] A similar direct nickel metallization process can be used by decomposing nickel carbonyl gas in the presence of an open-cell polyurethane foam substrate.
[0151] Starting with unmixed reactants for producing reticulated polyurethane foam (i.e. liquid isocyanate and liquid polyols, containing a catalyst and other additives) having an average cell diameter of about 300 microns, chopped or milled fibers 600 microns to 1.5 millimeters long are added to the unmixed reactants, and thoroughly mixed therein using, for example, mechanical stirring and/or sonification. The fiber-entrained polyurethane HPOCF is then allowed to cure.
[0152] All surfaces of the polyurethane HPOCF are then coated with nickel by infusing the polyurethane foam with nickel carbonyl gas and heating to decompose the nickel carbonyl gas, and depositing the nickel onto the polyurethane foam.
[0153] The nickel coated construct is subsequently heated to burn-off the polymer, catalysts and any foaming agents, and additives producing a final nickel HPOCF construct that has substantially the same form as the fiber-entrained polyurethane HPOCF template.
[0154] In-situ Process
[0155] FIG. 7 is a flow chart for a metal, metal alloy, metal oxide, carbon material or glass HPOCF fabrication process via an in-situ approach. Starting with unmixed reactants ( 70 ) for producing reticulated polymer foam having an average cell diameter of about 300 microns, chopped or milled fibers 600 microns to 1.5 millimeters long are added ( 71 ) to the unmixed reactants, and thoroughly mixed therein using, for example, mechanical stirring and/or sonification.
[0156] One or more metal, metal alloy, metal oxide, carbon material or glass, in a form of nanopowder, nanoparticles or nanofibers are also added ( 72 ) to the unmixed reactants. In one embodiment, silicon dioxide, silicon carbide or silicon nitride can also be added. Nanopowder and nanoparticle diameters are preferably 10 to 1,000 nanometers. Nanofiber lengths are preferably 20 nanometers to 50 microns, with diameters ranging from 10 nanometers to 20 microns. In one embodiment, the form of the nanopowder can be hollow spheres.
[0157] The concentration of the additive components is 5% to 95% (w/w or v/v), preferably 20% to 75%, preferably 30% to 60%. The polyurethane foam reaction not only creates the reticulated construct, but it also acts as a binder to hold the additive components in place until fused via sintering.
[0158] Metal nanopowder, nanoparticles or nanofibers can be made from, for example, nickel, titanium, iron, aluminum or copper. Metal alloys in the form of nanopowder, nanoparticles or nanofibers can be, for example, comprised from nickel-titanium, titanium-aluminum-vanadium, iron-carbon, aluminum-copper-zinc-magnesium, etc.
[0159] Metal oxide in the form of nanopowder, nanoparticles or nanofibers can be comprised from titanium dioxide or aluminum oxide. Carbon nanopowder, nanoparticles or nanofibers can be comprised of any allotrope of carbon. Glass nanopowder, nanoparticles or nanofibers can be comprised on any type of glass, such as quartz, pyrex, or aluminum, sodium, lead and/or boron doped glasses.
[0160] The doped reactants are then mixed ( 73 ) to allow foam formation and curing.
[0161] The cured foam construct is subsequently heated to burn-off the polymer, catalysts and any binder, and heated further ( 74 ) at higher temperature to sinter the additives producing a final product 75 that is a metal, metal alloy, metal oxide, carbon or glass HPOCF construct that has substantially the same form as the fiber-entrained polymer HPOCF template form.
[0162] In the ease where the HPOCF construct is comprised of an oxide such as TiO 2 or Al 2 O 3 , such construct can be further treated to reduce the oxides to their pure metal form as per the FCC Cambridge method described for the slurry process.
[0163] FIG. 8 is a flow chart for a graphite HPOCF fabrication process via an in-situ approach. Starting with unmixed reactants ( 80 ) for producing reticulated polyurethane foam having an average cell diameter of about 300 microns, chopped or milled fibers 600 microns to 1.5 millimeters long are added ( 81 ) to the unmixed reactants, and thoroughly mixed therein using, for example, mechanical stirring and/or sonification.
[0164] Carbon nanopowder, nanoparticles or nanofibers are then added to ( 82 ), and mixed with, one or more of the reactants. The doped reactants are then mixed ( 83 ) to allow foam formation and curing.
[0165] The cured foam construct is subsequently heated ( 84 ) to burn-off the polymer, foaming agents, catalysts and any binder, and heated further at higher temperature to fuse the carbon additives.
[0166] The carbon construct is then heated ( 85 ) to approximately 3,000° C. to graphitize the carbon, producing a final product 86 that is a graphite construct that has substantially the same form as the fiber-entrained. polymer HPOCF template form.
[0167] The carbon nanopowder, nanoparticles or nanofibers diameters are preferably 10 to 1,000 nanometers. Carbon nanofiber lengths are preferably 20 nanometers to 50 microns, with diameters ranging from 10 nanometers to 20 microns.
[0168] The concentration of the additive carbon material is 5% to 95% (w/w or v/v), preferably 20% to 75%, preferably 30% to 60%. The polyurethane foam reaction not only creates the reticulated construct, but it also acts as a binder to hold the additive carbon in place until fused by heating.
[0169] FIG. 9 is a flow chart for a nickel HPOCF fabrication process via an in-situ approach. Starting with unmixed reactants ( 90 )for producing reticulated polyurethane foam having an average cell diameter of about 300 microns, chopped or milled fibers 600 microns to 1.5 millimeters long are added ( 91 ) to the unmixed reactants, and thoroughly mixed therein using, for example, mechanical stirring and/or sonification.
[0170] Nickel nanopowder, nanoparticles or nanofibers are then added to ( 92 ), and mixed with, one or more of the reactants. The doped reactants are then mixed ( 93 ) to allow foam formation and curing.
[0171] The cured foam construct is subsequently heated ( 94 ) to burn-off the polymer, foaming agents, catalysts and any binder.
[0172] The final product is a nickel construct 95 that has substantially the same form as the fiber entrained polymer HPOCF template form.
[0173] The nickel nanopowder, nanoparticles or nanofibers diameters are preferably 10 to 1,000 nanometers. Nickel nanofiber lengths are preferably 20 nanometers to 50 microns, with diameters ranging from 10 nanometers to 20 microns.
[0174] The concentration of the additive nickel material is 5% to 95% (w/w or v/v), preferably 20% to 75%, preferably 30% to 60%. The polyurethane foam reaction not only creates the reticulated construct, but it also acts as a binder to hold the additive nickel in place.
[0175] An Imidization Process
[0176] FIG. 10 is a flow chart for a graphite HPOCF fabrication process via an imidization approach. Starting with unmixed reactants ( 100 ) for producing reticulated polymer foam having an average cell diameter of about 300 microns, chopped or milled fibers 600 microns to 1.5 millimeters long are added ( 101 ) to the unmixed reactants, and thoroughly mixed therein using, for example, mechanical stirring and/or sonification.
[0177] The doped reactants are then mixed ( 102 ) to allow foam formation and curing. The cured HPOCF is then impregnated (and imidized) ( 103 ) with poly(amide acid) and heated ( 104 ) to burn off the polymer, foaming agents, and catalysts. In one embodiment, the cured HPOCF is impregnated with thermosetting phenolic resin, followed by pyrolysis of the HPOCF.
[0178] The resulting carbon construct is then heated ( 105 ) to approximately 3,000° C. to graphitize the carbon, producing a final product that is a graphite construct 106 that has substantially the same form as the fiber-entrained polymer HPOCF template form.
[0179] An Direct Coating Process with Poly(hydridocarbyne)
[0180] FIG. 11 is a flow chart for a diamond HPOCF fabrication process via direct coating with poly(hydridocarbyne). Methods for the preparation of poly(hydridocarbyne) are disclosed in Berrang, PCT Application No. PCT/CA2011/000134, titled “Method for Making Poly(hydridocarbyne)”.
[0181] Starting with unmixed reactants ( 110 ) for producing reticulated polymer foam having an average cell diameter of about 300 microns, chopped or milled fibers 600 microns to 1.5 millimeters long are added ( 111 ) to the unmixed reactants, and thoroughly mixed therein using, for example, mechanical stirring and/or sonification.
[0182] The doped reactants are then mixed ( 112 ) to allow foam formation and curing.
[0183] The cured HPOCF is then immersed ( 113 ) in an organic solution containing poly(hydridocarbyne). The organic solvent (i.e. acetone, chloroform, dichloromethane, etc.) is evaporated ( 114 ), leaving a coating of poly(hydridocarbyne) over all surfaces of the HPOCF.
[0184] The HPOCF is then heated ( 115 ) to burn off the polymer.
[0185] The poly(hydridocarbyne) construct is then heated ( 116 ) to approximately 1,000° C., preferably in an inert atmosphere, to convert it to diamond and diamond-like carbon, producing a final product that is a diamond or diamond-like carbon construct 117 that has substantially the same form as the fiber-entrained polymer HPOCF template.
[0186] In an alternate embodiment, the poly(hydridocarbyne) construct is converted to diamond and diamond-like carbon by immersing the construct in liquid ozone to remove the pendant hydrogen, producing a final product that is a diamond or diamond-like carbon construct that has substantially the same form as the fiber-entrained polymer HPOCF template.
[0187] It will be appreciated by those skilled in the art that the preferred and alternative embodiments have been described in some detail but that certain modifications may be practiced without departing from the principles of the invention, which are to be reasonably inferred from this disclosure as a whole, from the summaries provided herein, from the detailed description of the preferred and alternative embodiments and the claims.
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A reticulated foam structure comprising a plurality of closely-spaced fibers extending across and between the cells. A reticulated polymer foam structure is enhanced by fibers of metal, metal alloys, metal oxides, carbon or glass that are chopped or milled and introduced into the foam structure during foam formation or by entrainment of fibers into the foam. The resulting structure is used as a template to create a high porosity reticulated foam structure of a non-polymer material by coating the non-polymer onto the fiber-enhanced structure and removing the polymer by heating or pyrolizing. The design has utility for applications such as filtration, implants, heat transfer and electrodes, which require structures with low cost, high porosity, small effective pore sizes and large contact surface area.
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This application is a continuation, of application Ser. No. 426,935, filed Sept. 29, 1982.
BACKGROUND OF THE INVENTION
The invention relates generally to a conduit spacer and clamp system for supporting a bank of conduits and, more particularly, to an improved system for supporting a plurality of conduits of different diameters in parallel, spaced relationship using a minimum number of parts.
Conduit spacers are commonly used for supporting a bank of conduits or pipes which may convey fluids or contain electrical power and/or telephone lines. Generally speaking, a plurality of interlocking conduit spacer members combine to form an assembly or system for securely holding conduits in parallel, spaced relationship for reasons to be set forth below. As mentioned, the conduits may be used for carrying electrical lines, and in such installation it is required to maintain minimum spacing between adjacent conduits to insure that the electrical fields do not interfere with each other. Furthermore, the conduits are normally installed in a trench below ground level and subsequently covered with an appropriate filling material such as sand, gravel, or concrete. In such application, it is essential during the filling operation that the conduits be provided with appropriate supporting means to prevent displacement and possible fracture of the conduits and also that they be maintained in a parallel, spaced relationship to permit free flow of the material around the conduits to insure complete encasement thereof.
In many installations it has been advantageous to include different sized conduits, i.e., conduits with different size diameters, within the same system. Various conduit spacers have been developed to effectively maintain separation and support of conduits in a system, although most have been designed for use with only one size conduit. Generally, it is not possible to interconnect the parts used for supporting one size conduit with those of another. Thus, if there is a need to install a conduit, e.g., of small diameter, in a spacer system for supporting large diameter conduits, it is necessary to tie or wire the smaller conduit to the larger spacer, which is time-consuming, therefore adding to the cost of the installation. There have been systems developed to accommodate different size conduits that have worked well but, unfortunately, they require several different parts and thus are time-consuming and difficult to assemble. For the sake of efficiency and economy, it is desirable that the conduit system utilize a minimum number of parts, be made of lightweight, low cost, inert material, and be of a design which is easy to assemble with a minimum of skill.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a modular conduit spacer system for supporting conduits of different sizes in parallel, spaced relationship that overcomes all of the above-noted shortcomings. The present invention requires a combination of only two standard interlocking modular units and a unitary adapter clamp to form the entire system. The two units which make up the basic structure consist of a base member and what is referred to in the art as an intermediate member. The members have complementary, opposed arcuate surfaces that engage opposite sides of a conduit and are maintained in clamping engagement therewith by cooperating interlocking means provided on each member. Both units also include appropriate side interlocking means whereby adjacent units may be connected together. Thus, any number of these modular units may be assembled together as needed, to form the basic structure of the system. A conduit of smaller diameter may be integrated into the system by means of the novel adapter clamp or conduit holder of the present invention. The unitary adapter includes a U-shaped body for receiving and clamping a smaller size conduit, and a base with a snap-on clip for detachably securing the adapter to an arcuate surface of one of the modular units. It can be readily appreciated that the adapter may be used in a wide variety of spacer systems that incorporate conduit holders with arcuate support surfaces.
Therefore, it is a primary object of the present invention to provide a novel conduit holder that may be detachably secured to an arcuate surface.
Another object of the invention is to provide such a holder that is of one piece construction and which is quick and easy to install.
Another object of the invention is to provide a modular conduit spacer system for supporting a plurality of conduits of different sizes in parallel, spaced relationship.
Still another object of the invention is to provide such a system using a minimum number of parts, which are of lightweight construction, self-supporting, and easy to assemble by relatively unskilled labor.
Other objects and advantages will become more apparent during the course of the following description when taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings, wherein like numerals refer to like parts throughout:
FIG. 1 is an exploded perspective view of the component parts of the modular conduit spacer system of the invention;
FIG. 2 is a front elevational view of the conduit spacer system assembled below ground level;
FIG. 3 is an enlarged, fragmentary elevational view of the spacer adapter clamp with a conduit supported thereby, mounted on the arcuate surface of a conduit spacer; and
FIG. 4 is an enlarged, fragmentary sectional view taken substantially along the line 4--4 of FIG. 3 with the conduit removed.
DESCRIPTION OF THE INVENTION
Referring now more particularly to the drawings, there is illustrated in FIG. 1 the components of the conduit spacer system of the invention consisting of a modular base unit 10, a modular intermediate unit 12, and an adapter clamp 14. Although the system will be described with reference to conduits, it is understood by those skilled in the art that pipes may be similarly supported and spaced in the same manner as are conduits. Therefore, the term conduit as used herein and in the claims is understood to include pipes, ducts and other tubular constructions as well as conduits. The modular units 10 and 12 may be assembled and interlocked together, as will be explained hereinafter, to form appropriate support and clamping means for a plurality of conduits of the same diameter. It will also be appreciated that any number of these units may be combined to make up the basic structure of the system. The adapter 14 is designed for supporting a smaller diameter conduit and is detachably securd to either of the modular units 10 or 12 as needed. The modular units and adapter clamp are preferably made of a molded, somewhat resilient plastic material, either a thermoplastic or a thermoset polymer resin, such as, for example, high impact styrene resin, ABS resin (acrylonitile-butadiene-styrene), polyvinylchloride, polyolefins, e.g., polypropylene, etc.
The modular base unit 10 is in the form of an open, generally rectangular frame 16 having two substantially parallel and upright sides 18 and 20 joined at their lower ends by an enlarged planar base 22. Opposite the planar base 22 is an inwardly recessed, arcuate side 24 which forms a surface or saddle for receiving a conduit to be supported thereby. The arcuate side 24 is sized and shaped to receive a given diameter conduit and is of suitable thickness and width to provide sufficient strength and support thereto. A plurality of post members or struts 26, three in number in the example illustrated, extend between the side 24 and the planar base 22 for added strength and support. Projecting inwardly from the perimeter of frame member 16 is a continuous central reinforcing rib 27 which merges with ribs 28 formed on opposite surfaces of each strut 26. The modular unit 10 thus provides a substantially rigid and strong open frame made of a lightweight material which can be readily surrounded by earth or poured concrete, for the reasons hereinbefore mentioned.
The modular intermediate unit 12, like base member 10, is also in the form of an open, generally rectangular frame 29 to insure uninhibited flow of filling material therethrough. The frame is provided with two substantially parallel and upright sides 30 and 32 which are joined at their opposite ends by inwardly recessed, symmetrically disposed, arcuate sides 34 and 36. These sides form surfaces sized and shaped to receive a conduit of given diameter and are of a suitable thickness and width to provide strength and support thereto. A post member or strut 38, intermediate sides 30 and 32 and parallel thereto, extends between arcuate sides 34 and 36 to provide increased support for superimposed tiers of conduits to be supported by the intermediate modular unit 12. A continuous central reinforcing rib 39 projecting inwardly from the perimeter of frame member 29, merges with ribs 40 formed on strut member 38 for added strength and rigidity.
As previously mentioned, the modular units 10 and 12 include cooperating interlocking means, which upon assembly, provide a positive locking engagement therebetween. The interlocking means, although not restricted thereto, can be of the type disclosed and claimed in U.S. Pat. No. 3,856,246, which is incorporated herein by reference. Briefly, as illustrated in FIGS. 1 and 2, there is provided adjacent opposite ends of each arcuate side 24 and 36, a pair of elongated bifurcated lugs 42 and 44, respectively. The inner surfaces of the bifurcated lugs 42 and 44 include a series of parallel, transversely oriented wedge-like projections, designated respectively at 46 and 48. Additionally, there is provided adjacent opposite ends of arcuate side 34 of intermediate unit 12, a pair of elongated prong members 50 each having on opposite sides thereof, a series of parallel, transversely oriented wedge-like projections 52, complementary to the wedge-like projections 46 and 48.
It can thus be seen that when assembling the modular units 10 and 12 together, the prongs 50 with projections 52 will be forceably inserted between the inner surfaces of the bifurcated lugs 42 and associated projections 46 in interlocking engagement therewith. Once the modular units are interconnected in this manner, they cannot be separated by forces exerted in opposite directions and in the plane of the drawing, i.e., substantially perpendicular to the axis of the conduit supported therebetween. However, if so desired, they may be disconnected by sliding one relatively to the other in opposite directions substantially parallel to the axis of the conduit supported thereby.
It is readily understood that a plurality of intermediate modular units 12 may be properly interconnected one above the other by the means just described to provide complementary saddle-like surfaces for supporting conduits in vertically spaced, parallel arrangement. The top conduit of a row may be disposed so as to be freely supported by the arcuate surface 36 of the last intermediate unit 12 if so desired, or, preferably, the conduit may be securely clamped in position by another intermediate unit 12 or a base unit 10 (e.g., with the addition of adapter prongs as disclosed in the aforementioned U.S. Pat. No. 3,856,246) to prevent the conduit from floating during the burial thereof.
Although the modular base unit 10 has been shown provided with bifurcated lugs 42 at the two upper corners for interlocking with the prong member 50 of the modular intermediate unit 12, it is obvious that such an arrangement could be reversed or, alternately, that the base unit 10 be provided at each upper corner with a lug 42 and a prong member 50 and that the intermediate unit 12 have disposed on diagonally opposite corners thereof, lugs 42 and prong members 50, respectively.
The modular units 10 and 12 are also provided with lateral connecting means to interlock the modules in a side-by-side or horizontal arrangement. To this end, side 18 of base unit 10 and side 30 of intermediate unit 12 have a pair of spaced, generally cylindrical tongue portions 54 and 56, respectively. In addition, the opposite side 20 of base unit 10 and the opposite side 32 of intermediate unit 12 is provided with a pair of similarly spaced cylindrical grooves 58 and 60, respectively, which are adapted to receive respective tongue members 54 and 56 on adjoining modular units.
Thus, a bank of properly spaced and parallel conduits of a given diameter may be built up using the modular units 10 and 12 to form the basic structure of the system. To this end, a plurality of predetermined size base units 10 which correspond to the diameter of the conduit to be supported are first interconnected side-by-side on the ground or, as shown in FIG. 2, in a trench 62 by tongue and groove means 54 and 58. Parallel rows of the interconnected base units 10 are arranged at spaced intervals along the bottom of the trench 63, and a number of conduits 64 are disposed such as to be supported above the ground at axially spaced points along the length of the trench 63 on the saddle surfaces formed by the arcuate sides 24 of the base units 10. A like plurality of intermediate units 12 are then interconnected by tongue and groove means 56 and 60, and each row is clamped over the conduits, onto a row of base units 10 by the interlocking engagement between prongs 50 and bifurcated lugs 42. Although only one row of horizontally disposed conduits 64 is illustrated in FIG. 2, it is apparent that in like manner, several rows or partial rows of conduits of the same diameter may be superimposed in proper vertical and lateral spacing and in substantially parallel alignment.
As was previously mentioned, it is often advantageous to include different diameter conduits within the same system. Although there are some systems known in the industry which will accommodate conduits of different diameter, they are either difficult or inconvenient to install, e.g., threading a spacer over the end of a conduit, or they contain several parts which are time-consuming to assemble adding considerably to the cost thereof.
In accordance with the present invention, there is provided as best shown in FIG. 1, a U-shaped adapter clamp or conduit holder 14 of one piece construction that can be readily attached to any one of the arcuate surfaces of modular units 10 and 12. The adapter 14 is molded of a resilient, plastic material and includes a flexible planar base member 66 having novel means which permits the easy and secure attachment thereof to concave arcuate surfaces of various radii and thicknesses. The base 66 as viewed in FIG. 1 is of a generally rectangular, elongated configuration having opposite ends 68 and 70 and including upper and lower surfaces, 72 and 74, respectively. Although the base is shown and described as being rectangular, it is to be understood that it may be of another configuration, with the only requirement being that it be of sufficient length to meet the needs of the invention, which will be more fully hereinafter explained. In this same connection, the base 66 may be tapered in thickness, being thinner adjacent the ends 68 and 70 than at the center portion. As used herein, the terms upper, lower, top, bottom, and the like, are applied only for the convenience of description with reference to the drawings and should not be taken as limiting the scope of the invention.
The adapter 14 also includes a resilient, generally U-shaped body 76 having its open end extending outwardly away from the upper surface 72 of the base member 66 and its opposite, closed end integrally joined to the base member by a transversely disposed web portion 78 intermediate opposite ends 68 and 70. The axis of the U-shaped body 76 lies in a plane parallel to the base member 66 and is normal to the longitudinal direction thereof.
The inner configuration of the U-shaped body 76, i.e., the conduit engaging surface 79 (FIG. 3), is generally circular in shape having a diameter approximately equal to the outside diameter of a conduit 80 to be supported thereby, with the spacing between the open ends 82 and 83 being less than the outside diameter of the conduit 80. The width of surface 79 is sufficient to provide suitable bearing support for the conduit to be supported thereby. Extending upwardly and outwardly from the open ends 82 and 83 and integral therewith are angular walls or cams 84 and 86, respectively. The angular walls 84 and 86 are integrally connected to opposite side walls or arms 88 and 89 of the U-shaped body 76 by top walls 90 and 92, respectively. Projecting radially outwardly from the body 76, as best shown in FIG. 3, is an integral, central reinforcing rib 93 for increased strength and rigidity.
As mentioned above, the U-shaped body 76 is made of a resilient material. Thus it can be readily appreciated that as the conduit 80 is inserted into the open end of body member 76, the sides thereof will engage the angular walls or cams 84 and 86 urging them outwardly together with arms 88 and 89 to permit passing of the conduit therebetween and into engagement with surface 79. As the widest (diameter) portion of the conduit 80 passes through the innermost ends 82 and 83, the arms 88 and 89 return to their natural position, firmly capturing the conduit within the U-shaped body 76. It should be understood that the angular disposition of integral members 84, 90 and 88 on one side and 86, 92 and 89 on the other side, together with rib 93, provides sufficient rigidity to the body member 76 to maintain surface 79 in a clamping engagement with the conduit 80. This prevents the conduit from floating out of the body member 76 when being encased with concrete or other filling material in a trench.
A significant feature of the present invention is the provision of a snap-on clip, generally designated 95, that permits easy and secure attachment of adapter clamp 14 to any of the arcuate surfaces 24, 34 and 36 of modular units 10 and 12. As will be explained, not only can the novel clip be attached to various diameter arcuate surfaces of the units 10 and 12, they can be readily attached to the arcuate surfaces of a wide variety of spacer systems used in the industry.
Referring to FIGS. 1, 3 and 4, the flexible base member 66 which is a vital part of the unique snap-on clip 95 and depending from opposite longitudinal sides thereof, two pairs of opposed, centrally located, resilient legs 96. As illustrated in FIG. 4, the opposed legs 96 of each pair (only one pair being shown) have inner surfaces formed with inwardly directed shoulders 98 and include diverging cam surfaces 99 which extend downwardly from shoulders 98, i.e., away from base member 66. The clip is designed so that the distance between the innermost reach of each pair of opposed shoulders is less than the width of the arcuate surface on which the clip will be supported, and the distance between the shoulders and the base 66 is greater than the thickness of the arcuate surface.
To attach the snap-on clip 95, and thus the adapter clamp 14, to an arcuate surface such as 36 (FIGS. 2 and 3), the adapter 14 with each pair of opposed legs 96 placed astraddle the surface 36 is simply forced downwardly thereover, flexing the opposed cam surfaces 99 and shoulders 98 sufficiently apart to allow the shoulders 98 to pass beyond the edges of arcuate surface 36. In this connection, the pairs of opposed legs 96 are spaced longitudinally along the base and centered with respect thereto to straddle the strut 38 and assure centering of the adapter 14 on the arcuate surface 36. The resilient base member 66 extends longitudinally beyond each pair of legs 96 a predetermined distance so that as the clip is being attached to the arcuate surface 36, the lower surface 74 of opposite ends 68 and 70 comes into engagement with a portion of surface 36, resisting the downward force being applied thereto and, upon continued downward pressure, flexing upwardly and placing the clip 95 under the influence of an upward bias. Thus, as the shoulders 98 are forced beyond the edges of arcuate surface 36 they will snap back to their normal or natural position due to the resiliency of leg members 96 and, upon the downward pressure ending, will be urged upwardly into locking engagement with the underside of surface 36, securely attaching the adapter 14 thereto. If for any reason it should become necessary to remove the adapter, this may be accomplished by deflecting the legs 96 on one side of the base outwardly disengaging the shoulders from the underside of surface 36 and releasing the clip therefrom.
Snap-on clip 95 of the conduit holder 14 is designed to be easily adapted for attachment to arcuate surfaces of varying radii and thicknesses. Thus, it will be appreciated that by decreasing the length of the base member 66 on either side of the legs 96 while maintaining the spacing as shown between the surface 74 and shoulders 98, the clip would more readily conform to an arcuate surface of considerably smaller radius than that illustrated. Conversely, lengthening the base on either side of the legs would provide secure attachment to an arcuate surface of considerably larger radius than shown. Alternately, the same effect may be accomplished by maintaining the length of the base member as shown and either increasing or decreasing the spacing between the surface 74 and shoulders 98. The spacing between surface 74 and shoulders 98 also, of course, determines the range of thicknesses of support surfaces the snap-on clip may be attached to.
With reference to FIG. 2, the basic structure consisting of a plurality of modular units 10 and 12 of predetermined radius is assembled to support a bank of conduits 64 of given diameter in parallel, spaced relation, as hereinbefore described. When it is desired to use smaller diameter conduits such as shown at 80 in the same system, a plurality of adapter clamps 14 having the same diameter as the smaller conduit 80, are simply forced down into a snap-fitting engagement with the arcuate surfaces 36 of each intermediate unit 12 as needed. After a series of adapters are in place, i.e., longitudinally spaced along the intended path of installation, the conduit 80 is aligned with the open ends of the respective U-shaped body members 76 and forced downardly thereinto to provide a clamping arrangement therewith. Alternately, if so desired, the adapter clamps may be first snapped onto the conduit 80 and then forced into snap-fitting engagement with the arcuate surface 36.
The adapter clamp 14 may be made in a variety of sizes, i.e., diameters, to support conduits of different diameters and it is apparent that more than one size of adapter may be used in any one system, such as shown at 14' in FIG. 2.
It should be understood that although the snap-on clip 95 is illustrated and described in the preferred embodiment as having two pairs of opposed legs 96, one pair would suffice. Also, while the adapter is shown as being centrally located within respect to the arcuate surface 36, it is conceivable that it may be attached at any point on the surface. For that matter, it is possible to attach the adapter to the opposed arcuate surface 34 in a hanging, upside down orientation, if so desired. In this latter respect, and when installing a smaller diameter conduit in the system, the conduit is first disposed freely on the arcuate surfaces of a series of aligned, longitudinally spaced modules which can be either units 10 or 12. A like series of intermediate units 12, each having an adapter 14 secured to the upper surfaces 34 thereof, is then interconnected with respective support units 10 or 12. Finally, the conduit is pulled upwardly into the U-shaped body 76 and into clamping engagement therewith. This can be accomplished either after each intermediate unit is connected to its respective support unit or after the entire series thereof is in place.
It is to be understood that the forms of the invention herewith shown and described are to be taken as preferred embodiments of the same, and that various changes in the shape, size and arrangement of parts may be resorted to without departing from the spirit of the invention.
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A conduit system for supporting and clamping a bank of conduits of different diameters in a substantially parallel and spaced apart relationship which requires a minimum number of parts and which can be assembled simply and rapidly. The basic structure is comprised of a plurality of vertically and horizontally interlocking modular units, each consisting of a frame member having at least one side thereof including an arcuate surface corresponding to the outside diameter of a first conduit. The conduit is supported on the arcuate surface of one frame member and clamped thereon by a second, superimposed, interlocking frame member. A unitary generally U-shaped adapter is employed to support a smaller diameter conduit within the system. One end of the adapter includes a snap-on clip to facilitate attachment to an arcuate surface of a frame member and the opposite end comprises a pair of opposed resilient arms for receiving and holding the smaller conduit in a fixed relationship to the arcuate surface.
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BACKGROUND OF THE INVENTION
The invention relates to a plant for the manufacture of glass stoppers provided with a head part for the closing of bottles, in particular of wine bottles and sparkling wine bottles, comprising a multi-part mold which determines, in the closed state, the negative contour of the stopper to be manufactured, a feeder system for the supply of the mold with molten glass, a multistation press and an arrangement for the removal and for the further handling of the glass stoppers produced as well as glass stoppers in particular produced by means of such a plant.
Glass stoppers for the closing of bottles are known. These known glass stoppers are usually manufactured by means of the so-called injection method, i.e. liquid glass material, which fills the hollow space of the mold, and is injected into a closed mold from the lower side or from the upper side. After corresponding cooling, the solidified glass string at the supply side has to be cut off. It is not only a disadvantage in this process that the cut position also has to be ground and polished for the re-establishment of the glass character, but substantial residual glass above all arises in the reservoir which has to be eliminated or, optionally, sent to recycling. Generally, this injection process for the manufacture of glass stoppers is technically complex and accordingly also expensive.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a plant for the manufacture of glass stoppers for the closing of bottles which, on the one hand, ensures a glass stopper production in accordance with precisely pre-determined contours and, on the other hand, permits a dramatic reduction in the production costs and thus the use of such glass stoppers in particular subsequently completed with an elastic seal in a large volume and also permits conventional closing corks as a replacement.
A plant in accordance with the invention includes a multi-part mold which determines, in the closed state, the negative contour of the stopper to be manufactured, a feeder system for the supplying of the mold with molten glass, a multistation automatic press and an arrangement for the removal and for the further handling of the glass stoppers produced; and this plant is characterized in that the mold is formed by a base part having a cut-out corresponding to a first part length of a stopper, by a middle part of two part elements of a mold which can be displaced relative to one another and perpendicular to the longitudinal mold axis, which can be coupled in a self-centering process and which determine a hollow space corresponding to a second part length of a stopper and to at least one main region of the head part in the coupled state and in the state contacting the base part, and by an upper part closing the hollow space of the head part and having a central pressing stamp axially displaceable relative to the upper part for the formation of a tolerance compensating recess in the head part of the stopper.
It is possible in a surprising manner by means of such a plant, despite unavoidable fluctuations of the weight of the glass gob required to feed the mold and despite unavoidable changes in the mold volume caused by necessary mold cleaning processes, to permanently satisfy the pre-determined precision demands, and indeed by the specific design of the mold, on the one hand, and the provision of a tolerance compensating recess in the head part of the stopper, on the other hand.
A particularly advantageous aspect of the invention is characterized in that the hollow space of the mold associated with the middle part extends axially upwardly beyond the planar surface of the head part and the upper part with an associated pressing stamp closing the hollow space of the head part and engages in a shape-matched manner with a ring neck into the hollow space determined by the part elements of the mold, with the outer diameter of the ring neck being smaller than the outer diameter of the head part.
In this manner, the head part of the stopper—to the extent its radially outer contours are affected—is shaped in the hollow space formed by the part elements of the mold. The planar surface of the head part is bounded by the ring neck and by the plunger of the upper part of the mold. When the mold is closed, the position of the dividing line between the upper part of the mold and the part elements of the mold forming the middle part of the mold is selected such that it is disposed beneath the planar surface in the region of the stopper rounding. In this manner, any disturbing, in particular function-disturbing burr-formation, is eliminated with certainty and, moreover, a perfect surface of the upper planar surface and of the upper cylindrical surface of the head part is ensured.
The part elements of the mold determining the individual regions of the mold are made such that they center themselves when moved together, for which purpose the mold surfaces contacting one another in the closed state are provided with complementary mold closing members which preclude any lateral offset. The avoidance of lateral offset is of substantial importance for the observation of the precision criteria. In this connection, the provision of a cross-centering device between the middle part and the upper part also has a particularly advantageous effect.
A further special feature of the invention consists of the fact that the station designed for the feeding of the mold with glass gobs is simultaneously made as a station for the carrying out of the pressing process. In this manner, a substantial quality improvement of the glass stopper is achieved, since the pressing process is carried out immediately directly after the introduction of a glass gob into the mold, i.e. without any disturbing time loss, and thus a fast attachment of the still relatively liquid glass to the mold on all sides is promoted which in turn results in a high surface quality of the finished product.
The feeder system used is made such that the individual glass gobs can impact onto the base of the mold while falling through the middle part of the mold without touching, for which purpose the diameter-to-length ratio of the individual glass gobs is selected to be in the range from approximately 1:3.5 and it is thus achieved that the respective glass gob length is larger than the depth of the total hollow space of the mold.
A likewise important measure for the high quality of the manufactured glass stopper consists of the fact that a fall and guide channel is provided in the feed station for the mold-centered supply of glass gobs with a pre-settable drop height. By this selectable drop height, which can, for example, lie in the range of approximately 1 m, so much kinetic energy can specifically be imparted to the respective glass gob that the impact energy resulting therefrom in the hollow space of the mold is just sufficient to bring the liquid glass of the glass gob practically abruptly into contact with the mold wall over the total mold height, and indeed up to and into the upper region, where the ring neck and the stamp of the upper part of the mold then become effective. This abrupt and full-area striking of the whole mold wall ensures a high quality of the glass or of the article.
The mold consisting of the individual components is preferably suspended freely hovering in a mold holder, in particular via a type of collar arm such that a free space is created beneath the mold into which any cullets which may arise, or also stoppers not correctly transported away, can fall so that no risk of a disturbance of the closing movement of the mold can arise.
To ensure that releasing tendencies of the glass from specific regions of the mold wall during the cooling process which can result in a reduced quality are eliminated, in accordance with the invention, a mechanical or pneumatic follow-up pressing takes place in one or more stations downstream of the feeding and pressing station, which results in a stabilization of the outer skin. For this purpose, the recess and/or the planar surface are also acted on by pressure by compressed air or also by means of a stamp for a brief period, e.g. during approximately half a second.
A device which becomes active directly after the pressing process is preferably used for the short-term heating of the region of the recess of the head part to achieve shrinking processes being restricted to this region not representing a functional surface. If the collapsing of the surface due to shrinking in this non-critical region is to be prevented or minimized, a pressing stamp with a concavely formed end face is preferably used so that the convex region initially created is changed to a substantially planar region after shrinking has taken place and thus a higher quality product is created.
The measures described above also contribute entirely to the fact that the tolerances in the region of the seal to be received can be pre-determined in a very defined manner and can be observed precisely, which is of substantial importance for the trouble-free function of the finished glass stopper in cooperation with a bottle to be closed.
A glass stopper in accordance with the invention for the closing of bottles which is in particular suitable for the reception of a ring-shaped seal element in the transition region from the stopper part to the head part is characterized in that this glass stopper is made as a pressed glass stopper and in that a plate-shaped or dish-shaped recess with or without lettering is provided in the head part adjoining the stopper part.
The volume of this recess does not have to remain constant in the production of a plurality of such glass stoppers, but it is characteristic for the glass stoppers in accordance with the invention that this volume is variable to a certain extent in order to compensate tolerances of the glass gobs and/or changes of the hollow space of the mold in this manner.
The stopper part has a ring-shaped recess adjacent to the head part for the reception of a ring-shaped seal, in particular a seal L-shaped in cross-section, wherein the part of the L-shaped seal disposed in the recess is designed somewhat in the manner of a bead in the manner of an O ring and the part of the L-shaped seal adjoining the lower side of the head part is designed in the form of a flat ring so that this seal part of flat-ring shape comes to lie between the upper end of a bottle and the head part.
Glass stoppers for the closing of bottles are subjected to very substantial strains and stresses in practice, with damage to such glass stoppers being able to result in a restriction of their function and in particular also to risks for the consumer. There is accordingly a large interest in ensuring that such glass stoppers are not damaged where possible on their way between the manufacture in the glass press and their end in the glass container for recycling glass.
It becomes possible in accordance with the present invention to dramatically increase the insensitivity of such glass stoppers with respect to mechanical damage, for which purpose the glass stoppers are subjected to a controlled hardening process directly after their mold removal in the press.
In this controlled hardening process, the glass stoppers are first heated to a substantially uniform temperature throughout, in particular in the range of 500 to 600° C., and are then cooled very intensely, in particular with fan air, with first the outer skin of the glass stopper being cooled very fast as part of this intense cooling and thus being stabilized.
Since glass is a poor conductor of heat, it takes some time until the heat stored at the interior of the glass stopper can move outwardly and be dissipated by the fan air. During the cooling of the core of the glass stopper, this core attempts to shrink or to contract, which is, however, prevented by the already cooled and so firm outer skin. The consequence of this is that very strong tensile stresses build up at the interior of the glass stopper which are compensated and balanced by corresponding pressure stresses inside the outer skin.
The glass stopper thermally hardened by controlled quenching in accordance with the invention has substantial compression stresses in its outer regions; i.e. before the glass stopper breaks, tensile stresses must first be introduced into these outer regions which are higher than the compression stresses induced by the controlled quenching. The glass stopper accordingly has a substantially increased strength in use.
This high strength of the glass stopper in accordance with the invention represents a substantial safety aspect in the handling and practical use of the glass stoppers and also ensures an always absolutely secure closing of the bottles. This could not be ensured in the required manner if the stopper were even slightly damaged and if in particular the support surface for the seal were impaired.
Such disturbing damage can in particular also occur in the bottling machine of the bottles; however thermally hardened stoppers in accordance with the invention are decisively less sensitive to such risks of damage.
If, however, such a stopper in accordance with the invention is actually damaged, e.g. by scratching or the like, this stopper would immediately disintegrate into a plurality of small particles due to the high stresses present in the glass; i.e. a practically automatic separating out of damaged stoppers takes place. The disintegration into a plurality of small particles also represents an advantage under safety aspects.
Embodiments of plants in accordance with the invention will be described in the following with reference to the drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic axially sectional representation of the mold used inside the plant for the manufacture of glass stoppers;
FIG. 2 is a schematic axially sectional representation of an embodiment variant in which the pressing mold is suspended freely hovering in a mold holder;
FIG. 3 is a representation substantially corresponding to FIG. 2 , with two molds, however, being received simultaneously in the mold holder; and
FIG. 4 is a further schematic axially sectional representation approximately analogous to FIG. 1 , with a particularly advantageous aspect and a corresponding interaction between the part elements of the mold and the upper part of the mold, however, being realized.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with FIG. 1 , a mold suitable for the manufacture of a pressed glass stopper 10 in accordance with the invention includes a base part 1 , a middle part 2 and an upper part 3 to which an axially movable pressing stamp 5 belongs.
The preferably cylindrical pressing stamp 5 is guided separately or precisely in the upper part 3 of the mold and is supported with respect to this upper part via a plurality of compression springs 6 , which are preferably arranged in ring shape, and a centrally arranged compression spring or pneumatic cylinders such that, in the mold closing process, the upper part 3 first comes into contact with the middle part 2 and the pressing stamp 5 then comes into lagging effect.
A cut-out 7 is provided in the base part 1 which is closed at the base side by a plunger 4 whose diameter is smaller than the base area of the cut-out 7 . This plunger 4 has a planar, concavely or convexly formed shape or any end face forming a desired shape in the article and is axially movably supported. The plunger 4 takes over an ejection function with respect to a finished glass stopper when the mold is open. It is particularly advantageous to design the axial movability of the plunger 4 such that it can be retracted in the feeding process while enlarging the hollow space of the mold. An improvement of the feed is achieved in this manner since the elongate drop can be received in the mold in a particularly favorable manner with a retracted plunger such that the upper mold region initially remains free, i.e. does not come into contact with the molten glass, and the danger of an unwanted tilting of the elongate glass drop is moreover eliminated. On the closing of the mold, the plunger 4 and the pressing stamp 5 can be moved in opposite directions.
The slightly conical shape of the lower part of the stopper 10 is pre-determined by the cut-out 7 . A discontinuity 13 is provided at the transition from the base part to the middle part in the outer contour of the stopper, since a transition from the conical region to a cylindrical region takes place at this point. A disk-shaped head part 11 adjoins this cylindrical region of the stopper 10 and its outer contour is pre-determined in this case by the middle part 2 and the upper part 3 of the mold. An embodiment preferred with respect to this will still be explained with reference to FIG. 4 .
The two mold halves 8 , 8 ′ of the middle part 2 are made in a self-centering manner for the avoidance of any lateral offset on the putting together and determine a hollow space 9 which is closed by the upper part 3 . This hollow space 9 defined in this manner can be pre-set very precisely and the mold in accordance with the shape ensures not only a precise pre-setting of the thickness dimension of the ring-shaped head part, but also a planar surface of high quality at the front face of the stopper.
The formation of a recess 12 in the head part 11 by means of the pressing stamp 5 is of particular importance since tolerances of the glass gobs and/or changes of the hollow space of the mold, originating from required cleaning processes, can be compensated by this recess such that the demands on the precision of the outer contours of the stopper 10 can always be ensured.
On the operation of the mold in accordance with the invention, the introduction of the glass gobs provided by means of the feeder apparatus can take place such that the glass gob formed can fall freely downwardly to the base of the base part 1 and an attachment of the glass mass to the mold walls takes place in the course of the collapse of the elongate glass gob, with the mold being closed by means of its upper part 3 when the glass mass has substantially filled up the hollow space 9 .
FIG. 4 shows an embodiment substantially corresponding to the previously described plant, but improved, with the outer contour of the head part 11 being largely pre-determined by the middle part 2 of the mold. For this purpose, the hollow space 9 determined by the part elements 8 , 8 ′ of the mold is guided upwardly in the axial direction beyond the planar surface 14 of the head part 11 , and the upper part 3 with the associated pressing stamp 5 closing the hollow space of the head part is fitted with a ring neck 20 which engages in a shape-matched manner into the hollow space 9 determined by the part elements 8 , 8 ′ of the mold. In the closed state of the mold shown on the left-hand half of the representation, the upper part 3 is seated on a ring shoulder 19 of the part elements 8 , 8 ′ of the mold. The outer diameter of the ring neck 20 is smaller than the outer diameter of the head part 11 . The radially outer region of the ring neck 20 is concavely curved, which has the consequence that the dividing line between the upper part 3 of the mold and the middle part 2 is disposed beneath the planar surface 14 so that any burr formation in the region of the planar surface 14 representing a functional surface is generally precluded. The quality of the stopper produced is thus further increased and a possible source for rejects is eliminated.
The cross centering device 21 provided, which also always functions well at different temperatures, contributes to the achieving of an always constant high quality. The grooves marked by a crossed quadrilateral are arranged concentrically to the ring neck 20 and are fitted to the part elements 8 , 8 ′ of the mold, whereas the associated noses engaging into the grooves are provided in a corresponding manner at the upper part 3 of the mold. The arrangement of the grooves and of the associated noses can also take place in a reverse manner with respect to their position.
It is important for all the described embodiments of plants in accordance with the invention that the introduction of the molten glass gob into the mold and the closing of the mold associated with the final molding of the glass gob take place in connection with the pressing process in one station, since this ensures a minimization of the time span between the lens gob supply and the demolding of the glass stopper and thus ensures a high quality.
A fall and guide channel is preferably provided in the feed station in order to achieve the desired high quality of the produced glass stopper, the fall and guide channel making it possible to release the glass gob at a defined height above the mold and to accelerate it by gravity such that a practically direct contact of the liquid glass to the whole mold wall takes place up to and into the region in which the stamp becomes effective by the reshaping of the kinetic energy on the impact of the glass gob onto the mold wall. Whereas a deterioration of the article quality could result at specific regions of the mold surface without this measure due to fast hardening of a thin glass layer, this undesired effect is eliminated with certainty by the glass gob supply described above via an almost perpendicular fall and guide channel which can also additionally have a shaping effect with respect to the glass gob.
It is required by the feeding of the mold and by the carrying out of the pressing process taking place in the same station for the upper part 3 of the press with the pressing stamp 5 to be designed to be able to be pivoted away or moved, which can take place, for example, via a suitable cam guide in the manner of an S curve. It is of importance in this connection that this movable pressing unit already starts during the fall of the glass stopper, accelerates in the course of the cam track and is braked again before the closing of the mold so that disturbing impact actions on the mold are avoided and ideally short cycle times can be ensured.
To preclude the glass releasing from the mold at an unwanted point during the cooling process due to shrinking and lesser quality thereby being created, a mechanical or pneumatic follow-up pressing is preferably carried out for the stabilization of the outer skin in one or more of the stations downstream of the feeding and pressing station. The corresponding pressure action takes place in the region of the head part 11 , i.e. in the region of the recess 12 and, optionally, on the planar surface 14 surrounding this region.
To restrict the shrinking procedures to a region not critical with respect to the function of shrinking, the recess 12 in the head part 11 is preferably again heated directly and briefly, e.g. by means of a burner, directly after the pressing process, with this heating being restricted to this recessed region. It is achieved in this manner that shrinkage-induced collapsing effects are restricted exclusively to this non-critical region of the recess and have no effect on functional surfaces, in particular not on the planar surface 14 representing the functional surface.
If a shrinkage-induced subsiding of the surface of the recess 12 should be precluded or minimized, a pressing stamp 5 with a concave end face can be used, since the surface of the recess 12 can in this manner first be convexly shaped and then be changed into a practically planar surface by shrinkage.
All these measures contribute to both the technical demands with respect to high precision and the esthetic demands with respect to the appearance of the glass stopper being satisfied in the mass production of such glass stoppers and above all also to the tolerances in the region of the seal to be received being able to be observed very precisely.
The required cooling of the mold primarily takes place by radiation of the heat, with the mold already being able to be opened after a relatively short time and the stopper obtained, which still has a temperature of approximately 500° C. in the outer region, being able to be removed. This removal after the mold opening has taken place takes place by an ejection movement by means of the plunger 4 and by a suction grip engaging at the head part. Any jamming of the stopper in the mold is precluded in this manner.
The stopper removed in this manner can then be gripped laterally by claws and can be led via a line guide while simultaneously performing a rotary movement bringing the planar surface 14 downwardly to a transport belt which leads to a cooling track. After a corresponding cooling, the stoppers are preferably arranged in a row on a further transport track while using a so-called single-liner, where the stoppers can be checked in a fully automatic manner and can be provided with an elastic seal.
The packaging takes place subsequently, and indeed preferably in pallet form, with approximately 900 pieces being able to be accommodated in one layer per square meter so that, for example if a possible 33 layers on a pallet are used, approximately 30,000 stoppers can be combined together and a total weight of approximately 0.8 tons is obtained. This means that approximately 33 pallets or approximately 1 million stoppers can be transported without problem on a truck and, accordingly, that the transport costs per piece are largely negligible. The invention thus makes it possible to operate the respective plant for the production of glass stoppers in the location best suited for it, since the transport costs to the bottling location where the stoppers are required are of no import cost-wise.
For the practical use of the plant in accordance with the invention, it is generally of importance that the glass stoppers exit the pressing machine complete and ready for use and that no rework at all is necessary and that the glass requirements are equal to the weight of the finished parts; i.e. no disturbing residual glass at all occurs in the production. It is furthermore of importance for the economy of the plant that the glass stoppers can be transported fully automatically from the pressing mold up to and into the cooling track and can be automatically removed, checked and completed or packed at the end of the cooling track.
FIG. 2 shows in a schematic manner a preferred embodiment with a mold holder 16 in which the middle part 2 of the mold consisting of the base part 1 , middle part 2 and upper part 3 is suspended in a practically freely hovering form. It is achieved by such a mold holder that cullets or complete stoppers which cannot be transported away cleanly fall downwardly into the free space 17 and can be removed from there. It is thus ensured that such cullets or stoppers or stopper parts can in no way disturb the closing movement of the shape as would then be the case if the molds were to slide on a base plate in a conventional manner and if the pressing forces exerted from above were transmitted directly from the mold onto the base plate and were absorbed there. In the case of the use provided in accordance with the invention of a mold holder 6 , the mold is supported via a base part 18 which is individually associated with the mold and next to which the required free spaces 17 result.
FIG. 3 substantially corresponds to the representation in accordance with FIG. 2 ; however, in this case, two molds are received simultaneously in the mold holder 16 to permit a double-drop operation so that two glass stoppers 10 can be pressed simultaneously. An individual support of the individual molds via a base part 18 is also achieved here while forming free spaces 17 disposed beneath the molds.
To take account of impact strains which occur on the handling of the glass stopper and in particular also on the closing of bottles and to further increase the security against possible breakage effects in the region of the flange, in accordance with the invention, the planar surface is preferably provided with a thin damping layer, preferably of a plastic material. In an analogous manner, such a damping layer could also be provided in the aluminum hood disposed opposite the planar surface of the stopper, the aluminum hood being applied engagingly over the stopper as part of the closing of bottles. Optionally, a loose damping element could also be used between the stopper and the aluminum hood.
The thickness of the damping layer to be applied to the planar surface of the stopper corresponds to a thin foil and can, for example, be applied by rolling and subsequent curing.
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The invention relates to an installation and a method for producing glass stoppers which are provided with a head portion and are used for sealing wine bottles and sparkling wine bottles. The installation comprises a mold for producing glass stoppers, a feeder system for supplying the mold with molten glass, a multistation press, and a removing and handling system for the finished glass stoppers. The mold is formed by a base that comprises a recess corresponding to a first partial length of the stopper, a central part consisting of two partial molding elements which can be displaced relative to each other as well as perpendicular to the longitudinal axis of the mold, can be coupled in a self-centering manner, and define a hollow space that corresponds to a second partial length of the stopper and to at least one main area of the head portion when the partial molding elements are coupled and rest against the base, and a top part which seals the hollow space of the head portion and is provided with a central male die that can be displaced in an axial direction relative to the top part so as to embody a recess in the head portion of the stopper, the recess compensating tolerances.
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FIELD OF THE INVENTION
The present invention relates to the field of supporting plants, fences or objects by structures extending from and anchored below an exposed ground surface.
BACKGROUND OF THE INVENTION
It is often desirable to provide support and protection to plants, fences and object that are located above the exposed surface of the Earth, such as soil, sand, or an agrarian or rural landscape. The prior art includes a plurality of devices intended to anchor a support arm into earth, e.g., clay or topsoil. U.S. Pat. No. 202,179 discloses an “Improvement in Fence-Posts” comprising a slotted a hollow tube that may be driven into the ground. The tube slots are located at the tube end intended for placement into the ground, during which process individual elements of the tube defined by the slots are typically driven apart. The tube elements thus form support legs that angle away from a central axis of the tube body. The tube body is further configured to accept insertion of a solid post that provides support to a vertical fence.
U.S. Pat. No. 1,153,380 also includes a hollow tube with anchor elements defined by slots, but in distinction the slots run most of the length of the hollow tube are sized widely to accept fence wires that extend horizontally through the slots at vertical locations above the supporting earth. The hollow tube therein is itself a fence post that directly intersects with horizontal fence elements that are fastened to the tube. U.S. Pat. No. 1,263,132 discloses a long tube having short, narrow slits, whereby four legs are formed from the slotted end of the tube. Each leg is meant to fan out and away from a longitudinal access of the tube.
Other prior art devices attach anchoring features to a single solid post. U.S. Patent Application Publication Serial No. 20060236620 discloses three solid legs attached to and extending from a unifying solid post. U.S. Patent Application Publication Serial No. 20080271388 presents a solid post having one or more anchoring members, wherein the anchoring member presents both an insertion position and an anchoring position. The anchoring member is formed like a blade that is thinner than the solid insertion post to which the anchoring blade is coupled.
The prior art fails to provide solid elements that are driven into the ground to form both a linear supporting post section above the ground and an anchoring length that after insertion into the ground extends at an angle away from a longitudinal axis of the post section.
SUMMARY OF THE INVENTION
This and other objects of the present invention are made obvious in light of this disclosure, wherein a support system includes an anchoring post and a support module. The support module may be or include one or more arms that support or helps to protect at least a portion of a plant or object. The anchoring post includes two or more elongate elements that are coupled together substantially in parallel along a longitudinal axis, i.e., an elongate axis. The anchoring post presents a post section and an anchor section, wherein each anchor section is configured to angle progressively away from the longitudinal axis as the anchoring post receives a force that drives the anchor section substantially into the ground. The post section may comprise a combination of a post end of each of the elongate elements and the anchor section may comprise a combination of an anchor end of each of the elongate elements, wherein each anchor end extends continuously from a same elongate element that additionally comprises a post end. One or more second elongate elements may include an anchor tine that is configured for insertion into a ground material.
In various alternate preferred embodiments of the present invention, the anchoring post may comprise three or more elongate elements. Each elongate element may present a striking point distal from the anchor sections, wherein a plurality of striking points are disposed substantially proximate to a striking plane that is normal to the longitudinal axis. The striking points may be partially or wholly enclosed by a collar that compresses, maintains, and/or supports the anchor sections in a substantially parallel orientation.
In various still alternate preferred embodiments of the present invention, the anchoring post may be or comprise metal, metal alloy, a solid metal material such as metallic rebar, and/or a suitably rigid but malleable material known in the art. The post sections may alternatively or additionally be welded to each other and/or to one or more metal collars.
According to a first aspect of the method of the present invention, the support module may include one or more arms that are configured to alternately, optionally or additionally support one or more of the following: a. a netting; b. a protective plant cover; c. a tree trunk; d. a plant pot; e. a sign; f. a cistern and enclosed water; g. an animal barrier; h. a branch or other element of a plant extending above ground; and i. a fence.
One or more arms may be or comprise metal, metal alloy, a solid metal material such as metallic rebar, and/or a suitably rigid but malleable material known in the art. One or more arms may be welded to each other, to one or more anchoring posts, and/or one or more metal collars.
According to a second aspect of the method of the present invention, a plurality of support systems are installed to (a.) provide support or be comprised within a fence; (b.) provide support or protection to one or more plants; and/or (c.) at least partially protect or enclose an area.
According to a third aspect of the method of the present invention optionally, alternatively or additionally, a coupling element, such as a flexible tube, may be applied to couple arms of a same support module and/or arms of neighboring support systems. The coupled arms of one or more support modules may be configured and positioned to support a plant, such as a tree, or support a fence or fence element, such as netting.
The foregoing and other objects, features and advantages will be apparent from the following description of aspects of the present invention as illustrated in the accompanying drawings.
INCORPORATION BY REFERENCE
All publications mentioned herein are incorporated herein by reference to disclose and describe the methods and/or materials in connection with which the publications are cited. All publications, patents, and patent applications mentioned in this specification are herein incorporated by reference in their entirety and for all purposes to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference.
Such incorporations include U.S. Pat. No. 202,179 (Inventor: Lennon, S. N.; Issued on Apr. 9, 1818) titled “Improvement in fence-posts”; U.S. Pat. No. 1,153,380 (Inventor: Fussell, J. E.; issued on Sep. 14, 1915) titled “Fence-post”; U.S. Pat. No. 1,263,132 (Inventor: Sharpe, G. C.; Issued on Apr. 16, 1918); U.S. Pat. No. 6,088,953 (Inventor: Morgan, W; Issued on Jul. 18, 2000) titled “Collapsible protective plant cover”; U.S. Pat. No. 6,014,837 (Inventor, Morgan, W.; Issued on Jan. 18, 2000) titled “Adaptable plant protector”; U.S. Patent Application Publication Serial No. 20060236620 (Inventor: LaCrosse, W.; Published on Oct. 26, 2006) titled “Ground anchor”; U.S. Patent Application Publication Serial No. 20070062109 (Inventor: Jolley, W. B.; Published on Mar. 22, 2007) titled “Permanent underground staking system ad apparatus for vines and weakly rooted trees”; U.S. Patent Application Publication Serial No. 20080271388 (Inventor: Bayly, et al.; Published on Nov. 6, 2008) titled “Anchoring stake”.
The publications discussed or mentioned herein are provided solely for their disclosure prior to the filing date of the present application. Nothing herein is to be construed as an admission that the present invention is not entitled to antedate such publication by virtue of prior invention. Furthermore, the dates of publication provided herein may differ from the actual publication dates which may need to be independently confirmed.
BRIEF DESCRIPTION OF THE FIGURES
These, and further features of various aspects of the present invention may be better understood with reference to the accompanying specification, wherein:
FIG. 1 is an illustration of a first alternate preferred embodiment of the present invention, or first version, that includes two elongate elements;
FIG. 2 is a close-up partial view of an elongate element of the first version of FIG. 1 ;
FIG. 3 is a close-up partial view of an alternate, hollowed elongate element of the first version of FIG. 1 ;
FIG. 4 is a perspective side view of a second alternate preferred embodiment of the present invention having three elongate elements;
FIG. 5 is a perspective view of a third alternate preferred embodiment of the present invention having four elongate elements and four support arms;
FIG. 6A is an illustration of the third version of FIG. 5 , wherein the elongate elements are packaged for shipment;
FIG. 6B is an illustration of the third version of FIG. 5 and FIG. 6A in an unpackaged state and ready for installation;
FIG. 6C illustrates the third version of FIGS. 5 , 6 A and 6 B after an installation in a ground material by means of application of force by a hammer to the elongate elements;
FIG. 7A is a close-up view of an anchor section of the third version of FIGS. 5 and 6 A- 6 C positioned above the ground material of FIG. 6C ;
FIG. 7B is a close-up view of the anchor section of the third version of FIGS. 5 , 6 A- 6 C and 7 A partially inserted into the ground material of FIGS. 6C and 7A ;
FIG. 7C is a close-up view of the anchor section of the third version of FIGS. 5 , 6 A- 6 C and 7 A- 7 B fully inserted into the ground material of FIGS. 6 C and 7 A- 7 B,
FIG. 8 is an illustration of the second version of FIG. 4 that includes three elongate elements, the collar, and two support arms positioned to constrain a tree trunk;
FIG. 9 is an illustration of the second version of FIGS. 4 and 8 combined with a coupling element to constrain the tree trunk of FIG. 8 ;
FIG. 10 is a close-up partial view of the support arms of the second version of FIGS. 4 , 8 and 9 and the coupling element of FIG. 9 ;
FIG. 11 is an illustration of the third version of FIG. 5 positioned to support a plant pot and a flower pot;
FIG. 12 is an illustration of the third version of FIGS. 5 and 11 having two support arms configured into a rectangular outline;
FIG. 13 is an illustration of the third version of FIGS. 5 , 11 and 12 further comprising a visual sign;
FIG. 14 is an illustration of the third version of FIGS. 5 and 11 - 13 and positioned to support a vessel holding a liquid, e.g., a water bowl;
FIG. 15 shows a fourth alternate preferred embodiment of the present invention wherein a plurality of second versions of FIG. 4 are further comprised with a total of four support arms and are mechanically coupled together to form a fence in combination with a fence material;
FIG. 16 is an illustration of a fifth alternate preferred embodiment of the present invention, or fourth version, wherein a plurality of support arms initially extend upwards from a collar;
FIG. 17 is an illustration of the fifth version of FIG. 16 as installed into a ground material;
FIG. 18 is an illustration of the fifth version of FIG. 16 in a first deployed state;
FIG. 19 is an illustration of the fifth version of FIG. 16 in a second deployed state;
FIG. 20 is an illustration of the fifth version of FIG. 16 located proximate to a plurality of plants and supporting a netting; and
FIG. 21 is an illustration of the fifth version of FIG. 16 supporting the netting of FIG. 20 and enclosing a leaf-bearing plant.
DETAILED DESCRIPTION
It is to be understood that this invention is not limited to particular aspects of the present invention described, as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only, and is not intended to be limiting, since the scope of the present invention will be limited only by the appended claims.
Methods recited herein may be carried out in any order of the recited events which is logically possible, as well as the recited order of events.
Where a range of values is provided herein, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range, is encompassed within the invention. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges and are also encompassed within the invention, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits ranges excluding either or both of those included limits are also included in the invention.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present invention, the methods and materials are now described.
It must be noted that as used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise. It is further noted that the claims may be drafted to exclude any optional element. As such, this statement is intended to serve as antecedent basis for use of such exclusive terminology as “solely,” “only” and the like in connection with the recitation of claim elements, or use of a “negative” limitation.
Referring now to FIG. 1 , FIG. 1 is a side view of a first alternate preferred embodiment of the present invention 2 , or first version 2 , that includes a first elongate element 4 A and a second elongate element 4 B. Each elongate element 4 A & 4 B includes a striking end 6 A & 6 B, an elongate length 8 A & 8 B, and an anchor end 10 A & 10 B. One or more of the elongate elements 4 A & 4 B may be formed by a continuous solid material or a fully or partially hollowed-tube. The first version 2 preferably includes at least two elongate elements 10 A & 10 B.
The elongate elements 4 A & 4 B are coupled together at one or more coupling points 12 A, 12 B, 12 C and 12 D and held substantially in parallel with an elongate axis A, i.e., wherein each elongate element 4 A & 4 B is preferably within five degrees of planarity with the elongate axis A along the longest dimension of the respective elongate element 4 A & 4 B. The coupling points 12 A, 12 B, 12 C and 12 D may be or comprise single or combined welds and/or a pressure fitting. Each anchor end 10 A & 10 B includes a tine 34 A & 34 B that extends from an anchor coupling point 12 D.
A support module 14 configured may be attached to the elongate elements 12 A & 12 B as depicted in FIGS. 8 through 21 herein.
The anchor ends 10 A & 10 B of the elongate elements 4 A & 4 B in combination form an anchor section 16 of the first version 2 . The striking ends 6 A & 6 B and the elongate lengths 8 A and 8 B of the elongate elements 4 A & 4 B and in combination form a post section 18 of the first version 2 .
Each striking end 6 A & 6 B further comprises a striking point 20 A & 20 B that are each located within a same striking plane S.
Referring now to FIG. 2 , FIG. 2 is a close-up partial view of an elongate element 4 A & 4 B. It is understood that certain alternate preferred embodiments of one or more elongate elements 4 A & 4 B may comprise a length of number three U.S. imperial bar size rebar having a nominal diameter D 1 of 0.375 inch. Alternatively or additionally, one or more elongate elements 4 A & 4 B may be or comprise metal, a metal alloy, a solid metal material such as steel or aluminum, and/or a suitably rigid but malleable nonmetallic material known in the art.
Referring now to FIG. 3 , FIG. 3 is a close-up partial view of an alternate elongate element 22 , wherein the alternate elongate element 22 is at least partially hollowed and a lumen 23 of the alternate second element 22 has a diameter D 2 preferably in the range of 0.90 to 0.20 of a total diameter D 1 of the alternate elongate element 22 .
Referring now to FIG. 4 , FIG. 4 is a close-up partial view of a second alternate preferred embodiment of the present invention 24 , or second version 24 , configured with three elongate elements 4 A, 4 B & 4 C, a collar 26 and four support arms 28 A, 28 B, 28 C & 28 D. It is understood that one or more elongate elements 4 A, 4 B & 4 C may comprise a continuous length of number three U.S. imperial bar size rebar having a nominal diameter of 0.375 inch. Alternatively or additionally, one or more elongate elements 4 A, 4 B & 4 C may be or comprise a continuous length of metal, a metal alloy, a solid metal material such as steel or aluminum, and/or a suitably rigid but malleable nonmetallic material known in the art.
One or more of the support arms 28 A, 28 B, 28 C & 28 D may be or comprise an organic plastic material, a nonorganic plastic material, a metal such as aluminum, steel or iron, and/or a metal alloy. In one exemplary preferred embodiment of the present invention, one or more of the support arms 28 A- 28 D may comprise a length of rebar, steel, aluminum or iron having a nominal diameter of 0.250 inch.
The collar 26 may be a press fitting that holds the support arms 28 A, 28 B, 28 C & 28 D and the elongate elements 4 A, 4 B & 4 C under compression. Alternately or additionally the collar 26 , the support arms 28 A, 28 B, 28 C & 28 D and/or the elongate elements 4 A, 4 B & 4 C may be welded together. An optional weld material 29 may be provided to support a welding of the collar 26 , the support arms 28 A, 28 B, 28 C & 28 D and/or the elongate elements 4 A, 4 B & 4 C. The weld material 29 may alternatively be derived from the process of applying a welding heat to the collar 26 , the support arms 28 A, 28 B, 28 C & 28 D and/or the elongate elements 4 A, 4 B & 4 C.
The collar 26 may comprise steel, stainless steel, aluminum, iron, a metal, a metal alloy, or other suitable plastic, organic or inorganic material or structure known in the art. The collar 26 of the second version preferably presents a width dimension in parallel with the elongate axis in the range of 0.25 inches to six inches.
The elongate elements 4 A, 4 B & 4 C are coupled together at one or more coupling points 12 A, 12 B, 12 C and 12 D and held substantially in parallel with an elongate axis A, i.e., wherein each elongate element 4 A, 4 B & 4 C is preferably within five degrees of planarity with the elongate axis A along the longest dimension of the respective elongate element 4 A, 4 B & 4 C.
Referring now to FIG. 5 , FIG. 5 is a perspective view of a third alternate preferred embodiment of the present invention 30 , or third version 30 , a depth registration marking 32 , having four elongate elements 4 A, 4 B, 4 C & 4 D and four support arms 28 A, 28 B, 28 C & 28 D. The post section 18 of the third version 30 is formed by the combination of the portion elongate elements 4 A, 4 B, 4 C & 4 D that extend from each elongate element striking point 20 A- 20 D to the fourth coupling point 12 D.
The depth registration marking 32 is a visual indicator of the position of the post section 18 relative to the ground material 40 whereby a user may visually calibrate the length of the third version 30 that is protruding from the ground material 40 as the anchor section 16 is inserted into the ground material 40 . This visual calibration by the user supported by the depth registration marking 32 helps the user to set the anchor section 16 of a single third version 30 at a preferred depth into the ground material 40 , and to position a plurality of third versions 30 at approximately a same depth within the ground material 40 .
The anchor section 16 of the third version is formed by the fourth coupling point 12 D and a plurality of tines 34 A- 34 D of the anchor ends 10 A- 10 D
The exemplary elongate elements 4 A, 4 B, 4 C & 4 D may each comprise an individual steel reinforcing bar, known as a rebar in the art, wherein each rebar preferably presents a length in the range from 0.5 foot to twelve feet and a cross-sectional diameter preferably in the range of from 0.25 inch to 2.0 inches. Each exemplary elongate element 4 A, 4 B, 4 C & 4 D preferably presents an individual length in the range from 1.0 foot to four feet and an individual cross-sectional diameter preferably in the range of from 0.25 inch to 0.75 inch. The exemplary elongate elements 4 A, 4 B, 4 C & 4 D most preferably have equal lengths along the elongate axis A. It is understood that certain alternate preferred embodiments of one or more first elongate elements 4 A, 4 B, 4 C & 4 D may comprise a length of number three U.S. imperial bar size rebar having a nominal diameter of 0.375 inch. It is further understood that certain alternate preferred embodiments of one or more elongate elements 4 A, 4 B, 4 C & 4 D may comprise a length of metric size number ten rebar having a nominal diameter of 9.525 millimeters. The elongate elements 4 A, 4 B, 4 C & 4 D each preferably exhibit a yield strength preferably in the range starting from 250 Newtons per square millimeter of area and extending to 500 Newtons per square millimeter of area. Alternatively or additionally, one or more first elongate elements 4 A, 4 B, 4 C & 4 D may comprise a continuous length of (a.) American Society for Testing and Materials (hereinafter, “ ASTM ”) A 615 Deformed and plain carbon-steel bars; (b.) ASTM A 706 Low-alloy steel deformed and plain bars; (c.) ASTM A 955 Deformed and plain stainless-steel bars; and/or (d.) ASTM A 996 Rail-steel and axle-steel deformed bars.
Alternatively or additionally, one or more elongate elements 4 A, 4 B, 4 C & 4 D may be or comprise metal, a metal alloy, a solid metal material such as steel or aluminum, and/or a suitably rigid but malleable nonmetallic material known in the art. In certain still alternate embodiments of the present invention, one or more elongate elements 4 A & 4 B may be shaped as a hollow tube, or alternatively partially hollowed in some fraction of total length.
One or more of the support arms 28 A- 28 D may be or comprise an organic plastic material, a non-organic plastic material, a metal such as aluminum, steel or iron, and/or a metal alloy. In one exemplary preferred embodiment of the present invention, one or more of the support arms 28 A- 28 D may comprise a length of steel, aluminum or iron having a nominal diameter of 0.250 inch.
Each support arm 28 A- 28 D preferably presents a length no longer than any of the elongate elements 4 A- 4 D. Each arm 28 A- 28 D more preferably presents a length no longer than any of the post sections 14 A- 14 D of the elongate elements 4 A & 4 B.
The plurality of support arms 28 A- 28 D and the plurality of elongate elements 4 A, 4 B, 4 C & 4 D are coupled together by or within the collar 26 by welding and/or by a press fitting 36 formed by the collar 26 as shown in FIG. 4 .
The elongate elements 4 A, 4 B, 4 C & 4 D are coupled together at one or more coupling points 12 A, 12 B, 12 C and 12 D and held substantially in parallel with the elongate axis A, i.e., wherein each elongate element 4 A, 4 B, 4 C & 4 D is preferably within five degrees of planarity with the elongate axis A along the longest dimension of the respective elongate element 4 A, 4 B, 4 C & 4 D.
One or more bindings 38 are shown in FIG. 6A that apply compressive force to maintain the first version 2 in a shipping position, or first state of the anchor section 16 . The bindings 38 may be metal wire, plastic or other suitable means known in the art.
Referring now to FIG. 6B , FIG. 6B presents the first version 2 with the bindings 38 removed and a plurality of anchor tines 34 A- 34 D that are optionally preformed to angle away from the elongate axis A in a second state of the anchor section 16 .
A user may manually, or optionally with the aid of a manual or powered tool, adjust the angle of the tines 34 A- 34 D relative to the elongate axis A after the bindings 38 have been removed from the anchor section 16 . This user adjustment of the tine orientation in the second state enables the user to compensate for an observed or expected conditions of the ground material 40 and with the purpose of inserted the anchor section 16 into a more preferred orientation within the ground material 40 .
Referring now to FIGS. 6C , 7 C and 8 , the third version 30 is shown fully installed into a ground material 40 in a third state of the anchor section wherein each anchor tine 34 A- 34 D is further splayed away from the elongate axis A as a consequence of having receiving a force delivered by a hammer 42 at a plurality of striking points 26 A- 26 D of the first elongate elements 4 A, 4 B, 4 C & 4 D. The striking points 20 A- 20 D of each elongate element 4 A- 4 D are located within the striking plane S.
A top collar edge 43 may be positioned in various alternated embodiments of the third version 30 to lie (a.) below the striking plane S; (b.) within the striking plane S; or (c.) above the striking plane S. It is preferable in certain other alternate preferred embodiments of the present invention that the striking points 20 A- 20 D are positioned within the striking plane S and the top collar edge 43 is located below the striking plane S by a displacement in the range of from 0.125 inch to 0.250 inch, whereby the hammer 42 may deliver force directly to the plurality of first elongate elements 4 A, 4 B, 4 C & 4 D by direct physical contact with the striking points 20 A- 20 D.
Referring now to FIG. 7A , FIG. 7A is a close-up view of an anchor section 16 of the third version 30 positioned above the ground material 40 . The ground material 40 may be or comprise a supporting material such as soil, earth, sand, artificial ground covering, and/or exposed Earth surface.
FIG. 7B is a close-up view of the anchor section 16 of the third version 30 partially inserted into the ground material 40 as a consequence of a downward force being delivered to the striking points 20 A- 20 D. The plurality of anchor tines 34 A- 34 D of the anchor section 16 are splayed further away from the elongate axis A as the anchor section 16 is driven further into the ground material 22 . More particularly, each anchor end 10 A- 10 D comprising one individual anchor tine 34 A- 34 D may splay further from the elongate axis A as the anchor section 16 is forced into the supporting ground material 40 .
FIG. 7C is a close-up view of the anchor section 16 of the third version 30 fully inserted into the ground material 40 , wherein the plurality of anchor tines 34 A- 34 D are further splayed away from the elongate axis A.
The placement of the anchor tines 34 A- 34 D in the splayed position of FIG. 7C provides the post section 18 with a superior stability of the anchor tines 34 A- 34 D that is achieved by the spreading process represented in FIGS. 6A-6C and FIGS. 7A-7C . This transition of the anchor tines 34 A- 34 D from the second state of the anchor section 16 shown in FIGS. 6B and 7A to the third state of the anchor section 16 shown in FIGS. 6C and 7C produces an advantageous form of anchoring. The splaying of the anchor tines 20 A- 20 D from the elongate axis A enables the present invention and the second version 24 and then third version 30 particularly, to be more securely wedged into the ground material 40 .
The advantageous third state of the anchor section 16 is also a result of the tines 34 A- 34 D deflecting off of obstructions located within the ground material, e.g., rocks and tree roots. In contrast, rigid prior art anchoring systems typically do not allow anchoring components thereof to conform or to deflect around or off of ground material obstructions. These more rigid prior art systems therefore limit the flexibility of positioning of an anchoring post within certain ground materials 40 , whereas the method of the present invention provides an anchor section 16 that supports positioning of the attached post section 18 at a desirable or acceptable orientation in a wider variety of ground materials 40 .
The third state of the anchor section 16 of FIGS. 6C and 7C presents a placement of the tines 34 A- 34 D in the ground material 40 that is better able to resist wind flow from multiple directions, and more stably support unbalanced loading and offset loading caused by the weight of, and forces delivered from, the support arms 20 A- 20 D.
In addition, as a user repositions the support arms 28 A- 28 D of the support module, the user will typically delivers a force component that will act to pull the anchor section 16 up and out of the ground material 40 and/or deliver torque forces to the tines 34 A- 34 D. The third state of the anchor section 16 enables the third version 30 to better resist these forces of uplift and torque as instantiated when a user prepares the support arms 28 A- 28 D for plant or structure protection application after the anchor section 16 has been inserted into the ground material 40 .
It is understood that each anchor tine 34 A- 34 D is preferably formed from a continuous material that in total length forms an individual first elongate element 4 A, 4 B, 4 C FIG. 8 illustrates the second version 24 , that includes three elongate elements 4 A, 4 B, & 4 C, the collar 26 , and two support arms 28 A & 28 B. The support arms 28 A & 28 B initially extend from the collar 26 and may be positioned to support a variety of plants and structures, such as a trunk 44 of a tree 46 as pictured in FIG. 8 . The support arms 28 A & 28 B may be positioned to constrain motion of the tree trunk 44 .
FIG. 9 illustrates the second version 24 additionally including an optional coupling element 48 used to mechanically couple the two support arms 28 A & 28 B and to more stably constrain motion of the tree 46 .
FIG. 10 illustrates the coupling element 48 , wherein the coupling element 48 may comprising a hollow flexible rubber or plastic tube with two hollowed ends 48 A & 48 B, wherein each hollowed end 48 A & 48 B is sized to enable a friction fit with a support arm 28 A & 28 B. Each coupling element end 48 A & 48 B presents a coupling aperture 50 sized to enable an interference fit with a support arm 28 A & 28 B by insertion of the support arm 28 A & 28 B into the coupling aperture 50 .
FIG. 11 illustrates an alternate configuration of the second version 24 , wherein one or more support arms 28 A & 28 B are positioned to substantially or partially enclose, and support, a container, such as a plant pot 52 or a flower pot 54 . An additional optional plurality of press fit coupling features 56 A- 56 D more proximate to the anchor tines 34 A- 34 D than the collar 26 are presented in FIG. 11 , wherein the optional additional plurality of press fit coupling features 56 A- 56 D support a rigidity of the post section 18 of the second version 24 by combined alignment in parallel with the elongate axis A of each of the elongate elements 4 A- 4 D.
FIG. 12 illustrates a still alternate configuration of the second version 24 , wherein two support arms 28 A & 28 B are positioned to form a rectangular border shape. The optional coupling element 48 additionally may be applied to stabilize the two support arms 28 A & 28 B in the rectangular border shape.
FIG. 13 illustrates the alternate configuration of the second version 24 , wherein a sign material 58 bearing a visual signage 60 is installed upon the support arms 28 A & 28 B.
FIG. 14 presents a yet alternate configuration of the second version 24 wherein the support arms 28 A & 28 B are positioned to support a vessel 62 shaped to contain water 64 .
FIG. 15 shows a fourth alternate preferred embodiment of the present invention, (hereinafter, “the fourth version 66 ”), that comprises at least two second versions 24 mechanically coupled together to form a fence 68 in combination with a fence material 70 . A plurality of second versions 24 may be positioned to protect a tree 46 , one or more plants, or an area or structure, from intrusion by human, deer 72 , and/or other animals. The fence material 70 may be or comprise a sheet of Ross Deer Netting.™. deer netting material or a sheet of Wild Life Netting.™.
When the fourth version 66 is intended to encircle protect the tree 40 from the deer 62 , it is preferable that each support arm 28 A- 28 D have a length in the range from three feet to six feet and that each post section 18 of the second version 24 be at least as long as the longest support arm 28 A- 28 D. It is additionally preferable in certain additional alternate preferred embodiments of the method of the present invention that the second version 24 comprise support arms 28 A- 28 D that are all substantially equal in length within plus or minus 0.5 inches.
Two of the support arms 28 A & 28 B of the second version 24 are positionable downwards from the collar 26 toward the ground material 40 . The two other support arms 28 C & 28 D of the same second version 24 are positionable upwards and away from the collar 26 . A plurality of second versions 24 may be located proximate to each other and may be coupled by one or more coupling elements 48 , wherein a downward angled support arm 28 A of a first exemplary second version 24 is coupled to a downward angled support arm 28 B of a neighboring second version 24 , and an upward angled support arm 28 C of the first exemplary second version 24 is coupled to an upward angled support arm 28 D of the same neighboring second version 24 .
Referring now to FIGS. 16 & 17 , FIG. 16 is an illustration of a fifth alternate preferred embodiment of the present invention 74 , or fifth version 74 , wherein the plurality of support arms 28 A- 28 D are extend upwards from the collar 26 . FIG. 17 illustrates a plurality of additional striking points 76 A- 76 B of the fifth version 74 are available to receive a downward force directly from the hammer 42 .
Referring now to FIGS. 18 and 19 , FIG. 18 partly illustrates the positionable mobility of the support arms 28 A- 28 D. FIG. 19 illustrates the support arms 28 A- 28 D of the fifth version 74 angled upwards and away from the collar 26 .
FIG. 20 illustrates the fifth version 74 located proximate to a plurality of plants 78 and supporting a netting 80 , wherein the netting 80 substantially encloses the plurality of plants 78 , e.g., flowering plants, seedlings and shoots. It is understood that the netting 80 may be positioned to extend to, and make contact with, the ground material 40 .
FIG. 21 illustrates the fifth located proximate to a leaf-bearing plant 82 and supporting the netting 80 , wherein the netting 80 substantially encloses a leafed region 84 of the leaf-bearing plant 82 .
The foregoing disclosures and statements are illustrative only of the present invention, and are not intended to limit or define the scope of the present invention. The above description is intended to be illustrative, and not restrictive. Although the examples given include many specificities, they are intended as illustrative of only certain possible applications of the present invention. The examples given should only be interpreted as illustrations of some of the applications of the present invention, and the full scope of the Present Invention should be determined by the appended claims and their legal equivalents. Those skilled in the art will appreciate that various adaptations and modifications of the just-described applications can be configured without departing from the scope and spirit of the present invention. Therefore, it is to be understood that the present invention may be practiced other than as specifically described herein. The scope of the present invention as disclosed and claimed should, therefore, be determined with reference to the knowledge of one skilled in the art and in light of the disclosures presented above.
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A method and device for securely anchoring a plant protection structure is provided wherein a support system includes an anchoring post and a support section. The anchoring post presents a post section and an anchor section, wherein each anchor section is configured to angle away from the longitudinal axis as the anchoring post receives a force that drives the anchor section into the ground. The anchoring post is topped by a support module that may include one or more arms that support and/or help protect at least a portion of a plant or object. The arms are configurable to enable the device to help secure or protect plants or objects in a variety of embodiments as best suited to the needs of the object. The anchoring post may include solid or hollow continuous elongate elements that form both the post section and the anchor section.
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BACKGROUND OF THE INVENTION
The present invention relates to a method and an apparatus for efficient proliferation and culture of adhesive cells followed by transfer of said cells into a mass culture tank so as to produce a physiologically active substance.
Culture of adhesive cells has conventionally been performed by use of various culture system as follow:
(a) So-called liquid tight system generally comprising a plurality of plates arranged in a parallel manner within a container in order to obtain a sufficiently large surface for cell adhesion. Upon completion of said cell adhesion onto the plates, a quantity of culture fluid is circulated in the container under control of pH and DO (dissolved oxygen). The so-called rotary system generally comprising a plurality of discs or the like also arranged in parallel within a cylinder set upright to achieve the cell adhesion onto the discs and then laid down to be rotated.
(b) A system comprising scrolled plastic film charged within a cylinder, wherein cell culture is performed in the same manner as the so-called roller culture. Then a quantity of culture fluid is circulated in the cylinder, set upright, for example, by air supplied into the cylinder.
(c) The multitray system of box-nest construction similar to the system set forth above in (a) except that there is gaseous phase and the culture can be stationary as achieved in roller botter, without the requirement for the culture fluid circulation.
(d) The plastic bag system comprising an oxygen or carbon dioxide-permeable plastic bag rolled up like the fire hose through which a quantity of culture fluid flows. This system facilitates the control of DO and pH.
(e) The hollow fiber system comprising hollow fibers as usually used for artificial kidney dialysis, wherein adhesion and proliferation of cells occur on the exterior side while nutrient supply occurs from the interior side of each hollow fiber, i.e., from the near side of the cell layer.
(f) The glass beads filled column system in which adhesion and proliferation of cells occur on the surfaces of glass beads charged within a container under circulation of a culture fluid having pH and DO previously adjusted.
(g) The microcarrier system utilizing, instead of said glass beads, minute beads of such specific gravity that these minute beads float in culture fluid under a gentle agitation in order of 20 to 40 r.p.m. and the culture, as well as proliferation of cells occur on their surfaces.
The systems (a) through (d) are exclusively for the batch production and the number of cells which can be cultivated for each process results in a poor yield of the target substance.
The systems (e) through (f), of the continuous culture medium circulation type, are also restricted in the number of cells which can be cultivated and is not suitable for mass culture.
Presently, the mass culture has mostly relied on the microcarrier system set forth above in (g) and such system having a capacity of 8000 is known.
One example of the microcarrier system is disclosed in Japanese Disclosure Gazette No. 0982-5670, which aims at efficient cell culture within a culture tank containing a cylindrical member set upright therein, by providing said cylindrical member therein with deflectors and connecting said cylindrical member with a culture fluid outlet conduit so that a desired quantity of culture fluid may be stably circulated for a long period. As a similar example, Japanese Disclosure Gazette No. 1985-168379 discloses a cell cultivating apparatus having a unit comprising a plurality of hollow fibers each having a wall-membrane which is cell-impermeable but nutrient-permeable, said unit being provided at opposite ends or one end with an inlet and an outlet for cell culture fluid so that high mass and high density culture can be achieved by suspension culture. As still another example, Disclosure Gazette No. 1985-259179 discloses a similar mass and high density cell culture tank of the suspension type which is provided at the top with an inlet for fresh culture fluid, at the bottom with an outlet for used culture fluid, and adjacent the top with an impeller.
The above-mentioned systems of the prior art are disadvantageous in that the cultivating capacity can be improved only by making the culture tank volume correspondingly larger and proliferation of cells from the initial stage in such larger culture tank would not only encounter additional problems as those in circulation and control of correspondingly increased culture fluid but also take a longer time period.
Particularly when it is desired to produce physiologically active substance by cell culture, the culture medium for cell proliferation has ingredients different from those for cell culture and the former becomes wasteful especially in the larger culture tank.
Accordingly, the method according to the present invention, in view of such problems encountered by the microcarrier system of well known art, intends to achieve an efficient cell culture by performing the initial cell proliferation and the subsequent cell culture for production of the physiologically active substance in different tanks.
For the cells which are readily subject to damage due to the shearing force and have relatively low colony formation efficiency it is very difficult to perform the microcarrier culture. To reduce the effect of said shearing force, the method is preferably, one in which the cells themselves are adhesively fixed onto particular material having a larger surface area in the stationary culture method and the culture medium is circulated, therethrough.
The previously mentioned hollow fiber system is one embodiment of such method. Specifically, the culture medium is continuously circulated not only through the interior but also along the exterior surface of the hollow fiber on which the adhesive cells are to be prolifirated so that the nutrient and metabolism product are efficiently moved between the interior and the exterior of the fiber, enabling the cells to be cultivated at a high density.
However, this system unacceptably complicates the apparatus and has not been commercially adopted for mass production.
Japanese Disclosure Gazette No. 1984-154984 discloses a simplified hollow fiber system in which the cells are proliferated, cultivated on ceramic matrix and the culture fluid is continuously circulated.
According to this prior art, alumina, silica, titanium, zircon or the like or combination thereof is sistered to form porous ceramic carrier which is a cylindrical monolithic carrier having at least about 20 through-holes extending in parallel to one another per square inch of cross-section. However, this system is inconvenient in that the carrier is readily clogged as it is continuously used.
As will be appreciated from the foregoing description, all of the conventional system are disadvantageous for mass production in commercial scale. To over come such problems, the inventors disclosed a solution in Japanese Disclosure Gazette No. 1987-236480. This solution is a method comprising steps of providing ceramic particles consisting for the most part of alumina suitable for all adhesion and having an approximately uniform size of 5 to 9 meshes, supplying culture fluid into a column filled with said ceramic particles, exchanging the quantity of aged culture fluid, after movement through the first half of the column, due to proliferation of cells with quantity of fresh culture fluid at an intermediate level of column, and removal of said aged culture is further continued through the second half of the column.
This method is characterized by that the effort of culture fluid to the cells is relatively uniform, the cells are free from the damage due to a shearing force and the carrier facilitates the cell adhesion, and thus the method is suitable for mass culture of adhesive cells.
Nevertheless, there still remains an important problem that, when cultivation is performed within a column or tank filled with granular sedimentary immobilizing carrier whether it is ceramic or not, filling and removal of the immobilizing carrier should not prevent the cells from achieving their uniform adhesion onto said immobilizing carrier.
With this method, however, a quantity of cell suspension supplied to the immobilizing carrier stack is initially apt to stagnate at the cell suspension supply side on the stack surface and at the area adjacent the supply pipe. This is inconvenient in that a long time is taken before the cells can be proliferated through out the whole immobilized carrier stack.
The cell culture apparatus of the present invention intends to solve such problem.
SUMMARY OF THE INVENTION
An object of this invention is to provide a method for efficient cell cultivating method adapted to perform initial cell proliferation and subsequent cell culture for production of a target substance in different tanks.
This object is achieved, in accordance with the present invention, by a method for cell culture comprising steps of: proliferating adhesive cells in a preliminary culture tank of smaller size; stripping off the cells thus proliferated from immobilizing carriers and then mixing these cells with a part of culture medium which has been adjusted in an intermediate reservoir to obtain a quantity of cell suspension; collecting the cell suspension thus obtained into said intermediate reservoir to be stored therein; transferring, as occasion demands, said cell suspension stored in said reservoir, after the cell distribution therein has been uniformalized, into a main culture tank filled with immobilizing carriers containing ceramic material as a main ingredient so that the cells adhere to said immobilizing carriers and are further cultivated and finally producing physiologically active substance on a culture ground of this purpose.
This method is effectively carried out by a cell culture apparatus comprising a preliminary culture tank of a smaller size, a main culture tank filled with immobilizing carriers containing ceramic material as a principal ingredient, and an intermediate reservoir interposed between said preliminary culture tank and said main culture tank. After cell proliferation, a quantity of cell suspension is supplied to said main culture tank filled with immobilizing carriers containing ceramic material as the principal ingredient.
Efficient cell adhesion onto the immobilizing carriers is accomplished by providing the above-mentioned cell culture apparatus with a separate tank. The cells profilerated in the small preliminary culture tank are stripped off from the immobilizing carriers to prepare cell suspension. The latter is transferred to the main culture tank filled with immobilizing carriers. The cell suspension is supplied to said main culture tank from top and bottom thereof so as to uniformalize cell adhesion onto said immobilizing carriers. This also serves to adjust the nutrient and gas content in the culture fluid, as well as to control circulation of said culture fluid within said main tank filled with the immobilizing carriers principally made of ceramic material.
It should be understood that the microcarrier type culture tank is most preferable a small size preliminary culture tank, since cells, as many as possible, will be supplied to the subsequent mass culture tank.
The method and the apparatus for cell culture according to the present invention provide a unique effect as will be described hereinafter.
Generally, proliferation as well as culture can be efficiently achieved by proliferating cells to be used in a next process of production in the preliminary culture tank while the target substance is produced, because the initial cell proliferation and said production of the target substance are performed in the different culture tanks.
More specifically, it is possible to confirm the number of cells so that the cell proliferation in the preliminary culture tank can be efficiently achieved. The proliferation medium can be effectively supplied for the minimum time and thus the change over from said proliferation medium to the culture fluid for production of the physiologically active substance is shortened, which results in shortening of the cultivating time.
The efficient cell culture as mentioned above has various merits in view of a fact that, in general, the life of a cell is relatively short.
In addition, supplying the cell suspension to the immobilizing carriers from top and bottom of the culture tank enables the cell adhesion onto said immobilizing carriers to be uniformly and effectively accomplished.
Another object of the present invention is to provide a culture apparatus adapted to uniformly supply the cell suspension to the immobilizing carriers and to facilitate charging as well as removal of said immobilizing carriers.
Uniform supply of the cell suspension to the immobilizing carriers set forth above as one factor of this object is achieved, in accordance with the present invention, by a culture apparatus filled with segmentary immobilizing carriers for adhesive cells and aiming at production of a target substance. The culture apparatus comprising an inversed funnel-shaped inlet located above the immobilizing carriers filling the apparatus and having a perforated bottom plate for uniform distribution of a quantity of cell suspension supplied from above to said immobilizing carriers. A netty plate located under the immobilizing carriers holds said immobilizing carriers, and another perforated plate is also located under the immobilizing carriers for uniform distribution of a quantity of cell suspension supplied from the bottom to said immobilizing carriers.
To facilitate filling and removal of the immobilizing carriers, i.e., to achieve another requirement of the above-mentioned object, the present invention provides an apparatus comprising a cover portion adapted for detachably carrying the inversed funnel-sharped fluid inlet having the perforated bottom plate for uniform distribution of the quantity of cell suspension supplied from above to the immobilizing carriers filling the apparatus. A drum portion is fixed to a stand and a bottom portion is adapted for detachably carrying the netty plate to hold the immobilizing carriers from the underside and the perforated plate for uniform distribution of the quantity of cell suspension supplied from bottom portions.
The culture apparatus of the present invention provides an effect as follows:
Supply of cell suspension to the immobilizing carriers occurs from both top and bottom of the apparatus filled with said carriers so that the quantity of said cell suspension supplied from the top is uniformly supplied through the perforated plate as a part of the inverted funnel-shaped inlet and the quantity of cell suspension supplied from the bottom is uniformly distributed through the lower perforated plate and then the netty plate supports the immobilizing carriers. Thus, cells uniformly adhere onto the immobilizing carriers.
Furthermore, the bottom portion of the culture apparatus can be separated from and connected to the cover and drum portions of the culture apparatus by means of a linkage and a cylinder so as to facilitate charging and removal of the immobilizing carriers and thereby shorten the time taken for such operation.
Additionally, dividable construction of the culture apparatus facilitates manual washing and checking.
Thus, both washing and checking are further easier than those usually performed for the conventional culture tank of one-piece type and the culture apparatus constructed according to the present invention is novel one as such apparatus utilizing segmentary immobilizing carriers.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects as well as advantages of the present invention will become clear by the following description of preferred embodiments of the present invention with reference to the accompanying drawing, wherein,
FIG. 1 is a flow chart schematically illustrating the method for cell culture according to the present invention;
FIG. 2 is a flow chart illustrating a manner in which culture fluid for cell proliferation supplied to the culture apparatus of the present invention is circulation;
FIG. 3 is a sectional view showing the culture apparatus of the present invention;
FIG. 4A is perspective view showing a mechanism to detach the bottom portion of the culture apparatus according to the present invention; and
FIG. 4B is diagram illustrating a manner in which the detaching mechanism operates.
DETAILED DESCRIPTION OF THE INVENTION
First, the method for cell culture according to the present invention will be described in reference with FIG. 1.
Reference numeral 1 designates a small sized culture tank used to perform the method of the present invention and, specifically, a microcarrier culture tank is used here as this small sized culture tank, within which proliferation of adhesive cells occurs according to the microcarrier culture process. It should be understood that, although said microcarrier culture tank used in the inventive method, the culture tanks of other types may be effectively employed.
Reference numeral 2 designates a nutrient reservoir to supply said microcarrier culture tank 1 with nutrient.
The cells initially proliferated within the microcarrier culture tank 1 are stripped off by the well known technique from the microcarriers to obtain a suspension, which is then transferred via a conduit 13 into an intermediate reservoir 3. The cell suspension is temporarily stored in this intermediate reservoir 3 to uniformize cell distribution.
Reference numeral 4 designates a mass culture tank filled with ceramic carriers. A quantity of cell suspension is supplied by a pump 17 from said cell suspension reservoir 3 through a conduit 14 and then through an upper conduit 6 extending through the top of the culture tank 4 into a layered ceramic 5 while another quantity of cell suspension is supplied through a conduit 15A and 15B (see FIG. 2) branched from the conduit 14 and then through a lower conduit 7 connected to the bottom of the culture tank 4 into said layered ceramic 5.
Cell suspension is supplied in the two-way fashion to the culture tank in the manner as has been mentioned above and thereby uniform adhesion of the cells onto the immobilizing ceramic carriers is achieved.
The quantity of cell suspension to be supplied to the mass culture tank in the two-way fashion must be previously adjusted to the optimum quantity at a stage of culture medium adjustment within the intermediate reservoir, since it would be impossible to achieve uniform adhesion of cell onto the ceramic carriers if said quantity of cell suspension is excessively larger than the quantity of the ceramic carriers within the mass culture tank and effective utilization of whole the ceramic carriers would be impossible if said quantity of cell suspension is smaller thah the quarity of the ceramic carriers.
Reference numeral 8 designates a culture fluid adjusting tank adapted to effect the culture fluid circulation within the culture tank 4 and to control nutrient and gaseous content of the culture fluid. The culture tank 4 is supplied from its top and bottom with the cell suspension from the intermediate reservoir 3 so that the cells uniformly adhere onto the individual ceramic carriers forming the layered ceramic 5 and then the culture tank 4 is supplied with culture fluid for cell proliferation under action of a pump 9 from the culture fluid adjusting tank 8. Referring to the method of efficient proliferation, channeling can be prevented where the carries are filled, by having upward and downward circulation alternately. Downward circulation occurs in such a manner that said culture fluid is pumped by pump 9 from the culture fluid adjusting tank 8 into the culture tank 4 via conduits 18, 48, 15A, 14, 6 and the inverse funnel-like inlet 34, and returned to said tank 8 via conduits 7, 46, and 16B. Upward circulation occurs in such a manner that said culture fluid is pumped by pump 9 from the culture fluid adjusting tank 8 and into said culture tank 4 via conducts 18, 7 and then though the inverse funnel-like inlet 34, and returned to said tank 8 via conduits 6, 14, 16A, and 16B.
These upward and downward circulation occurs alternately automatically every certain minutes and the uniform distribution and proliferation of the cell without causing channeling will be realized.
Further, an air pressure supplied from an air inlet 11 into the culture tank 4 under control of an air valve 12 operatively associated with a level control rod so as to maintain a fluid level within the culture tank adjacent the inverse funnel-like inlet 34.
Furthermore, instead of said alternate circulation, either the upward or downward circulation can be used alone.
After the cells have been proliferated to a predetermined number under circulation of said culture fluid for proliferation, change-over occurs from this culture fluid for proliferation to the culture fluid for production of a physiologically active substance is supplied from a reservoir not shown. Now the culture fluid for production of the physiologically active substance supplied into the culture tank 4 and, after the physiologically active substance has been produced, this culture fluid containing therein said substance is recovered through line 10 into a column for elution of the physiologically active substance.
Upon completion of the recovery, the cell suspension is supplied again from the intermediate reservoir 3 into the culture tank 4 and the cell culture is repeated.
In this manner, the initial cell proliferation occurs within the microcarrier culture tank 1 while the final cell culture for production of the physiologically active substance occurs within the culture tank 4. Thus, the proliferation and the culture are carried out within the different culture tanks being in communication with each other via the intermediate reservoir.
As has previously been described, cell stripping in the small sized culture tank may be performed by any suitable conventional techniques. One of these useful techniques will be described in detail. Upon completion of the cell proliferation, circulation of culture fluid is stopped. Then, the entire quantity of culture fluid is removed out from the small sized culture tank, and washed with phosphate buffer saline (PBS), followed by stripping of the cells effected by supplying a suitable quantity of trypsin or collagenase. It should be noted here that contact of trypsin or collagenase with the cells for a long time would destroy the cells. To avoid this, a quantity of culture fluid containing trypsin inhibitor is supplied thereto in order to devitalize said trypsin or collagenase and thereby a quantity of cell suspension in which the cells float. If the culture is not serumless culture, said trypsin inhibitor may be substituted by serum containing culture fluid, because serum intrinsically contains therein said trypsin inhibitor.
In view of a fact that the cells are apt to be deactivated and to stick together, when the cells are left in floating condition for a long time, the cell suspension must be transferred to the immobilizing carriers as soon as possible. Namely, storage of the suspension in the intermediate reservoir is a temporary storage for adjustment.
Said intermediate reservoir 3 has an additional important function as will be described below. During the cell proliferation within the small sized culture tank 1, the intermediate reservoir 3 serves for circulation and adjustment of the culture fluid and, upon completion of the cell proliferation and once the circulation has been stopped, the reservoir serves to adjust the quantity of culture fluid to be supplied to the mass culture tank 4 for the subsequent process. The quantity of culture fluid thus adjusted is now partially supplied to the small sized culture tank, in which removal of the culture fluid, washing and stripping of the cells have already been completed, to obtain a quantity of cell suspension which is, in turn, collected into the intermediate reservoir where a quantity of uniform and adjusted cell suspension is necessary to be supplied to the subsequent mass culture tank. The intermediated reservoir is essential for such process.
The respective culture tanks as have been mentioned above require the associated adjusting tanks in order to adjust pH, temperature and nutrient properly during circulation of culture fluid, and nutrient occurs form a reservoir not shown.
Now the apparatus for cell culture constructed according to the present invention will be discussed by way of example. The apparatus of the invention has been developed by overcoming the disadvantages of the microcarrier type cell cultivating apparatus and comprises a cell culture apparatus filled with carriers adapted to immobilize sedimentary adhesive cells. This cell culture apparatus is particularly suitable as the culture tank for production of physiologically active substance, which is provided separately from the small sized preliminary culture tank for the initial cell proliferation in the method for cell culture as has been mentioned above and accordingly the apparatus of the invention will be described in connection with a specific embodiment constructed as such culture tank. However, application of the inventive apparatus is not limited to such culture tank.
FIG. 2 schematically illustrates an embodiment of the culture apparatus according to this invention.
Reference numeral 4 designates a mass culture tank filled with ceramic carriers. A conduit 6 extends from a conduit 14 for supply of cell suspension. As shown by FIG. 3, the conduit 6 is detachably mounted in a cover 32 of the culture tank 4 for supply of cell suspension and its front end terminates in an inversed funnel-shaped inlet 34 and a bottom of the inversed funnel-shaped inlet 34 is defined by perforated plate 35 adapted for uniformly supplying cell suspension to the top of immobilizing carriers.
The culture tank 4 is connected to a culture fluid adjusting tank 8 by conduits 16A, 16B, 18 so that a pump 9 disposed in the conduit 18 causes a quantity of culture fluid to circulate. The conduit 18 is connected to an inlet conduit 7 for the culture tank 4 while the conduits 16A and 16B is connected to the conduit 6 associated with the inversed funnel-shaped inlet 34 via a switchable value. Thus, a predetermined quantity of culture fluid is pumped into the culture tank 4 by said pump 9. In above-mentioned upward circulation, culture fluid is returned from the inversed funnel-shaped inlet 34 to the culture fluid adjusting tank 8 through the conduits 6, 14, 16A, 16B when the pump 9 is switched between ON and OFF by means of a fluid level control rod or when germ-free air is introduced through an inlet 11 into the culture tank 4 for pressurizing. In this manner, the fluid level is always adjusted in the proximity of the inversed funnel-shaped inlet 34.
Another embodiment of the culture tank 4 will be discussed in reference with FIG. 3. This culture tank 4 consists of an upper flange-like portion 4a, an intermediate drum-like portion 4b and a lower portion 4c which are separable from one another. The flange-like portion 4a is covered by a lid 32. The supply conduit 6 extends downwardly to the inversed funnel-shaped inlet 34 having a bottom covered by the perforated plate 35. The culture tank 4 is further provided across the lower portion with a netty plate 36 adapted to the immobilizing carriers and a perforated plate 37 directly underlying said netty plate 36. The netty plate 36 and perforated plate 37 are fixed by clamping bolts across the lower portion of the culture tank 4.
The conduit 7 is connected to the lower end of the culture tank 4. Reference numerals 38, 39 designate cooling jackets for the lower portion 4c and the drum-like portion 4b, respectively, of the culture tank 4.
It will be described how to use the culture tank 4 of the present invention particularly for production of physiologically active substance.
First of all, ceramic carriers are filled in said culture tank 4 and sterilized therein. Then, a quantity of cell suspension containing adhesive cells floating therein is supplied to the culture tank 4 through the conduit 14 and then through the conduit 6 which opens into the top of the tank 4 while another quantity of cell suspension is supplied to the culture tank 4 through the conduit 15A, 15B branched from the conduit 14 and then the inlet conduit 7 which opens into the bottom of the tank 4.
The conduit 6 terminates in the inversed funnel-shaped inlet 34 having its bottom defined by the perforated plate 35, so that the quantity of cell suspension is uniformly supplied from above into the culture tank 4 and the other quantity of cell suspension also is uniformly supplied from below into the culture tank 4 under the effect of the perforated plate 37 and the netty plate 36.
Thus, after the culture tank 4 has been supplied from top and bottom with cell suspension and the cells have uniformly adhered onto ceramic carriers, a quantity of culture fluid for cell proliferation is circulated by the pump 9 from the culture fluid adjusting tank 9 through the conduits 18, 16B, 16A for the purpose of cell proliferation. Upon adequate proliferation, culture fluid is changed over from that for cell proliferation to that for production of physiologically active substance coming from a reservoir not shown and thereby a target substance is produced.
The culture fluid adjusting tank 8 functions to adjust various factors such as pH, temperature, gaseous content and nutrient content of culture fluid.
Now a mechanism for removal of immobilizing carriers from the culture tank 4 will be explained by way of example in reference with FIGS. 4A and 4B.
The lower portion 4c of the culture tank 4 is separable from the intermediate drum-like portion 4b by means of a link mechanism and a cylinder, as will be described later more in details. Specifically the drum-like portion 4b is supported on stands 26 through links 24a, 24b mounted on the stands 26 at an intermediate level. Reference numeral 25 designates a supporting shaft by which the links 24a and 24b are pivotally supported by the stands 26 and the links 24a and 24b are interconnected by a tie rod 20 at respective angular portions of said links 24a, 24b. The lower portion 4c of the culture tank is pivotally lowered around the shaft 25 as said tie rod 20 is pulled by a piston rod 22 associated with a cylinder 21, and thereby the lower portion 4c is separated from the drum-like portion 4b of the culture tank 4. The links 24a, 24b are pivotally mounted at respective front ends to the lower portion 4c of the culture tank 4, so that the lower portion 4c can be maintained in a horizontal condition as shown by FIG. 4B, facilitating removal of the immobilizing carriers out from the culture tank 4.
As will be apparent from the foregoing description, the cell culture apparatus is advantageous in that the lower portion thereof is separable and thereby removal of the immobilizing carriers out from the apparatus is facilitated.
While there has been described what is at present considered to be preferred embodiment of the invention, it will be understood that various modifications may be made therein, and it is intended to cover in the appended claims all such modifications as fall within the true spirit and scope of the invention.
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Cell cultivation is carried out by proliferating cells in a small preliminary culture tank containing immobilizing carriers, stripping proliferated cells from the carriers, forming a cell suspension of the stripped cells in culture medium in an intermediate reservoir, intermittently transferring the suspension into a main culture tank containing ceramic immobilizing carriers and further culturing the cells. The main culture tank has an inversed funnel-shaped inlet above the carriers with a perforated plate attached to the bottom of the inlet for uniform distribution of cell suspension from above the carriers, and a plate in the form of a net under the carriers on a perforated plate for uniform distribution of cell suspension from beneath the carriers. The main tank additionally has a lid detachably carrying the inversed funnel-shaped inlet an intermediate drum-shaped portion from which the lid is detachable and a lower portion detachably carrying the plate in the form of a net and being detachable from the drum-shaped portion. The lower portion is held on or separated from the drum-shaped portion by means of a link mechanism and a cylinder capable of lowering the lower portion to separate it from the drum-shaped portion.
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BACKGROUND OF THE INVENTION
This invention relates to a pump of the kind used for producing a smooth and continuous outflow of liquid at relatively high pressure.
This invention has particular application to a pump used for liquid chromatography.
In liquid chromatography the performance and data which can be obtained from the column and detector of the liquid chromatograph is dependent upon the characteristics of the flow of liquids supplied. A smooth and continuous flow of liquid at pressures up to 6000 psi is necessary to ensure repeatability and accuracy of chromatographic data.
When the liquid supplied to the column and detector is formed as a composition of solvents, performance is also dependent upon accuracy and smoothness of the liquid composition.
The pressurization of the liquid is typically accomplished by piston type pumps. Single piston pumps and multiple piston pumps have been used in the prior art.
Single piston pumps are inherently pulsating type flow devices. Single piston pumps therefore present problems in achieving both of the above requirements.
The single piston pumps have required auxiliary devices to smooth out the pulsating flow. Hydraulic capacitor (such as bourdon tubes) type devices have been used with single piston pumps to try to smooth out the flow, but these type devices do not produce the essentially pulseless flow desired.
Because the single piston pump has no flow at the beginning of the pump cycle (during its intake stroke), single piston pumps have usually been constructed to provide a very fast intake stroke. This causes poor accuracy of composition when the liquid composition being pressurized is formed by proportioning valves at the inlet of the pump. Using a very short intake stroke for the single piston pump makes timing and actuation of the proportioning valves unnecessarily critical. To get good accuracy of composition forming it is better to have a suction stroke which is of sufficient duration so that any inaccuracies in the timing of the solvent proportioning valves do not become appreciable. This long intake stroke which is desired for accuracy of composition forming conflicts with the short intake stroke which is desired for minimizing pulsations in the outflow of a single piston pump.
The prior art has also used a two piston pump with the pistons flow connected in parallel to try to avoid the pressure pulsations in the outflow. In one prior art pump construction of this kind, the two pistons have been driven by one cam with the two pistons located on opposite sides of the drive came so as to be driven 180° out of phase with one another. These dual piston pumps provide almost pulseless flow but are more complex than single piston pumps. They require an inlet valve and an outlet valve for each piston.
This parallel piston pump arrangement of the prior art can present problems in obtaining pulseless flow because of compressibility of the liquid being pumped. In looking at the outflow from the pump there is a decrease in flow at the start of the expulsion stroke of each piston, and the amount of the decrease is largely a function of the compressibility of the liquid and the pressure.
One prior art technique which was developed to compensate for this decrease in flow at the start of the expulsion stroke was to speed up the pump motor in response to the dip. Mechanical inertia, friction, and hydraulic loading are factors which limit the achievable motor acceleration. Increasing the speed of a stepper motor rapidly enough under these conditions at the beginning of the displacement stroke can be a problem.
This parallel piston pump arrangement can also present problems in obtaining accuracy and smoothness of composition when the liquid composition is formed by proportioning valves at the inlet of the pump. Because of the parallel flow connection, a change in inlet composition will not be accomplished smoothly at the pump outlet. After one piston delivers the new composition, the second piston will also deliver the new composition but this will be preceded by the old composition contained in the flow passage between the second piston and the junction with the flow passage from the first piston.
SUMMARY OF THE INVENTION
It is a primary object of the present invention to produce a smooth and continuous flow of liquid at high pressure.
It is a related object of the present invention to produce the smooth and continuous outflow with a dual piston pump which permits a long, extended suction stroke of sufficient duration to obtain accurate composition forming from an inlet solvent proportioning valve.
It is another related object of the present invention to operate one of the pistons very much like a single piston pump and to operate the other piston as a mechanically driven flow damper to smooth out flow variations from the first piston.
It is another object of the present invention to produce a flow positive pulse, rather than a negative pulse, at a certain point in the cycle of operation of the pump so that a motor control system can slow down the pump (and thereby put less work into the system) to eliminate the pulse at this point rather than being required to speed up the pump to eliminate a negative pulse.
It is another object of the present invention to construct a dual piston pump which requires only two check valves.
It is another object of the present invention to improve composition smoothness when using an inlet solvent proportioning valve by flow connecting the dual pistons in series.
It is another object of the present invention to construct a control system for the pump which decouples short term effects from long term effects by responding to short term effects with an analog operated control loop and by responding to long term effects by a microprocessor digitally operated control loop.
A pump constructed in accordance with one embodiment of the present invention has two piston assemblies connected in series.
The first pressure piston assembly includes a pressure piston which has a long inlet stroke and a relatively short and abrupt expulsion stroke.
The second piston assembly includes a damper piston which is driven in cooperation with the movement of the pressure piston to smooth out the outflow from the pressure piston. This smoothing out is accomplished by storing some of the liquid displaced by the expulsion stroke of the pressure piston in the damper piston assembly during the inlet stroke of the damper piston and then delivering the stored pressurized liquid to the outlet of the pump during the suction stroke of the pressure piston.
The outlet from the pressure piston assembly is connected to the inlet to the damper piston assembly with a valve which allows flow in one direction only, which is into the damper piston assembly. The pump outflow is thus the sum of the outflow of the pressure piston assembly and the inflow or outflow of the damper piston assembly.
The pressure piston is driven by a pressure piston drive cam, and the damper piston is driven by a damper piston drive cam. Both drive cams are mounted on a common drive shaft.
The cams are contoured to produce the same amount of outflow of pressurized liquid from the pump at all points in the cycle of rotation of the cam shaft, except for a short interval at the beginning of the expulsion stroke of the pressure piston. Rotation of the cam shaft, during this short interval, at the same speed as the speed at which the cam shaft is rotated during the rest of the cycle, produces a positive outflow pulse at the beginning of the expulsion stroke of the pressure piston.
This positive pulse compensates for compressibility of the liquid. It permits a stepper motor drive to be slowed down in response to a sensing of increased flow at this point in the cycle of operation.
The control system for controlling the speed of rotation of the motor driving the pump has two control loops. One control loop uses a microprocessor to compute the pressure reference for longer term effects. The other control loop responds to short term effects with an analog system. It provides rapid response during the short interval time (at the start of the inlet stroke of the pressure piston) in which a positive pulse of flow would be produced if the speed of rotation of the drive motor were not properly slowed down from the rate of rotation produced during the rest of the cycle.
The system of the present invention utilizes only two check valve assemblies. It eliminates two of the check valve assemblies required in prior art parallel dual piston pumps. This has the advantage of eliminating two of the more unreliable components in liquid chromatography pumping systems, and it also reduces the cost of the system.
The series connected dual piston pump of the present invention enables the length of the suction stroke to be tailored to the particular liquid chromatography application and solvent compositions for which the pump is to be used.
Since the pump of the present invention does not require a rapid suction stroke, it eliminates or minimizes many of the problems previously associated with the rapid intake strokes of single piston pumps, such as, pressure fluctuations, cavitation of high vapor pressure solvents, bubbling of dissolved gases, and incomplete filling of the piston chamber with high viscosity solvents.
The long inlet stroke of the pump of the present invention, as noted above, improves accuracy of low pressure composition forming at the inlet. Timing accuracies of mixing valves become less critical.
The series connected dual piston pump of the present invention does not tend to introduce unwanted composition variations with a multicomponent solvent as do pumps with parallel connected pistons. Because both pistons are in line, the pump of the present invention provides no place for storage of the previous composition during change to a new solvent composition.
Dual piston pump apparatus and methods which incorporate the structure and techniques described above and which are effective to function as described above constitute specific objects of this invention.
Other and further objects 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 and what are now considered to be the best modes contemplated for applying these principles. 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 and the purview of the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevation view in cross section through the longitudinal axis of a dual piston pump constructed in accordance with one embodiment of the present invention. FIG. 1 is taken along the line and in the direction indicated by the arrows 1--1 in FIG. 2.
FIG. 2 is an elevation view in cross section of the pump shown in FIG. 1 and is taken along the line and in the direction indicated by the arrows 2--2 in FIG. 1, FIG. 4 and FIG. 7.
FIG. 3 is a fragmentary view in cross section of a part of the cylinder block of the pump. FIG. 3 is taken along the line and in the direction indicated by the arrows 3--3 in FIG. 2 and FIG. 4.
FIG. 4 is a top plan view of the pump shown in FIGS. 1 and 2 and is taken along the line and in the direction indicated by the arrows 4--4 in FIG. 2.
FIG. 5 is a fragmentary view showing details of the mounting of a pressure transducer for the pump shown in FIGS. 1 and 2.
FIG. 6 is a fragmentary view taken along the line and in the direction indicated by the arrows 6--6 in FIG. 4. FIG. 6 shows details of the bores for the damper piston and the pressure piston.
FIG. 7 is an elevation view taken along the line and in the direction indicated by the arrows 7--7 in FIG. 2 and FIG. 4.
FIG. 8 is an isometric view of the pump shown in FIGS. 1 and 2.
FIG. 9 is a fragmentary view taken along the line and in the direction indicated by the arrows 9--9 in FIG. 4 and shows details of the association of the inlet and outlet openings for the damper piston with the passage 93 associated with the pressure transducer shown in FIG. 5.
FIG. 10 is a fragmentary view (taken along the line and in the direction indicated by the arrows 10--10 in FIG. 2 and FIG. 5) and shows details of the structure on the underside of the cylinder block 67 for mounting the pressure transducer of FIG. 5.
FIG. 11 is a graph showing outflow per degree cam shaft rotation plotted against cam shaft rotation for the pump.
FIG. 12 is a graph of the independent pressure piston displacement per degree cam shaft rotation plotted against cam shaft rotation.
FIG. 13 is a graph of the independent damper piston displacement per degree cam shaft rotation plotted against cam shaft rotation.
FIGS. 12 and 13 are derived from mathematically differentiating with respect to cam shaft rotation the displacements shown in FIGS. 14 and 15.
FIG. 14 is a graph of displacement of the pressure piston plotted against cam shaft rotation.
FIG. 15 is a graph of displacement of the damper piston plotted against cam shaft rotation.
FIG. 16 is a schematic, diagrammatic view showing the flow path through the pressure piston and the damper piston.
FIG. 17 is a fragmentary, cross section view through the outlet check valve assembly for the pressure piston. FIG. 17 is taken along the line and in the direction indicated by the arrows 17--17 in FIG. 8.
FIG. 18 is a block diagram of a control loop for controlling the speed of rotation of the pump of FIGS. 1 and 2.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A dual piston pump constructed in accordance with one embodiment of the present invention is indicated generally by the reference numeral 10 in FIGS. 1, 2, 4, 7, 8 and 18 of the drawings.
As shown in FIG. 16 the pump 10 of the present invention has two pistons 47 and 81 flow connected in series between an inlet conduit 60 and an outlet conduit 68. The piston 47 is a pressure piston, and the piston 81 is a damper piston.
As will be described in more detail below with particular reference to FIGS. 11-15 (which graphically illustrate the mode of operation of the pump 10), the flow connection of the two pistons 47 and 81 in series and the related drive arrangement for these two pistons produce a smooth and continuous flow of the liquid being pumped. The pump 10 is effective to maintain substantially pulseless flow even at high pressures, where compressibility of the liquid can present the problem of avoiding a drop in outflow at the start of a compression stroke.
FIGS. 2-10 and FIG. 17 show details of construction of the pump 10, and the structure shown in these figures will now be described.
As illustrated in FIG. 8, the pump 10 comprises a pump housing 57 and a cylinder block 67.
A drive motor 11 drives the pump. The liquid to be pressurized is conducted to the pump by an inlet conduit 60, and the pressurized fluid is conducted from the pump by an outlet conduit 68.
In a particular embodiment of the present invention, the pump 10 is used for pressurizing solvents used for liquid chromatography; and, as illustrated in FIG. 8, a solvent selecting valve 115 is associated with the inlet conduit 60. The valve 115 shown in FIG. 8 is a ternary proportioning valve like that shown in U.S. Pat. No. 4,128,476 to Rock and U.S. Pat. No. 4,137,011 to Rock (both assigned to the same assignee as the assignee of this application).
FIG. 8 also shows a retaining ring 87 which holds a pressure transducer (shown and described in more detail below with reference to FIGS. 5, 9 and 10) in the underside of the cylinder block 67. A conduit 104 conducts the signal from the pressure transducer to one input of an amplifier in a control loop for controlling pump speed under certain conditions of operation, as will be described in greater detail below with reference to FIG. 18.
With reference now to FIG. 1, the drive motor 11 drives the cam shaft 21 of the pump 10 through speed reduction gears 13, 15, 17 and 19.
The cam shaft 21 is mounted for rotation within bearings 23 and 25.
Two cams are mounted on the cam shaft 21 for rotation with the cam shaft 21. These are the cams 27 and 29 shown in FIG. 1. The cams are separated by a spacer 31. Each cam drives a related rocker arm 33.
As illustrated in FIG. 2 and FIG. 7, each rocker arm 33 is mounted for rotation on a bearing 35 about a pivot shaft 36. Each of the cams 27 and 29 engages a related cam follower bearing 37 mounted at the lower end of a related rocker arm 33. An upper cam follower bearing 39, mounted at the upper end of the rocker arm 33, engages a push rod of a piston assembly.
As illustrated in FIG. 2 the cam follower bearing 39 engages a push rod 41 for a piston assembly 43 for the pressure piston 47.
While not illustrated in the drawings, the upper cam follower 39 of the rocker arm 33 associated with the cam 29 engages a similar push rod for the piston assembly containing the damper piston 81.
This rocker arm drive arrangement minimizes side thrust on the push rods. The rocker arm arrangement folds the power train to provide for more compact packaging.
With continued reference to FIG. 2, the push rod 41 pushes the piston assembly 43. The piston assembly 43 comprises a piston head 45 and the pressure piston 47.
A return spring 49 works against the piston head 45.
A seal 51 and a piston guide 53 encircle the pressure piston 47 within a bore 95 in the cylinder block 67.
A seal retainer 55 holds the seal 51 and piston guide 53 in place. The seal retainer 55 fits within a bore 131 in the cylinder block 67.
The piston 47 reciprocates within a bore 133 in the cylinder block 67.
With reference to FIG. 4, the line of action for the pressure piston 47 is indicated at 69 and the line of action for the damper piston 81 is indicated at 71.
The check valves assemblies 63 and 65 (see FIG. 16) are associated with the pressure piston 47 in the cylinder block 67 as shown in FIG. 2.
The center line for the inlet passage of the inlet check valve assembly 63 is indicated at 59 in FIG. 2, and the center line for the outlet passage of the outlet check valve assembly 65 is indicated at 61 in FIG. 2.
The inlet check valve assembly 63 fits within a threaded opening 75.
The outlet check valve assembly 65 fits within a threaded opening 73 in the cylinder block 67.
FIG. 17 shows details of construction of the outlet check valve assembly 65. As shown in FIG. 17, the valve assembly 65 comprises an inlet 117, a ball 119 which seats on a seat 121 a seat holder 122 and a second ball 123 which seats on a seat 125 and a seat holder 124. The valve assembly 65 has three plastic sealing disks 129, 131 and 132. The valve assembly 65 has an outlet 127 in a fitting 126 which receives a tube and the fitting 66 and applies compressive force to the sealing disks 129, 131 and 132.
The construction of the inlet check valve assembly 63 is the same as that of the outlet check valve assembly 65 except that the parts 119, 121, 122, 123, 124 and 125 are inverted.
Each of the check valve assemblies 63 and 65 has two balls and two seats in series for reliability.
With reference to FIG. 4 there are two ports in the cylinder block 67 associated with the damper piston 81. These are an inlet port 77 and an outlet port 79.
As illustrated in FIGS. 8 and 16, the inlet port 77 is connected by the tubing 66 to the outlet check valve assembly 65 associated with the pressure piston 47, and the outlet port 79 is connected to the tubing 68 which conducts the pressurized fluid to the liquid chromatograph, or other apparatus for which the fluid is pressurized by the pump.
With reference to FIGS. 3, 5, 9 and 10, the umderside of the cylinder block 67 has a bore 103 and a counter-bore 83 for receiving a pressure transducer 82. The upper end 101 of the pressure transducer 82 fits in the bore 103 and seats on a small flat seal 91. A central, flanged portion of the pressure tranducer 82 fits within the counter-bore 83, and the retaining ring 87 has a bore 107 which fits over a lower end 105 of the pressure transducer 82 to hold the pressure transducer against the seal 91 by means of cap screws 89.
A chamber 93 within the cylinder block communicates with both of the ports 77 and 79 and also with the bore 137 in which damper piston 81 reciprocates.
The bore 139 shown in FIG. 5 corresponds to the bore 95 for the pressure piston and receives the seal and the piston guide (not illustrated in the drawings) for the damper piston 81.
FIG. 6 shows the bore 111 in the pump housing 57 for receiving the piston assembly 43.
As also illustrated in FIG. 6 the pump housing 57 has a similar bore 113 for receiving the piston assembly for the damper piston 81.
Threaded holes 115 and 117 are formed in the pump housing 57 (as illustrated in FIG. 6) for attaching the cylinder block 67 to the pump housing 57.
As best shown in FIGS. 2 and 4, the upper part of the pump housing 57 has an opening 119 which facilitates inspection of the pistons and the springs of the piston assemblies.
As illustrated in FIGS. 1, 2 and 7, a tab 121 is attached to the cam shaft 21 for rotation with the cam shaft. The tab 121 interrupts a light beam path 125 to a photodetector 123 on each revolution of the cam shaft 21 and provides a signal for the control system call "cam marker" in FIG. 18.
The operation of the dual piston pump 10 will now be described with reference to FIGS. 11-15.
Starting with FIG. 14, the high point of the cam 27 for the pressure piston 47 is selected as the zero degree position on the cam and on the plot of the cam shaft rotation for FIG. 14. The zero degree position is therefore the point of maximum displacement of the pressure piston 47. As the cam shaft 21 rotates, the pressure piston 47 retracts and commences its suction or intake stroke. The suction stroke is a long suction stroke which is desired to provide better accuracy on composition forming (when two or more liquids are combined to form the composition of the liquid to be pressurized). In FIG. 14 the suction stroke is shown as continuing from zero degrees to 200 degrees of rotation of the cam shaft 21.
From the 200° point, the piston 47 starts its pressurization and expulsion stroke. The cam 27 is contoured to increase the displacement of the piston 47 relatively slowly up to 270° and then to increase the displacement rapidly up to the maximum displacement at 360°. At that point we are at the same piston displacement as at 0°, and this represents one complete stroke or cam cycle for the pressure piston 47.
A primary function of the damper piston 81 is to smooth out the rather abrupt flow expulsion of the pressure piston 47.
FIG. 15 shows the displacement of the damper piston 81 versus cam shaft rotation. As can be seen from FIG. 15, the cam 29 is contoured to cause the piston 81 to have a relatively slow displacement from 340° through 0° and up to 270°.
The displacement reverses rapidly from 270° to 340°.
There is a required relationship between the displacements of the two pistons 47 and 81, and the required relationship is necessary to produce the required total flow.
Looking now at FIG. 12, the flow velocity for the pressure piston 47 is plotted against cam shaft rotation. The flow velocity is defined to mean the change in displacement per degree of cam shaft rotation. The velocity curve of FIG. 12 is a mathematical derivitive with respect to cam degrees of the piston displacement curve of FIG. 14.
Similarly, the flow velocity curve of FIG. 13 is a mathematical derivative of the piston displacement curve of FIG. 15 for the damper piston.
Summation of the pressure and damper piston flow velocities is accomplished by flow connecting the pistons in series. A check valve at the inlet and a check valve at the outlet of the pressure piston directs flow in one direction only.
FIG. 11 shows the outflow of the pump into the tubing 68 and is the summation of the flows shown in FIGS. 12 and 13. At zero cam degrees the flow output is steady at the level F. The flow output remains steady in a constant value up through 200°. At 200° the outflow increases to approximately double the previous flow and remains at the level 2F to 250°. At 250° the outflow decreases to the original flow at 270°.
Summation of the flow velocities of FIGS. 12 and 13 is accomplished in the following manner. From zero cam degrees to 200° the pressurization piston moves through its inlet stroke. Liquid enters the bore 133 through the inlet check valve. Previously pressurized and expelled liquid is prevented from flowing back into the bore 133 by the outlet check valve.
From zero to 200 cam degrees, the damper piston moves through a portion of its expulsion stroke providing the constant flow F shown in FIG. 11.
From 200° to 270° the pressurization piston starts its pressurization and expulsion stroke and continues the expulsion stroke at a rate of F. The damper piston is still expelling liquid at a rate F so that the total damper outflow rises to 2F as shown in FIG. 11.
At 250° the damper piston starts decreasing its flow.
At 270° the damper piston stops expelling liquid and the pump outflow drops to F.
From 270° to 340° the pressure piston expulsion rises to a level of approximately 6F and then falls to F. The damper piston starts its storage stroke rising to a negative flow level of approximately 5F and then returning to zero flow. The summation of the pressure piston expulsion and the damper piston storage results in a pump outflow of F in this region.
From 340° to 360° the pressure piston expulsion falls from F to zero and the damper piston expulsion rises from zero to F and in summation results in a pump outflow of F.
The reason for producing the excess flow 2F is to accommodate compressibility of fluids at high pressures. At high pressures, such as the 6000 psi that the pump of the present invention can be used for, appreciable compressibility of liquids being pumped is encountered. Because of this fact the pressure piston 47 has to travel a certain number of cam degrees before it can actually displace a fluid against this pressure. This effect is illustrated in FIG. 12 by the dashed line 199. This effect is also illustrated in FIG. 11 by the dashed line 199.
As noted above, the amount of excess flow (which would be produced by a constant speed of rotation of the cam shaft 121) is designed to accommodate the compressibility of some of the more compressible fluids at the higher pressures encountered.
At lower pressures in order to eliminate this double flow condition that we see in FIG. 11, that is, in order to produce a smooth flow during this period of time, the pump motor is slowed down by a pump control system shown in FIG. 18.
It is an important feature of the present invention that a region of double flow has been chosen to handle compressibility rather than a region of depleted flow. Control systems using stepper motors can behave much more rapidly in slowing the motor down than in speeding it up.
Looking at FIG. 11, the pump is driven at a uniform speed up to 200°. Between 200° and 270° the pump is slowed down rapidly as required to eliminate the rapid rise from F to 2F shown as 199.
When it is time to speed the motor back up in the area from 250° to 270°, the increase in speed of the motor is prescribed by the slope of the outflow in this region. The pressure piston and damper piston cam profiles prescribe this slope and are designed to provide a relatively slow increase in motor speed.
It should also be noted that the effect of the area of double flow on outflow pressure in the tube 68 decreases with increasing levels of pressure of the fluid being pumped. Thus, when the pump is run at constant r.p.m. (without any pressure feedback control) variations in the output pressure due to the double flow area 2F become quite small at about 3000 psi and are very minimal at about 5000 psi.
FIG. 18 is a block diagram view illustrating a control arrangement for regulating the speed of rotation of the cam shaft 21 of the pump.
In FIG. 18 PREF is the pressure reference signal which is provided by the computer.
The DAC is a digital to analog converter that changes the digital computer output to an analog signal appropriate for the amplifier.
The acceleration limit constrains the pressure error signal to keep the error signal within acceleration and deceleration limits which are compatible with the capability of the drive for the pump. In one embodiment of the invention, the pump motor is a stepper motor. A stepper motor cannot always be accelerated at any rate required by a pressure error signal. For example, if the rate is too high, the stepper motor loses synchronism with the driver power frequency, and the motor stalls. The acceleration limit of the FIG. 18 control prescribes a slow acceleration rate for pressure errors requiring more than approximately a 2 to 1 speed change, a fast acceleration rate for pressure errors requiring less than an approximately 2 to 1 speed change, and an even faster deceleration rate independent of the pressure error signal.
The V/F converter converts the pressure error signal (as limited by the acceleration limit) into a frequency proportional to the pressure error.
The motor driver converts a frequency signal into power output to drive the pump motor at a speed proportional to the frequency.
The pump motor drives the pump. The pump contains the pressure transducer and the cam position sensor, and these components provide control signals to the amplifier and to the computer.
The cam position sensor provides a signal to identify the start of the cam cycle. From this start point, the inlet stroke and solvent proportioning and the flow pulse region are determined in the computer by motor step counting relative to this start point.
The computer, upon input commands of start and flow set point, cyclicly computes and supplies to the analog control loop a stepwise increasing pressure reference. This pressure reference continues to increase until the motor step input signal is comparable to the flow set point.
The control system shown in FIG. 18 is used to further smooth out pressure pulses in the outflow conduit 68.
The control system shown in FIG. 18 comprises basically two control loops for the pump.
One loop is an inner control loop 201 which is an analog control loop that uses the signal from the pressure transducer 82.
The pressure transducer signal is supplied to an amplifier 201 which when compared to a pressure reference signal (PREF in FIG. 18) then produces a control signal that calls for more pump speed or less pump speed (as required) to maintain the constant pressure. In a restrictive flow system, with constant fluid properties, pressure is proportional to flow and thus flow is controlled.
The outer control loop 203 observes the time for a specified number of motor steps, the pump speed. That signal goes into a computer 207 to algorithms that compare this against the required flow rate. If, for example, because of a viscosity change in the solvent, the pump has to slow down to maintain constant pressure, the computer 207 calculates the change of speed needed to keep the flow the same. In such a case more pressure would be required, so the computer 207 calculates and produces the appropriate increased pressure reference signal that goes to the amplifier 205. The computer 207 in the outer control loop is assigned the job of computing a pressure reference based on the actual pump speed compared to the desired speed.
The control system shown in FIG. 18 is thus a hybrid control system comprising an inner loop operating analog fashion and an outer loop which operates digitally and uses the pump speed to compute and reset the pressure reference for the inner loop.
The pump motor driven is under the control of the analog loop 201 at all times. The digital loop 23 resets the pressure reference signal under certain conditions of operation.
The analog control loop 201 provides a faster and more authoritative response than the digital computer 207 which is actually too slow to handle the pressure correction directly.
There are a number of conditions that can make it necessary for the computer to change the pressure reference. One condition is a viscosity change, as noted above. Other conditions that can cause changes in flow at constant pressure include, a change in the composition of the solvent, a leaky check valve, a piece of dirt that gets into a check valve. Temperature effects on the restrictions in the system can also cause changes in flow.
During most of the cam shaft rotation each cam degree is going to have an equal amount of flow. It should be noted that motor steps are proportioned to cam degrees because of rotational correspondence through the gears. There are certain areas, for example, where the double flow occurs, that the counting of motor steps is to be avoided. In this compressibility area the flow output is not proportional to motor steps. The cam marker 121 (see FIG. 1 and FIG. 2) indicates to the computer 207 where this area is. In this area the digital loop suspends its operation.
When the cam shaft rotation leaves the non proportional area, the computer resumes the motor step counting and recomputation of the pressure reference.
The computer 207 maintains constant pressure reference to the amplifier 205 during the blanked out portion of the stroke. At other times, outside the compressibility range, the computer varies the pressure reference signal to the amplifier 205 in response to the inputs shown in FIG. 18.
In a particular embodiment of the invention, the cam cycle is divided into ten segments. Each segment has an equal number of degrees corresponding to an equal number of motor steps. The computer computes a new pressure reference for each segment, except two of the segments that are blanked out because of the compressibility occurance. During these two blanked out segments the computer does not compute a new pressure reference. It (as noted above) instead maintains the previous pressure reference.
While we have illustrated and described the preferred embodiments of our invention, it is to be understood that these are capable of variation and modification, and we therefore do not wish to be limited to the precise details set forth, but desire to avail ourselves of such changes and alterations as fall within the purview of the following claims.
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A pump for producing a substantially smooth and continuous outflow of liquid at relatively high pressure has two piston assemblies flow connected in series. The first piston assembly includes a pressure piston having a long suction stroke and a relatively short and abrupt expulsion stroke. A valve at the inlet of the pressurization piston allows flow to enter (but not exit), and a valve at the outlet of the pressurization piston allows flow to exit (but not enter). The second piston assembly includes a damper piston which functions as a mechanically driven damper to smooth the outflow from the pressure piston. This smoothing is accomplished by storing of the liquid displaced by the expulsion stroke of the pressure piston and then delivering the stored pressurized liquid to the pump outlet during the suction stroke of the pressure piston.
The drive for the pistons is constructed to produce an increased outflow of pressurized liquid for a short interval at the beginning of the expulsion stroke of the pressure piston to compensate for compressibility of the liquid at high pressure. At low pressure, the stepper motor drive is slowed down in response to the sensing of the increase of the outflow during this short interval to maintain the outflow smooth and continuous during this part of the cycle of operation.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of, pursuant to 35 U.S.C. 119(e), U.S. Provisional Patent Application No. 61/534,201, filed on Sep. 13, 2011, the content of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This application relates to configurable websites, and more particularly to configurable access control of web pages.
BACKGROUND OF THE INVENTION
[0003] Configurable web pages are well known. Many web portals, such as Google® and Yahoo® for example, offer users the ability to customize a start or home page in addition to offering search engine capability. In the case of Google®, users can select and arrange so-called “gadgets” which add certain features to their pages. Each page is personal to the user, however, and cannot be accessed by anyone else.
[0004] Also known are online tools that are often hosted by domain registrars for generating websites. Typically these tools use templates and themes to generate boilerplate HTML by plugging user data and text into the template. Other tools such as Google® Sites are a bit more sophisticated and offer user selected functions, for example Google® “gadgets,” that can be plugged into template layouts to generate web pages. Google® Sites also permit user control at the site and page level such that pages can be published, or available only with the direct link, or private and require login to a permitted Google® account. There is no way to control access on a functional basis, for example to control access for each added “gadget”. Disadvantageously, therefore, a Google® Site can not include multiple gadgets on the same page with different access control limits to each “gadget”.
[0005] Social networking sites such as Facebook®, Twitter® and the like are also known and provide some ability to configure web served content. However access is only controllable on the site, not the functional, level and as with Google® Sites, access requires permitted users to login to a closed network. One has to have a Facebook® account to see a nonpublic Facebook® page and a Google® account to see a protected Google® site.
[0006] The social networking sites are generally organized as isolated silos on the Internet. For example, Facebook® does not want to make it easy for users to use Twitter®. Most social networking sites do provide APIs permitting users to mine their own data, and these APIs are used by social media aggregation sites such as Hootsuite® to present users their own data from different sites. The aggregators typically combine multiple streams of data into columns on a single screen presenting a dashboard view of a user's own information. These aggregation sites are not designed or intended to present users' data to third parties.
[0007] One service that is intended to present information to third parties about how to access a user's social media is About.me™. Users set up a page that includes links to their various social media sites, but there is no way to control access to individual accounts on a user-by-user basis and there also is no way for the users to manage their own social media accounts from the same page, much less post updates or additional information about themselves.
[0008] Blogging sites, such as Tumblr and the like, are also know. These sites allow users to set up their own pages for publication of a variety of types of data, e.g., images, text, links etc., but there is no way to control access to each of type of data on a single site. Blogging sites are typically public, but some offer the ability host private blogs as well; however, access is controlled on the site level only and most of the content is locally hosted.
[0009] There is no simple way to collect data feeds from a variety of social networking sites and combine it with other user data for presentation on a single webpage with access control limited by individual function on the page as opposed to all functions on the page or site.
[0010] What is desired, therefore, is web-based system for publishing a website with features and access configured on a user-by-user basis by the website owner to present personal data as well as social network feeds in a single interface. It is also desired that the website owner can update and manage his social media from the same page, as well as organize private data if desired.
SUMMARY OF THE INVENTION
[0011] Accordingly, it is an object of the invention to provide a webpage through which users can access the webpage owner's social media and other data.
[0012] Another object of the invention is to provide a system that controls access to the functionality of third party websites by user and function, and where different users can access different functions or sets of functions depending on the access they have been granted.
[0013] Another object of the invention is to provide a webpage containing an owner's social media data and functionality that is accessible by other users without the users needing to have access to a closed silo social network.
[0014] Another object of the invention is to provide a system that selectively presents access to data from the owner's individual social media accounts on a user-by-user basis.
[0015] Another object of the invention is to provide a system that allows the owner to manage his various social media accounts from the same page
[0016] Another object of the invention is to provide a system that collects data feeds from a variety of social networking sites, combines it with owner data, and presents the data to the web, where aspects of the presentation is by function.
[0017] These and other objects of the present invention are achieved by provision of a configurable website system that helps to organize Internet users and their data on the Internet. Many Internet users have multiple email accounts, own multiple cell phones, use one or more social media networks, and have uploaded photos/videos to several different sites, posted to a blog or two, added their profiles/resumes on a job site, written papers or other content published somewhere on the web, etc. Their digital fingerprints are scattered all over the Internet. Even the ‘secure’ footprints require one to remember a long list of website addresses, user names and/or not so secure passwords. Many Internet users have a tattered and out of date cheat sheet of user names and passwords. When they need it at work, it's at home. When they need it in the airport, it's at work. Putting their data in the cloud is convenient but only if they can find their paper list of usernames and passwords.
[0018] To make matters worse, many Internet users have accounts to many sites on which they haven't ever posted data. This is true because they need an account to a private site or network to see the photos of their best friend's wedding, to read the rest of that interesting newspaper article, to add their name to the signup sheet for their club picnic. The web has enriched our lives in many ways and helped us manage data, but it enslaves us anew to a veritable kudzu of usernames and passwords. Further complicating things are the sites that require 8 character passwords with at least one number and one special character.
[0019] It's not widely understood, but one of the reasons Facebook is useful to people is because it helps them manage the username password kudzu. Once they are logged into Facebook, users can post different kinds of data in one place and easily find similar data posted by their friends. With a single username and password they can access a private network on which they can leave their own virtual footprints and follow the virtual footprints of others. As long as enough of one's friends are leaving footprints on the same private network, Facebook is a way to cut away some of the kudzu and organize some of an Internet user's virtual footprints. As large and ubiquitous as Facebook has become, however, it is still only a small slice of the Internet and only includes a small amount of an Internet user's virtual footprints. Facebook only organizes users' Facebook data and Facebook takes ownership and control of that data away from the users in the process. Facebook owns and profits from their virtual footprints.
[0020] The system of the present invention empowers Internet users with very simple tools to control all of their virtual footprints, including not only the ones they have added to Facebook and other private networks but also those virtual footprints they have left elsewhere on the open Internet. Users create and own their own site by pointing out their virtual footprints on the Internet and specifying who (the public, one or more private friends or lists, or only they alone) should have access to each set of footprints, together with what level of access rights each user or list should have, e.g., view, edit (add and/or delete), own, and the like. Each user only gets access to those of the owner's footprints that are relevant to the user. As owner of a site, one can add and edit her footprints or change the list of friends with access to any of them at any time. One can post to his Facebook page, send an email, upload a photo all from within his site or directly to the third party account used to create this trail of one's virtual footprints to start with. Either way, the content, one's latest footprints, are available instantly on the owner's site, accessible only by the friends the owner wants to have access.
[0021] Each site on the system of the present invention is a website page that is unique to its owner. A site is its owner's virtual fingerprint and defines its owner in the virtual world of the Internet in the same way the whorl on one's finger is her real fingerprint and defines her in the physical world. Setting up a site is as easy as pointing to all of the owner's trails of virtual fingerprints on the Internet. It is the trailhead of the owner's life on the web. After identifying all of one's footprint trails, the owner decide who gets a map and how many trails each map includes. In other words, the owner decides which users get to follow each trail of his virtual footprints. After all, they are the owner's virtual footprints, and the owner should get to choose how many of them to share, and who to share them with. The owner may add as many virtual footprint trails as she wishes to her site, and make as many maps as she wishes to permit any number of different users or groups access to different trails. An owner of a site can add trails, delete trails, add or delete footprints, delete maps and users and groups, make new maps, add new users and groups, even keep private trails accessible only to himself. One owns and controls access to all of his data on the Internet, and has all of his virtual footprints organized in one place; his site on the configurable website system of the present invention. All of an owner's digital data in one place, plus access to all her friends' data, and only a single password to remember.
[0022] Users of an owner's site also benefit because they can access all of the owner's virtual footprints in one place. Using a messaging service, they can also always reach the owner, exactly in the way the owner wants. Users authorized by the owner drop a message into the message service of a site owner, and it gets delivered to the site owner in exactly the manner specified by the site owner. The site owner can organize incoming messages by time, calendar, user, viewing method, etc. The site owner can receive messages in the way she wants, but all her friends need to know is one address, the owner's site address.
[0023] With the system of the present invention, each owner is provided with a messaging service inbox that the owner can chose to associate with his personal site. The messaging service has some unique characteristics that put the owner in control of her incoming electronic messages and preserve her privacy in the process. The messaging service inbox of the present invention differs from other electronic messaging systems in several important ways. First, recipients have no address so there is nothing to be harvested or spammed and the owner is free to change his electronic inboxes at any time without any disruption in message delivery or burden on senders to update their address books. Second, only senders authorized by the owner have access to the owner's messaging service inbox. This means messages from any particular person can be permanently blocked by the recipient/owner at any time.
[0024] By employing the system of the present invention, users do not need to remember which cell phone number the site owner is currently using, which email address is still valid, where to find those photos from the site owner's last outing, or how to subscribe to the site owner's Twitter feed. Everything is right in one place and users have access to it all on an owner's site. Once users navigate to an owner's site, they have instant access to an updated map of the owner's virtual footprints on the web—the map the owner customized for them—and the data the owner wants to share are only a click away. As an owner's digital footprints grow, new trails are automatically added to his friends' maps.
[0025] Owners' sites are preferably programmed as web pages and therefore accessible on any kind of hardware device. The pages themselves preferably minimize the use of text menus to facilitate access on tablet computers and other touch screen devices, such as smartphones. Instead of traditional text menus, the pages may use easy to see and manipulate graphical methods of selection, such as buttons. Available options may be displayed as graphical scrolls instead of dropdowns or other text-based lists. Non-selected options may similarly be displayed as a scroll to facilitate navigation and reduce page reloads. The GUI is preferably intuitive and easy to use on any kind of browser with a finger or other pointing device for browsing and selection. However, in certain embodiments, hardware specific apps may be used to recreate the same user experience available in the web-based sites.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is a block diagram illustrating a configurable web server system according to the invention;
[0027] FIG. 1A is a block diagram illustrating in more detail a portion of the configurable web server system of FIG. 1 ;
[0028] FIG. 2 is an illustration of an example web page served by the configurable web server system of FIG. 1 ;
[0029] FIG. 3 is an illustration of an example web page served by the configurable web server system of FIG. 1 ;
[0030] FIG. 4 is an illustration of an example web page served by the configurable web server system of FIG. 1 ; and
[0031] FIG. 5 is a block diagram illustrating messaging system in accordance with the present invention, which may be used in conjunction with the configurable web server system of FIG. 1 or independently thereof.
DETAILED DESCRIPTION OF THE INVENTION
[0032] FIG. 1 depicts structures and operations pertaining to a configurable website and system with access control and social network features in accordance with the invention.
[0033] A configurable website according to the invention enables an owner to provide a user with access to the functionality of other websites. The authority to access this functionality is supplied on a per-function basis. For example, a user can be granted the use of certain functions of a particular website, but not to others, such as being granted the ability to read content on the website, but not to modify it. Or the ability to modify text on the website, but not images. Furthermore, the user can be granted different degrees of authority over the functionality of several websites. For instance, the user could be granted access only to read content on website A, but be granted access to modify as well as read content on website B, and so forth. Optionally, many users can access the configurable website, each being granted specific authority to access functionality on other websites. Furthermore, the configurable website itself can include functions and content to which specific access can be granted to users in the same way. These functions may be individual to the configuration webpage, or may be an aggregate of the functionality and content of the other webpages. These examples are not intended to be limiting, and it will be clear to those having skill in the art that many combinations of functionality authorizations are possible without departing from the spirit of the invention.
[0034] To this effect, a configurable web server 100 is provided connected to a network 102 . Web server 100 has access to various function modules 106 over network 102 , at least one of which function modules may include website data sets 104 .
[0035] The configurable web server 100 may be a traditional web server or any other hardware and/or software for serving a website to visitors, with a more detailed view of a preferred embodiment of the web server 100 being shown in FIG. 1A . The network 102 may be the internet, a subset of the internet, a local area network, wide area network, wireless network, cloud, or other arrangement for computer communications. Website data sets 104 can relate to any type of website, including social networking websites that provide a homepage, blog, comment posting, syndication, or other such functionality to the owner, and may require authentication for access to all or part of their content. Website data sets 104 may relate to websites requiring authentication for use on a per-function basis however, in which case, website data sets 104 may include data relating to a secondary authentication to an Internet computing resource.
[0036] Web server 100 can be used to generate a configurable website (not shown) for use as an interface, whereby an owner can aggregate content from website data sets 104 , and can control access to websites on a per-user and per-function basis. In this regard, web server 100 can be viewed as having a site setup portion 140 and a site serving portion 142 .
[0037] Function modules 106 can be accessed by the owner for incorporation into the configurable website, and can include various basic functionality for running a website, including applets, scripts, templates, style sheets, and the like. Function modules 106 may be provided on the web server 100 , or be provisionable from third parties 148 that hosting third party websites 146 that may be made available to the system 100 over network 102 . The third party websites 146 may also be directly accessed by the webpage owners using user setup hardware 108 in the usual way of employing account owner access 150 .
[0038] Example function modules 106 can include website data sets 104 which may include a secondary authentication 144 to a computing resource, such as a third party website 146 , such as a web server hosting a social media site (not shown). Further example function modules 106 can include an application programming interface (“API”), which may be used to retrieve and display data, change data, or supplement data. The API can be a configurable web server API 152 provided to a third party 148 for modification, or can be entirely created by the third party 148 , before being uploaded to the web server 100 as a third party API 154 . Function modules 106 may be generated by a third party (as shown in FIG. 1A ) and may provide access on the configurable website to third party data. As another example, function modules may simply comprise data itself. For example, individual pieces of art and blog posts may be tagged with permissions instead of subjects when they are uploaded. In this manner, new art only shows up in the appropriate collection(s) and blog posts are only viewable by the intended user/group.
[0039] User setup hardware 108 is also connected to network 102 and is accessible to the owner. Using the user setup hardware 108 , the owner can transmit account setup or site revision data 110 , a selection of functions 112 to be enabled on the configurable website, access control 114 for functions enabled on the configurable website, and optionally, status updates 116 , to system 100 .
[0040] User setup hardware 108 can be a computer, laptop, mobile device, smartphone, or other device for accessing a web server. Account setup or site revision data 110 may include information for running the configurable website, including owner personal information, passwords and multifactor authentications to access the configurable website, correspondence information such as e-mail addresses, information pertaining to the desired display of the configurable website, and URLs for the various websites that can be managed using the system 100 .
[0041] Account setup data 110 may include authentications which serve as access credentials for other website data sets 104 in addition to the configurable website. Access credentials can include passwords, multifactors, tokens, or other ways of controlling access to each website. Optionally, a permitted user list (not shown) is associated with the configurable website, website data sets 104 , and/or function modules 106 .
[0042] Optionally, website date sets 104 relate to social networking websites (not shown). Social networking websites may include but are not limited to websites for creating and connecting public, private, and semi-public user profiles, online communities, blogs, news feeds, audio and video sharing, and web syndication websites. Such websites are frequently closed-silo communities where only third party users having an account on that particular website would be able to view or interact with content belonging to an owner of a profile. The present invention provides the advantage of supplying access to an owner's information that is stored in such closed-silo communities, without requiring third party users to first obtain an account of their own.
[0043] Functions 112 can include a selection of functions 106 enabled for the configurable website. For instance, the owner can choose to enable content posting on the configurable website itself. Access control 114 is also specified for the functions enabled on the configurable website, i.e., who can access each function. Optionally, status updates 116 to the configurable website can be transmitted to system 100 from the user setup hardware 108 if this functionality has been selected. This various site data 156 , including the function selection and access control date 158 , specified by the owner may be stored in a database or other memory accessible to the web server 100 .
[0044] To access the configurable website (not shown), user access hardware 120 is accessible to either the owner or to third party users of the configurable website and is connected to network 102 . User access hardware 120 can be a computer, laptop, mobile device, smartphone, or other device for accessing a webpage, and optionally, can be the same hardware used as the user setup hardware 108 . The user first transmits an authentication 122 from the user access hardware 120 to the system 100 . Authentication 122 may be a password, multifactor authorization, hardware token, or other way of controlling access to the configurable website. System 100 responds by transmitting accessible website data 124 , regarding websites with functions that are accessible to that user. If the user is the owner or another user with proper authorization, accessible website data 124 can also include data regarding the configurable website itself. Subsequently, the user can select a website from amongst the accessible website data 124 , and transmit website selection 128 from user access hardware 120 to system 100 . System 100 then responds by transmitting accessible function data 130 to user regarding functions that are accessible to that user for the selected accessible website. The user can then select a function, and transmit function selection 132 from user access hardware 120 to system 100 .
[0045] User setup hardware 108 and/or user access hardware 120 may optionally include a touch screen 136 to facilitate user input, and/or may optionally include a wireless transceiver 138 to enable wireless communication.
[0046] Accessible website data 124 , accessible function data 130 , and selected function 134 will typically be transmitted to the user access hardware 120 from system 100 as a webpage, for display to the user on a GUI (not shown), as further discussed below. The GUI may be a combination of a display and driver software. Optionally, the accessible website data 124 and accessible function data 130 are presented to the user as thumbnail images (not shown) within a webpage. Thumbnail images may be a miniaturized image of the webpage or function they represent, or may be a different image.
[0047] FIG. 2 illustrates an example display 200 . Display 200 is an example of a page of the configurable website, which displays a selection of websites to which the user has been granted access via the configurable website. These websites may be represented by thumbnail images 206 . Display 200 may have a title bar 202 which displays a title 204 . If the user is the owner, or has been granted an appropriate level of authority, a thumbnail 208 representing the configurable website itself may also be displayed.
[0048] Optionally, display 200 is displayed on user access hardware 120 and reflects accessible website data 124 transmitted from system 100 , as shown and described with respect to FIG. 1 . In some embodiments, the user can choose a thumbnail 206 , 208 using a mouse cursor or other suitable selection means (not shown). A website selection 128 reflecting this choice is then transmitted as shown and described with respect to FIG. 1 .
[0049] FIG. 3 illustrates an example display 300 . Display 300 may have a title bar 302 which displays a title 304 . Display 300 displays thumbnail images 306 representing various website functions to which the user has been granted access by the owner of the configurable website, pertaining to a website chosen from display 200 ( FIG. 2 ). A website selection bar 308 displays thumbnail images 206 as described with respect to FIG. 2 . If the user is the owner, or has been granted an appropriate level of authority, a thumbnail 208 representing the configurable website itself may be displayed in website selection bar 308 , or in title bar 302 . A chosen website indicator 310 displays a thumbnail image of the currently chosen website, whose accessible functions are shown by thumbnail images 306 .
[0050] Optionally, display 300 is displayed on user access hardware 120 and reflects accessible function data 130 transmitted from system 100 , as shown and described with respect to FIG. 1 . In some embodiments, the user can choose a thumbnail image 306 using a mouse cursor or other suitable selection means (not shown). A function selection 132 reflecting this choice is then transmitted as shown and described with respect to FIG. 1 . Optionally, the user can also choose a thumbnail 308 , 208 to view accessible functions for a different website (not shown). A website selection 128 reflecting this choice is transmitted as shown and described with respect to FIG. 1 .
[0051] FIG. 4 illustrates a display 400 according to an embodiment of the invention. Display 400 may have a title bar 402 which displays a title 404 . Display 400 displays and provides access to a function 406 to which the user has been granted access by the owner of the configurable website. The function 406 may have been chosen from display 300 ( FIG. 3 ). The user may interact with function 406 via display 400 . For example, the user may edit text data if function 406 provides this capability.
[0052] Function selection bar 408 displays thumbnail images 306 as described with respect to FIG. 3 . Chosen function indicator 410 displays a thumbnail image of the currently chosen function 406 . Website selection bar 308 displays thumbnail images 206 as described with respect to FIG. 2 . If the user is the owner, or has been granted an appropriate level of authority, a thumbnail 208 representing the configurable website itself may be displayed in website selection bar 308 , or in title bar 402 . Chosen website indicator 310 displays a thumbnail image of the website whose accessible functions are shown by thumbnail images 306 .
[0053] Thumbnail images 306 representing various website functions to which the user has been granted access by the owner of the configurable website, pertaining to a website chosen from display 200 ( FIG. 2 ).
[0054] Display 400 can be displayed on user access hardware 120 and reflects accessible function data 130 transmitted from system 100 , as shown and described with respect to FIG. 1 . In some embodiments, the user can choose a thumbnail image 306 using a mouse cursor or other suitable selection means (not shown). A function selection 132 reflecting this choice is then transmitted as shown and described with respect to FIG. 1 .
[0055] The user may also choose a thumbnail 308 , 208 to view accessible functions for a different website (not shown) or chose a thumbnail 408 to access a different function A website selection 128 reflecting this choice is transmitted as shown and described with respect to FIG. 1 .
[0056] FIG. 5 depicts structures and operations pertaining to a messaging system in accordance with another aspect of the present invention, which may be used in conjunction with the configurable web server system of FIG. 1 or independently thereof.
[0057] The system includes a message server 500 connected to a network 502 . Message server 500 may be a traditional mail server, web server or any other hardware and/or software for serving messages. The network 502 may be the Internet, a subset of the Internet, a local area network, wide area network, wireless network, cloud, or other arrangement for computer communications.
[0058] Message recipient hardware 504 is also connected to network 502 and is in communication with the message server 500 . Message recipient hardware 504 can be a computer, laptop, mobile device, smartphone, or other device for communicating with a message server, and can be the same hardware as user setup hardware 108 described above when the messaging system is used in conjunction with the configurable website system described above, or can be separate therefrom. Message recipient hardware 504 is also be used to access one or more recipient electronic mailboxes 506 1 - 506 n , each of which may be configured in any known or yet to be developed messaging format.
[0059] Message sender hardware 508 is also connected to network 502 and is in communication with the message server 500 . Message sender hardware 508 can be a computer, laptop, mobile device, smartphone, or other device for communicating with a message server, and can be the same hardware as user access hardware 120 described above when the messaging system is used in conjunction with the configurable website system described above, or can be separate therefrom. Message sender hardware 508 is preferably configured to be able to read and manipulate web pages, as described in more detail below.
[0060] Initially, the message recipient uses message recipient hardware 504 to configure his messaging account by supplying account setup message data 510 to message server 500 . This message data may include a name or names associated with the message recipient, a list of one or more secondary electronic mailboxes to which the message recipient has access, an access list of senders authorized to send messages to the message recipient, and messaging routing rules. The message routing rules may be dependent, for example, upon parameters such as message sender (e.g., all messages from Sender A should be routed to Box 2 ), time of day (e.g., all messages received after 5:00 pm should be routed to Boxes 1 and 3 ), days of the week (e.g., all messages received on Saturdays should be routed to Box 3 ), particular dates (e.g., all messages received from Jan. 1, 2011-Jan. 8, 2011 should be routed to Boxes 1 and 2 ), etc. The rules may also comprise a matrix dependent upon two or more parameters (e.g., all messages received from Sender B after 10:00 pm should be routed to Box 2 ). Upon receipt of account setup message data 510 , or changes thereto, by message server 500 , message server may store the message data in a database 512 or other memory. Furthermore, the rules may specify one or more particular formats in which the recipient desires to receive messages for each of her electronic mailboxes.
[0061] When a message sender desires to send a message to a message recipient using the system of the present invention, the message sender may use message sender hardware 508 to supply an authentication 514 to message server 500 . In response, the message server 500 may, based upon the authentication 514 and the message data stored in database 512 , transmit to message sender hardware 508 a list of permitted names 516 to whom the message sender is authorized to send messages. The message sender may then select a recipient name from the list and transmit the selected recipient name 518 to the message server 500 .
[0062] Alternately, the transmission of the list of permitted names 516 may be omitted, and the message sender hardware 508 may be used to transmit both the authentication 514 and the recipient name 518 without the list of permitted 516 names being provided. In this case, the message server 500 may analyze the authentication 514 and the recipient name 518 against the message data stored in database 512 in order to determine whether the message sender is authorized to send messages to the identified message recipient.
[0063] This may be the case, for example, when each message recipient has his own personal web page, similar to that described above in connection with the configurable website system shown in FIG. 1 , such that the message sender may simply choose a “send message” function from the recipient's web page (it being the case that if the “send message” function is available for selection, the would-be message sender would have been authorized to send messages).
[0064] In any event, is it preferred that the message is received from the message sender via a non-public electronic mailbox address. More specifically, it is highly desirable that the manner in which the message is received from the message sender be strictly limited only to authorized message senders, and that the addresses for the secondary electronic mailboxes to which the message recipient has access, be kept private so as to prevent spammers from being able to obtain access to the electronic mailboxes of the message recipient.
[0065] Once the recipient name has been received, the message server may optionally transmit to message sender hardware 508 a description of any restrictions 520 placed on the message sender by the message recipient, as contained in the message data stored in database 512 . The message sender hardware may then be used to create and transmit a message 522 to the message server 500 . In one embodiment, the message server 500 may serve a web page to message sender hardware 508 with message creation and transmission functionality, thereby allowing messages to be send by any message sender hardware 508 capable of viewing and manipulating web pages.
[0066] Once the message 522 is received by the message server 500 , the message server 500 examines the parameters surrounding receipt of the message 522 in view of the message data stored in database 512 . Message reformat software 524 may optionally be provided for translating the message 522 into a desired format specified in the message data stored in database 512 , if necessary. Message router software 526 then determines, based upon the parameters surrounding receipt of the message 522 , the message data stored in database 512 (particularly, the rules and secondary mailbox information) and any necessary extrinsic information, such as time, date, etc. to which electronic mailbox or mailboxes the message should be routed, before routing the message 528 to the appropriate electronic mailbox or mailboxes.
[0067] By employing the messaging system described above, message addresses are kept private, but incoming messages are still allowed to be routed to one of several electronic inboxes as desired by the recipient/owner. Also provided is the ability to route incoming messages to a private address to an electronic box of a different messaging format, and the ability to limit incoming messages to an approved sender list. The ability to route the messages according to a matrix of parameters such as sender, time, date, etc. is also provided.
[0068] Although the invention has been described with reference to a particular arrangement of parts, features and the like, these are not intended to exhaust all possible arrangements or features, and many modifications and variations will be ascertainable to those of skill in the art.
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A web-based system allows for publishing a website with features and access configured on a user-by-user basis by the website owner to present personal data as well as social network feeds in a single interface. The website owner can update and manage his/her social media from the same page, as well as organize private data if desired. The system includes a messaging function, in accordance with which users can drop a message into the message service of a site owner, and it gets delivered to the site owner in exactly the manner specified by the site owner.
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BACKGROUND OF THE INVENTION
In the rotary drilling for oil and gas a drilling fluid is pumped down the drill pipe, out the drill bit, and up the annulus between the outside of the drill pipe and the drilled bore. The drilled fluid is examined at the well surface for gas, fluids and rock particles and are important in evaluating the possibilities of the subsurface formations for the production of oil and gas. However, it is critical to know the well depth from which the gas, fluids and rock were released by the drill bit. Therefore, a procedure has been employed to determine the lag time or delay interval between the time of the release of cuttings from the bottom of the well hole until they were pumped to the well surface for examination. By knowing the lag time, the annulus flow velocity and thus the depth of release could be calculated. The lag time is determined by pumping a "marker" (oats, carbide, etc. which could be identified by its appearance at the surface) down the interior of the drill pipe and back through the annulus to be observed, and identified at the surface. Time in minutes or pump strokes were used as a measure. This measurement included both dow pipe strokes or minutes (the passage of mud fluid down the interior of the drill pipe) and the "lag" (the passage of the mud fluid from the bottom to the surface in the annulus). Knowing the internal volume of the drill pipe, the down pipe strokes or minutes were calculated and then subtracted from the total circulation to obtain the lag from the bottom to the surface. The use of pump strokes meausrements was more accurate, since variations in pumping speed directly related to variations in the lag. Once a measurement in pump strokes was obtained the speed of the pump was irrelevant. However, a time base lag was inaccurate because it would not adjust to variable flow rates. Of course, as the depth of the bore hole increases both methods become inaccurate.
These methods above have been used with very few changes to the present. They are simple, easy to use, and the pump stroke counting switches and meters to count and keep totals are inexpensive. But the successful operation of the entire system was dependent upon the full-time presence of an observer-operator (mud logger). Two or three drilling mud pumps outputting different volumes per stroke pumped required the mud logger to calculate a lag for and switch counting instruments to each pump or combination of pumps used while drilling. In practice, this manual procedure has not been difficult but automatic switching of this sort would be very difficult, requiring considerable instrumentation.
Recently, industry efforts to develop an automatic, on-line, real time computerized mud logging system with the capability of gathering, storing and graphically presenting rate of penetration with mud gas accurately positioned to depth, all in an unattended situation, have had very limited success. The best efforts have been the pump stroke method which required elaborate expensive auto-switching instrumentation and the involvement of the driller or another rig crew member to keep the pump stroke counters operating and to route the proper counter(s) to the computer. Other efforts merely use a straight time lag which does not adjust for mud flow stoppages or variations. Elaborate auto-switching instrumentation on rig pumps introduces increased likelihood of equipment malfunction, and perhaps more important, the use of rig personnel in performing the switching is very unreliable.
SUMMARY
The present new method makes use of the relationship between mud flow rate (annular velocity) and pump pressure as a basis of computing lag. A computer is used for the entire integrated system of gathering logging data, storing it on a disc and presenting it tabularly and graphically on a screen and hard print.
Further, in accordance with this invention, in place of continuously using impulse switches on the drilling rig pumps for monitoring pump strokes or using straight time, a pumping pressure transducer sensing device to monitor mud pressure is inserted into the common pump output mud flow system. This pressure data is brought into the computer interface on a continuous basis. To accurately correlate logging data, the method incorporates a current lag, and effects adjustments of the lag time for continuously changing mud flow rate (annular velocity) in the well.
To begin, the operator obtains a lag in minutes using the standard circulated "marker" method. The pump strokes and pump pressure are observed while the "marker" is being circulated to establish a relationship between these and the calculated lag minutes and flowrate (annular vertical ft/min). This relationship is used with the pump pressure and strokes observed at other slower and faster rates. This establishes several points over the entire pumping range of that well, and is entered into a program logic as a table of pump pressure psi and annular flow rate ft/min. Data in this program table enables a computer logic to automatically adjust lag variations across the entire pumping pressure range and interpolating infinitely between these observed points. The annular flow rates for the additional pressures observed are calculated by determining the total pump output (unit vol/min) divided by annular volume (unit vol/100 ft). A table, preferably with at least five levels of pressure and annular flow rates, permits the program to continuously adjust lag by applying the table derived time base deviation to fluctuating pressures measured by the mud pressure sensor. This computerized method greatly simplifies all calculations of various phenomenon acting within the mud pumping system. Thus, further calculation of mud flow properties, hydraulics, pressure drops, etc., is unnecessary at that point.
The present invention is directed to a method of automatically determining drilling fluid lag time while drilling a well in which drilling fluid is pumped down the drill pipe, out of the drill bit and up the annulus by measuring the lag time, by inserting a marker in the drill pipe, and deriving a relationship between pump strokes, pump pressure and annular velocity at the then normal drilling condition. A relationship between pump pressure and lag time over a range of pump pressures is also determined by measuring the pump strokes and pump pressures at a plurality of different pump strokes and calculating the lag time at the measured values by use of equivalent annular velocities obtained. Thereafter, the pump pressure is continuously measured while drilling and the lag time is computer calculated from the relationship previously determined. In addition, the method includes measuring the depth of the drill bit and using the change in the depth measurement for adjusting the calculated lag time. The method also includes measuring a parameter such as gas, rock cuttings, formation fluids of the drilling fluid flowing out of the annulus and correlating the measured mud parameter with the calculated lag time thereby determining the depth from which the measured mud parameter originated.
The method of the present invention also includes repeating the above-named steps to determine a new relationship between pump pressure and lag time each time well drilling conditions change sufficiently to obsolete the earlier determined relationship.
Another object is wherein the measurement of a parameter of the drilling fluid includes measuring the amount of formation gas in the drilling fluid.
Still a further object of the present invention is wherein a base lag time is determined for one of the lag measurements and the other lag time measurements for different values of pump pressure are converted to a factor of the base lag time for providing an input to a computer.
Other and further objects, features and advantages will be apparent from the following description of a presently preferred embodiment of the invention, given for the purpose of disclosure and taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an electrical and mechanical schematic of the use of the present invention with a conventional rotary drilling rig,
FIG. 2 is a graph and table showing the method of determining a relationship between pump pressure and lag time for the particular set of drilling parameters noted, and
FIGS. 3A and 3B is a logic diagram for performing the method of the present invention
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, a partial schematic of a rotary drilling rig 10 is best seen in which a drill pipe 12 includes a bit 14 drilling a bore hole 16. Drilling fluid or mud is pumped through a pump discharge line 18 by one or more mud pumps (not shown) through a rotary hose 20, a swivel 22, a kelly joint 24, down the interior of the drill pipe 12, out the bit 14 and up the annulus 26 between the drill pipe 12 and bore hole 16 to a mud return line 28. At the well surface various characteristics of the return drilling fluid can be observed or measured such as the presence of formation gas, fluids and rock. For example, conventional gas extraction equipment 30 may be used for liberating gas in the return drilling fluid, to be drawn into the gas analyzer 47.
Referring still to FIG. 1, an electronic measuring and calculating circuit is generally indicated by the reference numeral 32 and includes a computer 34 such as sold by Hewlett-Packard, Model No. 9807A (Integral Personal Computer). The computer 34 includes a program source code 36, data storage 38, an operator interface 40, a screen display 42, and a printer 44. A field input pre-processor 46 is connected between the computer 34 for acquiring data relating to the drilling fluid such as a gas analyzer 47 which is connected to the gas extracter 30, a depth and drilling rate input from a rig depth and rate of penetration measuring device 50, and a pump pressure from a pumping pressure sensor 54, which in turn is connected to the output of the mud pumps. Therefore, the circuit 32 measures the pressure at the output of the mud pumps, uses the relationship between the pump pressure and annulus flow velocity for computing the lag and thus the depth at which the surface mud measurements originated.
Referring now to FIG. 2, a curve 54 is shown along with a table 56 which is developed for the particular well parameters noted. This information is then loaded into the program of the computer 34 for continuously computing the lag time until well conditions significantly change.
At the beginning of the operation of any particular well, the operator runs an actual lag with a marker as previously described. The number of minutes required to pump from the bit 14 to the surface is ascertained, simultaneously recording the pump speed (strokes/minutes) and the pump pressure (psi) to provide a point 58 on the curve 54. Using the lag minutes and the well depth, he obtains the overall annulus velocity (flow rate in feet/minute). The annular volume is calculated using the observed strokes per minute converted to pump output in gallons/minute multiplied by lag time Then, the mud pumps are manipulated to provide different pump pressure and pump speeds, preferably at two points 60 and 62 above the actual lag check point 58 and two points 64 and 66 below the actual lag check point 58. Using the information collected as to the volume of the bore hole 16 from the actual lag check point 58 and using pump, pipe, and hole capacity tables, along with the observed pressure and speed measurements at points 60, 62, 64 and 66, the flow rate and lag time is calculated at each of the pressure/strokes at each of the points 60, 62, 64 and 68. Now, the graph 54 and the table 56 provide an indication of the lag time and pump pressure over the entire range of pump pressures that may be utilized. This information is loaded into the program of the computer 34 and the computer 34 is enabled to use fluctuating pump pressures from the pressure sensor 54 to track the annulus velocity and the corresponding lag throughout the full range of drilling fluid movement up the annulus 26. Thus, with each one foot drilling interval, the drilling fluid lag is accurately timed to correspond with the gas, fluids and rock analyzed for that drilling interval.
For the actual lag check point 58 in the example given on FIG. 2, the pressure was 700 psi at thirty pump strokes of "x" gallons per minute giving a lag time of 44 minutes which provided a calculated flow rate of 159 feet per minute. From this, the annular volume can be calculated. Using the measured pressure and strokes at the other points 60, 62, 64 and 66, the flow rate and lag time are calculated in the example shown. The examples of pressure and flow rate were calculated from a low point of 115 psi and 79 feet per minute up to a high point of 2600 psi and 318 feet per minute. The time factor in the table 56 is based upon the actual measured point 58 which had a time lag of 44 minutes. For the interval when the pump pressure was lowered to 420 psi at point 64 the effective lag is 1.3 times 44 minutes or 57 minutes. For the point at which the pump pressure was raised to 1500 psi, the effective lag is 0.64 times 44 minutes or 28 minutes. Thereafter, the program 56 will interpolate infinitely between the points loaded into the table 56. Therefore, during drilling operations, when it is routine to be varying pump pressure due to rig procedures, this method of lagging accurately keeps track of drilled intervals when the mud system annular velocity is rising and falling.
This automatic continuously adjusted drilling fluid lag method using computerized pump pressure is superior to the pump stroke method because
(1) Unattended logging situations are more feasible while providing optimum accuracy,
(2) Computerized compensation is made of the varying pump pressures,
(3) This automatic system is much more hardware (computer and sensors) reliable. (Should the pressure sensor fail, the system automatically shifts to the straight time method until the sensor is repaired.),
(4) The compounding effect of combining a Duplex with a Triplex Pump does not affect this new method, and
(5) The switching of pumps and combinations of pumps, normally requiring personnel intervention with pump stroke counters in use, does not affect this new method.
However, a new base lag point 58 and graph 54 and table 56 must be created and entered into the computer 34 at any time there is a significant change in any of the parameters which would change the lag time. Normally, a new table 56 is determined when the depth of the bore hole 16 changes depth 200 feet or when other parameters change such as hole size, casing set, a significant change in mud weight or viscosity, bit jet nozzle size change, or diamond bit wear.
Referring now to FIGS. 3A and 3B, the logic flow diagram is generally indicated by reference numeral 80. At the beginning of the program 82, the operator inputs the initial logging parameters into the computer system, via the operator interface 40. These initial logging parameters include current depth, current lag time, the pressure threshhold and the pressure flow relationship data.
After the one time initial step 82, control passes to the beginning of the main data acquisition loop, step 84, where the field inputs are queried from the field input pre-processor 46. These field inputs are respectively:
fp1--drill time duration for the foot just completed.
fp2--a maximum gas value for a previously drilled column of mud that is transversing past the gas analyzer 47 at the surface.
fp3--the current pressure from the pressure transducer 54.
At step 86, the drill time duration parameter is examined to determine if a foot was just drilled. If a foot was not drilled, control passes to step 96.
After determining that a foot was just drilled control passes to step 88 whre the drill time duration is written to the field data file for later reference. Next, at step 90, the drill time duration is converted to a rate of penetration and is plotted on the display screen 42. Step 92 adds an incremental change to current lag of the well due to the incremental mud volume increase. In step 94 the drill time duration and flow rate deviation (from the initial flow rate) are saved for later correlation with the surface gas extraction.
At step 96, the max gas value parameter is examined to determine if a maximum gas value from a previously drilled column of mud has been extracted. If a max gas value is not present, control passes to step 104. After determining that a maximum gas value is ready for processing, control passes to step 98 where the gas value is written to the field data file for the associated depth. In this step the lag separation will determine how far to index back from the end of the file to address the correct depth. Step 100 plots the gas value on the display screen 42. Step 102 transmits the next pending previously saved drill time duration parameter (see step 94) to the field input pre-processor to start the next maximum gas value extraction process. Control now passes to step 104.
Step 104 begins the pressure processing section of the program by determining if this is the very first pressure queried from the field input pre-processor. If this is the very first pressure then the initial flow rate is calculated from the pressure-flow rate data table 56 and then control passes back to the step 84 (main loop). For subsequent pressures step 106 performs a running average with previous pressure values. Step 108 determines if a significant pressure change has taken place. If there is no significant change then control passes to the main loop, step 84. In step 110 a comparison flow rate is calculated from the running average pressure. Step 112 calculates the flow rate deviation and accordingly changes the time base insde the field input pre-processor 46 (via a special transmission) to compensate for the increase or decrease in flow rate. For example, if the drill time duration for a particular foot was one minute and if the flow rate was increased by 25% then the mud segment for that foot would accelerate from 60 seconds to 45 seconds while passing by the gas extraction point 30. Control now passes to step 114.
From time to time in the drilling process various changing well conditions will cause the lag time to change. These new lag times are entered via the operator interface 40. Step 114 determines if a new lag value has been submitted by the operator. If not, control passes to the main loop, step 84. If a new lag value is present, step 116 calculates the delta difference which will be utilized later in step 122. Step 118 readjusts the time base value in the field input pre-processor 46 (via a special transmission) back to the true time standard; one second equals one second. In step 120 all of the pending previously saved drill time duration values are readjusted as if they were drilled with the initial mud flow rate. The delta difference calculated in step 116 is now applied to the next pending drill time duration value in step 122. Control now passes to the main loop, step 84.
The lag control computer system includes the following important built-in features.
(1) Automatic update of the current lag with each foot drilled to compensate for the incremental increase in mud volume.
(2) An automatic time back-up lag system which is activated upon the detection of a pressure transducer malfunction. In the time back-up mode, special function keys are activated to allow manual operation of the system until the pressure transducer is back on line.
(3) All pending drill time duration and flow rate deviation data are automatically adjusted if a new lag is entered.
(4) Erratic pumping pressures are automatically dampened.
(5) A pumping pressure threshold to stop the upward movement of values (and corresponding parameters of gas, fluids and rock released) during pipe connections and other stoppages, and
(6) A maximum gas value for each foot drilled is processed regardless of the original drill time duration and all flow rate deviations up to and including the actual extraction process.
The present invention, therefore, is well adapted to carry out the objects and attain the ends and advantages mentioned as well as others inherent therein. While a presently preferred embodiment of the invention has been given for the purpose of disclosure, numerous changes in the details of construction, arrangement of parts and steps of the method will be readily apparent to those skilled in the art and which are encompassed within the spirit of the invention and the scope of the appended claims.
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A continuously adjusted calculated annulus drilling fluid lag time while drilling oil and gas wells and analyzing the drilling mud at the well surface for formation gas, fluids and rock in order to accurately index the release of the formation gas, fluids and rock released by the drill bit with the depth at which they were released. The method obtains such analyses by using a computer and pumping pressure to accurately track the drilling mud time lag and automatically adjusts for variations in the annulus flow rate to correlate the recorded data with its originating depth.
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This application is a division of application Ser. No. 08/295, 135, filed 08/24/94 now U.S. Pat. No. 5,525,934.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the design of electronic circuits, and in particular, relates to the design of an output stage in a CMOS integrated circuit.
2. Discussion of Related Art
Short circuit protection is typically provided in an output stage of an integrated circuit to prevent inadvertent short circuit caused by shorting of an output pin, thereby resulting in large currents to flow in the output transistors. If not properly protected, these output transistors can be irreversibly or permanently damaged. Some methods of output short circuit protection are disclosed in Bipolar and MOS Analog Circuit Design, by Alan B. Grebene, pp. 257-260, published by John Wiley and Sons (1984).
FIG. 6a and 6b show two output stages 600 and 650 having short circuit protection schemes of the prior art. As shown in FIG. 6a, a logic signal to be output is provided at the input terminal 601 of an inverter 602, which includes transistors 602a and 602b. The output signal of inverter 602, which is provided at terminal 603, is used to drive a pull-up output transistor 604. Output stage 600 is provided a resistor 610 to sense the output current flowing from the supply voltage V cc to the output terminal 605. A pull-up transistor 606 is provided at the gate terminal of output transistor 604 to sense the voltage drop across the resistor 610, and to turn off output transistor 604, when the voltage at the gate terminal of transistor 606 is more than a threshold voltage below the supply voltage V cc . A similar configuration is provided to the pull-down portion of output stage 600. In FIG. 6a, this pull-down configuration is represented by current source 607. The short-circuit protection scheme of output stage 600 is undesirable because both the output voltage swing at terminal 605 and the attainable gain in the output stage 600 are severely degraded.
In FIG. 6b, a logic signal to be output is provided at the input terminal 651 of an inverter 652, which includes transistors 652a and 652b. The output signal of inverter 652, which is provided at terminal 653, is used to drive a pull-up output transistor 654. The output signal of output stage 650 is provided at terminal 655. Output stage 650 is provided, instead of a resistor and a transistor, such as FIG. 6a's resistor 610 and transistor 606, a zener diode 660 to limit the output current by restricting the gate-to-source ("V Gs ") voltage of output transistor 654 to the breakdown voltage of zener diode 660. A similar configuration is provided to the pull-down portion of output stage 650. In FIG. 6b, this pull-down configuration is represented by current source 657. The output protection scheme of output stage 660 is undesirable, because a substantial leakage current is associated with zener diode 660 in certain manufacturer processes. The leakage current affects the value output short circuit current. Furthermore, the current in zener diode 660 under normal operation condition is high.
An example of an output stage of an amplifier using a zener diode to limit the output current is described in the article "A Quad CMOS Single-Supply Op Amp with Rail-to-Rail Output Swing" by D. Monticelli, published in IEEE Journal of Solid-State Circuits, Vol. sc-21, No. 6, December, 1986, pp.1026-34.
An alternative scheme, which replaces zener diode 660 by a number of serially connected diodes, is also possible. However, under this alternative scheme, the short-circuit current changes with the supply voltage. Further, under this alternative scheme, even though the leakage current of zener diode 660 is avoided, the current through the serially connected diodes remain high under normal operating conditions.
SUMMARY OF THE INVENTION
In accordance with the present invention, the present invention provides a comparator circuit, which includes: (a) an input protection circuit receiving a differential input signal and providing a differential output signal corresponding to the differential input signal; (b) an input stage circuit receiving the differential output signal, for providing a comparator output signal indicating whether the differential input signal is positive or negative; (c) an output stage circuit for amplification of the comparator output signal, the output stage including an output transistor having a gate terminal limited to a reference voltage between a first supply voltage and a second supply voltage; and (d) a bias circuit for providing a bias voltage used in the input protection circuit, the input stage circuit and the output stage circuit.
In accordance with another aspect of the present invention, an output circuit is provided. Such output circuit includes: (i) a reference voltage source providing a reference voltage between a first supply voltage and a second supply voltage; (b) a logic gate, coupled to the reference voltage source and an input signal, configured such that the logic gate provides an output signal limited in voltage by the reference voltage; and (c) an output transistor, having a gate terminal coupled to receive the output signal of the logic gate and a source terminal coupled to receive one of the first and second supply voltages, for providing at a drain terminal of the output transistor the output signal of the output circuit.
In one embodiment, the logic gate of the output circuit of the present invention is an inverter including: (a) a first transistor coupled to receive one of the supply voltages, a gate terminal coupled to receive the input signal of the output circuit, and a drain terminal; and (b) a second transistor having a gate terminal coupled to the gate terminal of the first transistor, a drain terminal coupled to the drain terminal of the first transistor and a source terminal coupled to receive the reference voltage.
In one embodiment, the output circuit of the present invention generates the reference voltage by serially connected diodes or serially connected diode-connected transistors.
In one embodiment of the present invention, a speed-up circuit for accelerating attainment of the reference voltage is also included to enhance the AC response of the output circuit.
Thus, the present invention provides short-circuit output protection without limiting the voltage swing in the output, or suffering a substantial leakage current, thereby avoiding high power dissipation.
The present invention is better understood upon consideration of the detailed description below and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a comparator 300, in accordance with one embodiment of the present invention.
FIG. 2a is a schematic diagram of an AB cascode amplifier 352, in accordance with the present invention.
FIG. 2b is a transistor level schematic circuit showing in further detail the schematic diagram of AB cascode amplifier 352.
FIG. 3a is a block diagram of input protection circuit 351 of the present embodiment.
FIG. 3b a schematic circuit of input protection circuit 351 of the present embodiment.
FIG. 3c is a transistor level schematic circuit showing in further detail input protection circuit 351 of the present embodiment.
FIG. 4a is a schematic circuit of output stage circuit 353 of the present embodiment.
FIG. 4b is a transistor level schematic circuit showing in further detail output stage circuit 353 of the present invention.
FIG. 5a is a schematic circuit of bias circuit 354 of the present embodiment.
FIG. 5b is a transistor level schematic circuit showing in further detail bias circuit 354 of the present embodiment.
FIG. 6a is a prior art output circuit 600 using a resistor 610 to limit the short circuit current.
FIG. 6b is a prior art output circuit 650 using a zener diode 660 to limit the short circuit current.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
One embodiment of the present invention is provided in a comparator circuit 300 shown in FIG. 1. FIG. 1 is a block diagram of comparator circuit 300, which can be implemented as a CMOS integrated circuit. As shown in FIG. 1, comparator 300 includes input protection circuit 351, input stage circuit ("AB cascode amplifier") 352, output stage circuit 353 and bias circuit 354. A differential signal is received into input protection circuit 351 across terminals 301 and 302. Input protection circuit is designed to minimize comparator 300's "V os " (offset voltage) performance. FIGS. 3a, 3b and 3c are respectively a block diagram and a schematic circuit, and a transistor level schematic circuit for input protection circuit 351, which is described in further detail in copending patent application entitled "Input Protection Circuit for a CMOS Comparator," by Kwok-Fu Chiu et al, Ser. No. 08/296,056, filed on the same day as the present application, assigned to National Semiconductor Corp., also the assignee of the present invention, bearing Attorney's Docket no. NS-2376. The detailed description of input protection circuit 351 and the accompanying drawings in the patent application, Attorney's docket number NS-2376, are hereby incorporated by reference. Input protection circuit 351 provides a differential output signal across terminals 303 and 304 substantially proportional to the differential input signal across terminals 301 and 302.
FIGS. 2a and 2b are, respectively, a schematic diagram and a transistor level schematic diagram of input stage circuit 352. Input stage circuit 352 is described in patent application entitled "AB Cascode Amplifier in an input stage of an Amplifier or Comparator," by Kwok-Fu Chiu et al, Ser. No. 08/296,057, filed on the same day as the present application, assigned to National Semiconductor Corp., also the assignee of the present invention, bearing Attorney's Docket no. NS-2378. The detailed description of input stage circuit 352 and the accompanying drawings in the patent application, Attorney's docket number NS-2378, are hereby incorporated by reference.
In response to the differential signal across terminals 303 and 304, input stage circuit 352 provides an output signal 305 which is indicative of whether the voltage at terminal 301 is higher than the voltage at terminal 302. The voltage V os represents the minimum voltage By which the voltage at terminal 301 must exceed the voltage at terminal 302 to drive the output signal at terminal 305 to "logic high".
The output signal at terminal 305 is amplified by output stage circuit 353 as the output signal of comparator 300. This output signal of comparator 300 is provided at terminal 307. Output stage circuit 353 includes a structure adapted for short circuit protection. FIG. 4a and 4b are schematic circuits of output stage 353, which is described in further detail below.
Input protection circuit 351, input stage circuit 352 and output stage circuit 353 all receive a bias voltage at terminal 308 from bias circuit 354. This bias voltage is designed to be process variation insensitive so as to ensure each implementation of comparator 300 provide the same reliable operation regardless of the variations in the manufacturing process. FIGS. 5a and 5b are schematic diagrams of bias circuit 354 of the present invention. Bias circuit 354 is described in patent application entitled "Circuit for Generating a Process Variation Insensitive Reference Bias Current," by Kwok-Fu Chiu, Ser. No. 08/295,331, filed on the same day as the present application, assigned to National Semiconductor Corp., also the assignee of the present invention, bearing Attorney's Docket no. NS-2375. The detailed description of bias circuit 354 and the related drawings in copending patent application, Attorney's docket no. NS-2375, are hereby incorporated by reference.
The present invention provides a substantially limited gate voltage range to an output transistor of an output stage, so as to limit the output current in the output transistor by limiting the gate-to-source voltage of the output transistor. This substantially limited gate voltage range is coupled through a source terminal of a transistor in a logic inverter. In the following description, the substantially limited gate voltage range is generated by a string of diodes. However, any circuit capable of creating a substantially limited voltage range between the supply voltage and the ground voltage is suitable.
FIGS. 4a and 4b are a schematic diagram and a transistor level schematic diagram, respectively, of an embodiment of the present invention in an output stage 400 of a comparator. Corresponding elements in FIGS. 4a and 4b are provided the same reference numerals to simplify this detailed discription. As shown in FIG. 4a, a signal to be output is provided at terminal 305 (terminal 305b in FIG. 4b), which is coupled to the input terminal of inverter 406. Inverter 406 is formed by a pull-up PMOS transistor 406a and a pull-down NMOS transistor 406b. However, the source terminal of transistor 406b is coupled not to the ground supply voltage, but to a reference voltage generated by a reference voltage ("V ref ") generation circuit 430. Thus, transistor 406b pulls down the voltage of output node 409 only to the voltage V ref . Output node 409 controls the gate terminal of pull-up output transistor 407. Reference generation circuit 430 includes a string of diodes (implemented by diode-connected transistors) 401a-401d. The number of diodes to be used is determined by the desired value of the reference voltage V ref . The current in diodes 401a-401d is determined by a current source 403, implemented by a NMOS transistor 403 (FIG. 4b). As shown in FIG. 4a and 4b, the voltage at the gate terminal of transistor 402b is limited to four forward-biased diode drops from the supply voltage. Consequently, the voltage on nodes 405 and 409, which are coupled to the source terminal of input transistor 406b and the gate terminal of output transistor 407, respectively, are limited also to four forward-biased diode drops for the supply voltage. In FIG. 4b, a speed-up circuit 404, including PMOS transistor 404a, and NMOS transistors 404b-404d, is provided to ensure a fast AC response, i.e. to ensure that node 405 attains the equilibrium voltage rapidly.
In FIG. 4a, the pull-down portion of output stage 400 is shown as current source 408. FIG. 4b shows such a pull-down portion of output stage 400 to a circuit analogous to the pull-up portion of output stage 400. Specifically, an inverter 456, having a source terminal of a pull-down transistor coupled to a substantially constant reference voltage source, is used to drive output pull-down transistor 457. This substantially constant reference voltage source is provided by reference voltage circuit 480. A speed-up circuit 454 is provided to increase the AC response performance. As shown in FIG. 4b, reference voltage circuit 480 includes diode-connected transistors 451a-451d, NMOS transistors 452a and 452b, and current source 453 (i.e. PMOS transistor 453). Inverter 456 includes PMOS transistor 456a and NMOS transistor 456b. In inverter 456, the source terminal of PMOS transistor 456a is coupled to receive the output substantially constant voltage of reference voltage circuit 480, thereby clamping the voltage at node 459, i.e. gate terminal of output transistor 457, to four diode forward-biased voltage drops above ground voltage.
The present invention provides the advantage that the gate terminal of an output transistor of an input stage is clamped to a predetermined voltage without a substantial leakage current, as in the use of the zener diode in the prior art circuit shown in FIG. 6b. The output transistor of such an output stage attains rail-to-rail voltage swing.
The above detailed description is provided to illustrate the specific embodiments of the present invention and is not intended to be limiting. Numerous variations and modification within the scope of the present invention are possible. The present invention is defined by the following claims.
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An output stage of a CMOS comparator is designed to have a limited short circuit current, while maintaining maximum output voltage swing and a low quiescent current. The output stage includes a reference voltage generation circuit, which generates a gate voltage at the output transistor of limited range, so that the short circuit current of the output transistor is limited. In one embodiment, the reference voltage is generated by a plurality of serially connected diodes.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is based upon and claims priority to German Patent Application 198 04 071.7 filed Feb. 4, 1998, which is herein expressly incorporated by reference.
BACKGROUND OF THE INVENTION
The invention relates to a claw coupling. The coupling connects in a rotationally fast way, two components which are rotatable around an axis of rotation. The coupling includes a first axially fixed coupling part which, at its end face, is provided with first claws. A second coupling part which, at its end face, is provided with second claws, faces the first claws. The second coupling part is adjustable along the axis of rotation between a coupled position and an uncoupled position. In the coupled position, the first and second claws engage one another. In the uncoupled position, first and second claws are disengaged.
DE 28 01 135 C3 shows a torque limiting coupling which has a switchable claw coupling. The claw coupling has two rotatably arranged coupling parts which have corresponding driving claws which face one another. In a torque transmitting position the driving claws engage one another. If a certain torque value is exceeded, one coupling part is transferred into a free-wheeling position while the driving claws are disengaged. A switching pin is provided to transfer the coupling back into the torque transmitting position. The switching pin is axially movably positioned in a bore in a driving claw of one coupling part. The bore extends parallel to the axis of rotation. A stop cam is connected to the other coupling part in a rotationally fast way. The stop cam pushes the switching pin into an opposed gap between two driving claws during the re-engagement process. This means, that initially, torque is transmitted by the switching pin. As the switching process continues, the driving claws slide on one another via chamfers until they fully engage one another. A disadvantage of this embodiment is that initially, during the switching-in process, torque is only transmitted by the switching pin. As the switching-in process continues, the driving claws transmit torque. However, the claws are not yet fully engaged relative to one another. This leads to a high load on the claw coupling. Furthermore, the claw with the bore for the switching pin has a weakened cross-section.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a switchable claw coupling where the load on the claws during the switching-in process are reduced.
In accordance with the invention, one of the two coupling parts, at its end face, includes at least one annular supporting face. The annular face extends co-axially relative to the axis of rotation. At least one cam, which rests against the annular face, is associated with the other one of the two coupling parts. The cam is able to slidingly support itself on its end face with the first and the second claws disengaged. A recess extends over part of the circumference of the supporting face. The recess is axially engaged by the cam. This engagement enables the second coupling part to move into the coupled position. When the cam is in the coupled position in the second coupling part, when viewed in the circumferential direction, the cam is not contacting any recess end in any of the two directions of rotation.
If the one coupling part includes a supporting face with exactly one recess which, if viewed in the circumferential direction, is approximately as long as a gap between adjoining claws, and if the other coupling part has one cam, the second coupling part can only be transferred into the coupled position in one particular pairing of the first and second claws relative to one another. If the second coupling part is re-set with the first and second claws, assuming a pairing relative to one another different from the particular pairing, the cam initially slides on the supporting face and holds the first and second claws out of engagement until the cam has reached the recess and engages the recess. This enables the second coupling part to move into the coupled position. Thus, switching error, due to the edges of the claws meeting one another and sliding on one another without the claws engaging one another, is only possible with one particular pairing of the first and second claws relative to one another. Thus, the probability of a switching error occurring is greatly reduced.
In order to prevent the claws from transmitting torque before they have completely engaged one another, the first and second claws, if viewed in the circumferential direction, are shorter than the gap formed between each two adjoining claws. If the claws engage one another at the start of a gap when viewed in the circumferential direction, which is always the case when the cam enters the recess after sliding on the supporting face, the claws are able to more deeply engage one another before reaching a torque transmitting position.
According to an advantageous embodiment, the recess is formed by a portion of an annular groove. The cam is a cylindrical bolt or pin positioned in a blind hole of the respective coupling part.
In order to avoid switching errors when the first and second claws are paired relative to one another, where the pairings would enable the claw coupling to be connected, part of the recess starting from at least one end is covered by a cover. In the coupled position of the second coupling part, the cover is adjustable. The cam adjusts the cover against a spring force to at least partially uncover the recess. If the first and second claws are paired relative to one another where the second coupling part is moved into the coupled position where the two coupling parts assume an angular position relative to one another, and where a switching error is to be expected in the angular position, engagement of the claw coupling is avoided in these cases. In such a case, when the second coupling part is reset, the cam, at its end face abutting the cover, slides as far as the supporting face. The cam continues to slide on the supporting face until it has reached the recess and engages the recess. The cam abuts the circumference of the cover and moves the cover against a spring force before the claws have reached a torque transmitting position. The cover at least partially uncovers the recess until the claws have reached the torque transmitting position. After the claw coupling has been disconnected and after, in consequence, the cam has moved out of the recess, the cover is returned by the spring force into the starting position.
From the following detailed description, taken in conjunction with the drawings and subjoined claims, other objects and advantages of the present invention will become apparent to those skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
Below, the preferred embodiments of the invention will be illustrated in the drawings wherein:
FIG. 1 is a longitudinal section view through a gear drive with a claw coupling in accordance with the invention.
FIG. 2 is a plan view of a first coupling part with a supporting face and a recess.
FIG. 2a is a cross-section view of the first coupling part along line 2a--2a thereof.
FIG. 3 is a plan view of a second coupling part with a cam.
FIG. 4 is a plan view of a first coupling part with a supporting face, a recess and a cover.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a gear drive which includes an inventive claw coupling 1. The coupling 1 has a first coupling part 2 associated with a gear 8. A second coupling part 3 is associated with a switching muff 10. The gear 8 is supported on a shaft 4. The gear 8 is axially fixed on the shaft 4. However, the gear 8 is rotatable on the shaft 4. The shaft 4 is supported by rolling bearings 5, 6 in the drive housing 7. A spiral-shaped lubricating groove 9 is provided on the circumference of the shaft 4 in the region of the gear 8 to enable the gear 8 to slide hydro-dynamically around the shaft 4.
The switching muff 10 is attached to the shaft 4 by a splined connection 14. The muff 10 is axially movable, however, it is rotationally fast. The switching muff 10 is actuated by a switching yoke 11. The switching yoke 11 engages a circumferential groove 13 of the switching muff 10.
A switching shaft 12 is provided which extends axis-parallel to the shaft 4. The switching shaft is connected to the switching yoke 11. The switching shaft 12 is guided out of the drive housing through sealed bores 33, 34 provided in the drive housing 7.
The switching muff 10, together with the second coupling switching part 3, is supported by a spring 15 against a flange 16 and a disc 17. The switching muff 10 is loaded in the direction of the second coupling part 3. The disc 17 is slid onto the shaft 4 and is axially supported against a securing ring 18. The securing ring 18 engages a circumferential groove 19 in the shaft 4.
The coupling parts 2, 3 include first claws 20 and second claws 21. The claws 20, 21 face one another. A recess 23 is provided in the first coupling part 2 to ensure that the claw coupling is only connected in certain angular positions of the two coupling parts 2, 3 relative to one another. The recess 23 extends over part of an annular supporting face 28.
The second coupling part 3 includes a cam 22. The cam 22 is in the form of a cylindrical pin. The cam 22 is positioned in and projects from a blind hole 36. The blind hole 36 extends parallel to the axis of rotation X--X. The blind hole 36 is arranged at the same distance from the axis of rotation X--X as is the recess 23.
The end face 35 of the cam 22 projects axially beyond the end faces 37 of the second claws 21. The end faces 38 of the first claws 20 are flush with the supporting face 28. In order to reset the second coupling part 3 to transfer the coupling part 3 into the coupled position, the end face 35 slides on the supporting face 28 without the first claws 20 and second claws 21 engaging one another. Only when the cam 22 enters the recess 23 is it possible for the first claws 20 and second claws 21 to fully engage one another.
FIG. 2 illustrates a first coupling part 2 according to FIG. 1. The first claws 20 each include torque transmitting flanks 30, 31. Each torque transmitting flank 30, 31 extends at an angle α towards the end face 38 of a first claw 20. Thus, the first claws 20 are tapered and wedge-like towards the end face 38. First gaps 24 are formed between each two adjoining first claws 20. If viewed in the circumferential direction, the first gaps 24 are circumferentially longer than the first claws 20. The supporting face 28 is co-axially arranged relative to the axis of rotation. The supporting face 28 is positioned inside the first claws 20.
A recess 23 is provided over part of the circumference of the supporting face 28. The recess 23 is in the form of an annular groove portion. If viewed circumferentially, the recess 23 is longer than a first gap 24. Recess ends 25, 26 are each positioned in the region of the first claw 20.
FIG. 3 is a plan view of a second coupling part 3 in accordance with FIG. 1. The second claws 21 include torque transmitting flanks 39, 40. Second gaps 27 are formed between each two adjoining second claws 21. The flanks 39, 40 and gaps 27 are designed to correspond to the first claw flanks and the first gaps according to FIG. 2.
The cam 22 is arranged at approximately the same angle relative to a second claw 21. The cam 22 is angularly positioned relative to the second claws 21. The angular position and length of the recess 23 relative to the first claws are dimensioned such that, in the coupled condition, the cam 22 does not contact the ends 25, 26 of the recess 23. Thus, torque transmission by the cam 22 and one of the recess ends 25, 26 is avoided.
FIG. 4 illustrates a plan view of a first coupling part 2' with a cover 29. The components corresponding with those of FIG. 2 have been given the same reference numbers and primed as in FIG. 2. The cover 29 covers part of the recess 23' starting from the end 25'. The cover 29 has a lever shape. The cover 29 is rotatably supported around a joint 41 which is arranged on the supporting face 28'. The cover 29 is flush with the supporting face 28'. In the region of the recess 23', the cover includes a stop face 42. The stop face 42 may be abutted by the cam 22 of the second coupling part 3. Due to the inclined position of the stop face 42, the cover 29 is pressed into a recess 43. When disengaging the cam 22, the cover 29 is pressed back into the starting position by a spring 45.
While the above detailed description describes the preferred embodiment of the present invention, the invention is susceptible to modification, variation and alteration without deviating from the scope and fair meaning of the subjoined claims.
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A switchable claw coupling has two rotatably arranged coupling parts (2, 3). One of said coupling parts (3) is axially movable. To reduce the loads on the claws (20, 21) during the coupling operation, the coupling part 3 has a cam (22). The cam (22) at its end face is able to slide on a supporting face 28 of the other coupling part (2). A recess (23), in the supporting face (28), is engaged by the cam (22) to enable engagement within only a limited range.
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This is a continuation-in-part of application Ser. No. 07/061100, filed June 10, 1987, now abandoned.
FIELD OF THE INVENTION
This invention relates to twist closures for containers and to means to assure consistent levels of sealing performance and application and uncapping torques. The invention also relates to methods of forming such caps and to child resistant closures.
BACKGROUND OF THE INVENTION
A great deal of attention has been focused by the packaging industry on efforts with twist caps to achieve consistent closure sealing performance and consistent levels of capping torques. A basic problem exists with the construction of the closures and with the methods and machinery used to apply caps to containers. This problem results in large variations of the torque required by the consumer to remove such caps so that some demand unusual strength or special implements while others may be so loosely applied that the effectiveness of their seal has been compromised.
With threaded closures it is typical that they are applied by capping machinery which turns the cap onto the container neck until a pre-set torque level required to assure an adequate seal is obtained. The required torque level is arrived at when the threaded engagement of the closure reaches the point where the liner or linerless sealing feature is compressed by the container neck rim to a level where the threads are so compressed against one another that they resist further engagement. Typically, the capping machine may be adjusted to provide a given capping torque level. However, most capping machines have a limited sensitivity to detect and disengage at a consistent level of torque. Some machines (e.g., those with magnetic clutches) are superior in this regard but still are lacking in consistency and are expensive. A major reason for the lack of consistency by capping machines lies in the normal variation in dimensions, surface lubricity, etc., in both caps and container neck finishes within the specifications employed for their quality control in production.
Typically, metal lug twist caps are applied to neck finishes which include a positive stop so that a limit is provided beyond which the cap cannot be twisted. The reason for such provision is that such lug engagement are short in span and, at the segment where seal compression takes place, low in pitch so that without a positive stop, the lug engagement could be exceeded and the cap would not be engaged. However, even with a positive stopping provision, wide variations in sealing force and uncapping torques are still experienced. This condition is made more severe by the high stiffness of metal and of glass containers which are typically employed for lug caps.
In general, plastic twist caps with lug engagement are seldom used where high seal integrity is needed because of the very high levels of localized stress and the resultant cold flow or creep which occurs to cause the caps to go out-of-round and to loose their sealing force. However, some use for lug type plastic caps has been developed by employing specially configured separate liners which incorporate a plug seal, a spring portion to act against the container rim and a positive stop so that very little stress is required for closure engagement, since the plug seal does not require a positive axial stress for its sealing engagement. Such caps find use for packaging dry products, primarily for prescription drugs and their design is directed towards making the closure child resistant by including a positive locking means which requires that the cap be pushed down and turned before it can be removed. Attempts to develop a one-piece closure wherein the integral liner also acts as a spring portion (see, U.S. Pat. No. 4,091,948) have been unsuccessful largely due to the fact that they have been unable to achieve the required level of flexibility and recoverable deformation in the integral liner.
In reference to the existing two-piece push-and-turn child resistant closures, problems exist with the inability of many adults to open such closures due to a lack of strength in their fingers. This fact has resulted in the use of separate caps for the same package--one child resistant and the other non-child resistant, or in the use of a two-sided cap where each side has the different feature. Both approaches are expensive and inconvenient.
Thus, known twist closures are beset with problems and drawbacks associated with their need to perform while having coacting surfaces with wide dimensional tolerance and surface lubricity, limited capping machinery sensitivity and inflexible materials resulting in specially configured and expensive liners, poor sealing performance and difficulty in opening.
SUMMARY OF THE INVENTION
In accordance wit the present invention, there is provided a new and unique closure consisting of a container and a unitary twist cap having a provision for producing a uniform level of capping and uncapping torque and sealing force. The cap is substantially rigid and includes plastic material and has a top wall which covers the container opening. The top wall has a depending skirt which engages the finish of the container for closure thereof and which has a positive stopping means to coact with a positive stopping means on the neck finish of the container. Spaced inwardly from the skirt and depending from the top wall of the cap is an integral spring portion which acts against the container neck and is employed in concert with the positive stopping means of the closure to stop and align the cap and container neck finish to predetermined levels of sealing force and capping torque. The integral spring portion has a high level of recoverable deformation or resiliency as a result of provisions in its design which significantly reduce its strength in the hoop direction while maintaining its strength in the adial direction. As the cap is twisted onto the container neck for closing, the spring portion compresses to provide a positive force to effect the engagement of the closure stopping means at the predetermined level of sealing force and capping torque. Preferably the closure engaging means consists of threads or lugs and the closure stopping means consists of suitable coacting projections and recesses on the neck finish and skirt inner wall.
In a preferred embodiment, the spring portion of the cap is an annular wall which depends from the lid and has a free end which is curled outwardly to provide at least about a quarter-round radial cross section which engages the rim of the container in an axial compressive engagement. Such a spring portion has a generally horizontal element at or intermediate the area of its engagement with the container rim and its attachment site on the top wall and, as a result, it provides a high level of resiliency in the axial direction. Optionally, the radial cross section of the spring portion may be a more fully curled "U" shape or "O" shape. It may also be essentially inarcuate in the region of said generally horizontal intermediate element. Optionally, the spring portion may have radial slits to facilitate its use or may have circumferential corrugations for the same reason. Optionally, the spring portion may also serve as a linerless rim seal, or it may be used in conjunction with a separate linerless plug seal which depends from the top wall to sealingly engage the bore of the container neck. In another option, the depending annular wall may have a free end which includes axial slits and which is bent outwardly to form generally horizontal flaps which act as a peripheral series of cantilevered springs. In a method for forming the cap and spring portion of this embodiment, the cap preferably is formed first by conventional molding techniques, such as injection or compression molding, with an internal preform for the spring portion. The preform includes an annular wall which is spaced inwardly from the peripheral skirt and which is integral with and depends from the lid. Thereafter, the free end is turned outwardly by reforming means which compressively engages its lip. To produce a generally quarter-round cross section, a curling tool may be used. To produce a "U" shape, the curling tool has provision to then turn the lip of the free end upwardly upon further compression. To produce an "O" shape, the preform is further compressed by the curling tool and the lip of the free end curls inwardly and completes the "O" shape as a result of the stresses imposed by its plastic memory. Optionally, slits can be produced in the curled spring portion during its initial molding, during curling by cutting edges included in the curling tool, or subsequently in a separate operation. To produce generally horizontal flaps, the free end may include slits around its periphery and at least the slitted portion is turned outwardly by compressive engagement with a reforming tool. Optionally, the slits may be created during the reforming by the tool itself. Optionally, circumferential corrugations can be produced in the spring portion during molding or by employing suitable forming tool surfaces.
In another preferred embodiment, the spring portion of the cap is an annular wall which depends from the top wall in a downwardly and outwardly direction. Its radial cross section may be straight or arcuate. In this embodiment, provision for reducing the hoop strength of the spring portion to enhance its level of resiliency in the axial direction is made by including radial slits or slots around its periphery. A separate linerless plug seal may depend from the top wall to engage the bore of the container neck for sealing purposes. Optionally, the spring portion may have circumferential corrugations to enhance its function. In a method for forming the cap of this embodiment, the cap preferably is molded by conventional molding techniques, in molds which have provision to produce the desired slots during molding. Optionally, the desired slits may be produced after molding employing tools with appropriate cutting edges.
In another embodiment of the invention, the closure also includes a positive locking means which requires a closure manipulation additional to twisting to unlock and remove the cap. The closure requires an axial displacement of the cap relative to the container to unlock their engagement prior to cap removal by twisting. Preferably, the axial displacement of the cap may be accomplished by pressing on a restricted portion of the cap lid with the locking mechanism therebelow so that a lower level of unlocking pressure may be employed while allowing maximum amount of sealing pressure.
In another embodiment, the closure may include a locking mechanism in one position of engagement and may have another position of engagement which is not locked. Preferably, the cap has a single bore with a top and a depending skirt including the engaging and locking means. Optionally, the locking means may be located on the container neck finish. Optionally, the cap may have two bores with a mutual top and an upwardly projecting skirt and a downwardly depending skirt wherein one skirt includes a locking means and its opposing skirt does not and the cap is inverted to switch from a locked engagement with the container to an unlocked engagement.
In another embodiment, the container is fitted with a curled portion at its rim which may have a U-shaped cross-section. The rim may also be provided with a depending annular ring which is adapted to depress the curled portion to thereby provide significant axial compression to effect engagement and disengagement of the cap from the container. The neck lip or rim may also be provided with a horizontal flange which can be depressed by the depending wall of the cap.
BRIEF DESCRIPTION OF THE DRAWINGS
The following is a detailed description together with accompanying drawings of illustrative embodiments of the invention. It is to understood that the invention is capable of modification and variation apparent to those skilled in the art within the spirit and scope of the invention.
FIG. 1 is a longitudinal sectional view of one embodiment of the cap of the invention.
FIG. 2 is a plan view of the cap of FIG. 1
FIG. 3 is a longitudinal view of a container, such as a bottle neck, upon which the cap of FIG. 1 can be applied.
FIG. 4 is a sectional view of FIG. 3, taken along the lines 4--4.
FIG. 5 illustrates the closing of the cap of FIG. 1 on the container of FIG. 3.
FIG. 6 is a longitudinal sectional view of one embodiment of the method of the invention, illustrating a preformed cap of the invention and a tool for curling the free end of the depending wall of the cap.
FIG. 7 generally is the same as FIG. 6, except that the tool has engaged and formed the curled free end in the depending wall of a cap of the invention.
FIG. 8 is a longitudinal view, partly in section, of another embodiment of the cap of the invention, wherein the cap also includes a plug seal having a curled free end.
FIG. 9 is a longitudinal view of another bottle neck which can be used in combination with the caps of the invention.
FIG. 10 is sectional view of FIG. 9, taken along the lines 10--10.
FIG. 11 is a longitudinal view partly in section of the cap of FIG. 8 on the container of FIG. 9.
FIG. 12 is a longitudinal view of an embodiment of a container which can be used in combination with the caps of the invention.
FIG. 13 is a longitudinal sectional view of a cap of the invention which can be used with the container neck of FIG. 12.
FIG. 14 is a longitudinal sectional view of a portion of another embodiment of a preform of the cap about to be engaged by a forming tool of the invention.
FIG. 15 is similar to FIG. 14, except that the forming tool has caused the depending wall of the cap to be curled and slit.
FIG. 16 is a plan view of FIG. 15, taken along the lines 16--16 of FIG. 15.
FIG. 17 is a longitudinal sectional view of a portion of the formed cap of FIG. 15 in engagement with a container.
FIG. 18 is a longitudinal sectional view of a child resistant cap of the invention.
FIG. 19 is a longitudinal view of a portion of a container for child resistant caps of the invention.
FIG. 20 is a longitudinal sectional view of the cap of FIG. 18 on the container of FIG. 19.
FIG. 21 is a longitudinal sectional view of an assembled cap and container of the invention.
FIGS. 22 and 23 are longitudinal sectional views illustrating the forming of the cap of FIG. 21.
FIG. 24 is a longitudinal sectional view of another embodiment of the cap of the invention.
FIG. 25 is a longitudinal sectional view illustrating the engagement of the cap of FIG. 24 with a container.
FIG. 26 is a longitudinal view of a child resistant or easily accessible container of the invention.
FIG. 27 is similar to FIG. 26 except it illustrates the operation of the container of FIG. 26 and cap of FIG. 24.
FIG. 28 is a longitudinal sectional view of the combination of a child resistant and easily accessible cap of the invention.
FIG. 29 is a longitudinal sectional view of another child resistant and easily accessible cap of the invention.
FIG. 30 is a partial sectional view showing an annular depression in the lip of the container formed of outwardly curled walls.
FIG. 31 is a longitudinal sectional view of a cap engaged to the container neck shown in FIG. 30.
FIG. 32 is a longitudinal sectional view of a horizontal flange extending from the lip of the container and engaged by the wall of a cap.
FIG. 33 is a longitudinal sectional view showing a curved flange extending from the lip of the container and engaged by the wall of a cap.
FIG. 34 is a longitudinal sectional view of a cap having horizontal elements integral with the depending skirt.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 to 4, there is shown a cap 10 and a coacting container neck 38 of the invention.
Referring first to FIGS. 1 and 2, there is shown a semi-rigid cap 10 of plastic having a lid 12, a depending peripheral skirt 14 including an internal thread 34 having a lead-in 60 and a recess 36 therein, and an integral curled or curved spring portion 16 which also provides a sealing surface 32. The illustrated spring portion 16 has an upper end 20 integral with the lid 12, a free end 22 and an intermediate element 44, which is generally horizontal, and has a large amount of compressibility. The recess 36 in the thread 34 has a generally vertical or circumferentially directed stopping face 48. FIGS. 3 and 4 show a container neck 38 having a transfer bead 58 and a side wall 56 including an external thread 52 having a projection 54 thereunder.
FIG. 5 shows the cap 10 of FIGS. 1 and 2 in closed and sealed engagement with the container neck 38 of FIGS. 3 and 4. To produce the closed engagement of cap 10 and neck 38 the lead-in 60 of the cap thread 34 engages the neck thread 52 and is turned and moves downwardly until it reaches the neck thread projection 54 at which point there is little or no compression of the cap spring portion 16. Without such compression and because there is sufficient clearance at the neck portion 62 between neck thread 52 where it overlaps, the cap thread lead-in 60 moves past the neck thread projection 54 with its stopping face 64. At this juncture, the cap spring portion 16 begins to develop significant compression and to exert significant pressure on the neck projection 54 by the cap thread 34. As the capping operation continues, when this compression and pressure reach a level which is well above that required for suitable sealing, the cap thread gap 36 reaches the neck thread projection 54 and the two threads are snapped into a continuous peripheral engagement at a specific and desired sealing force whereupon the capping operation positively stops as cap thread stopping face 48 meets the neck thread stopping face 64. The amount of compressibility of the spring portion 16 is large to allow a sufficient height to the neck projection stopping face 64 to provide a consistent buttressing surface to the cap stopping face 48 while providing additional compressibility to produce a significant sealing force and seal integrity. The preferred level of recoverable compressibility is well in excess of that achieved by typical cap liners and linerless rim seals and ranges from 0.020 to 0.100 inches and higher. Such high levels of compressibility derive from the curved cross section of the spring portion 16 and the fact that the sealing pressure is exerted at surface 32 which is close to or beyond the horizontal element 44. Such a shape for spring portion 16 results in its largely axial deformation during use with allow level of localized strain or resiliency needed for the successful operation of the spring portion 16 and for the development of a significant sealing force.
Referring to FIGS. 6 and 7, there is shown a preferred method of forming the curled portion 24 of the curved spring portion 16. In FIG. 6, the cap 10 already has been formed by conventional molding techniques, such as injection molding, with a vertical cylindrical or tubular wall 18 having its upper end 20 integral with the lid 12 and with its lower free end 22 ready for curling by the illustrated curling tool 26. As shown in FIG. 6, there is a taper in lower end 22 extending from the rim 30 which facilitates the initiation of the curl 24 and the wall 18 and the curl 24 are free of abrupt changes in thickness.
The curled portion 24 of the seal 16 is formed with a curling tool 26, which in FIG. 6 has been positioned within the cap 10 ready to engage the preformed wall 18 at its lip or rim 30. The curling tool 26 includes a circular or annular groove 28 of a concave cross section suitable for shaping and dimensioning the curled portion 24.
As shown in FIGS. 6 and 7, the forming operation is accomplished by pressing the groove 28 of the tool 26 against the rim 30 of the wall 18. In this embodiment, the deepest portion 33 of the groove 28 representing the center of its concavity is located outwardly of the cylindrical plane of the wall 18. Also the groove 28 has a slanted portion 39 inwardly and tangent to its concavity to facilitate centering of the tool and cap. As movement of tool 26 relative to the wall 18 are centered within groove 28 by the slanted portions 39 and are then forced outwardly and then upwardly to assume the desired curved shape having a curved cross section of from about 90 to 360 degrees but preferably from about 180 to 240 degrees, but in all . cases including a generally horizontal element 44 of the curled spring portion 16 has a measurable radial span.
To facilitate the curling operation, in the case of polypropylene, the tool 26 may be at a temperature of about ambient to about 300 degrees F. but preferably about 150 to about 300 degrees F. for curling cycles of about one-half to two seconds. The curl radius of the groove 28 and the resultant spring portion 16 may range from 0.040 to 0.100 inches or larger when used in conjunction with wall 18 thicknesses of about 0.005 to 0.030 inches. The thickness of wall 18 may desirably be tapered to include free ends 22 of about 0.005 to 0.015 inches and upper ends 20 of from 0.015 to 0.030 inches.
In FIG. 8, there is shown the cap 10 of FIG. 1, 2 and 5 wherein a separate curled linerless plug seal 80 as described in my copending application Ser. No. 809,058 is included, the entire disclosure of which is incorporated herein by reference. The plug seal 80 is formed by curling to produce a curled free end 84 with an outer sealing surface 80 and depends from lid 12 by its attached upper end 86. The seal 80 is used to supplement the spring seal 16 with those containers having suitable neck inside surfaces 46.
Referring now to FIGS. 9 to 11, there is shown a neck finish 37 which is similar to the neck 38 illustrated by FIGS. 3 to 5 except that a positive locking means 70 has been included in neck stopping means projection 54. When the cap 10 of FIGS. 1, 2 and 5 is applied to the neck finish 37 the threading operation continues until the neck stopping means face 64 stops further thread movement by engaging the cap stopping means face 48 whereupon the neck locking means 70 is in opposition to the cap locking means 50. In order to disengage such opposition, the cap 10 must be pressed axially against the neck 37 whereupon the curved spring portion 16 compresses to allow the cap locking means 50 to pass the neck locking means 70 when turned.
Referring now to FIGS. 12 and 13, there is shown a container neck 38a having separate projections 54a, used for stopping engagement and 54b, usedfor locking engagement with similar recessed means 36 in the cap 10 including cap stopping face 48 and locking face 50. The projections 54a and 54b are spaced apart along neck thread 52 by a thread portion 66. The cap 10 is applied and removed from the neck finish 38a in the same manner as in FIG. 9. However, in this embodiment, the cap 10 may be reapplied in an unlocked but otherwise secure position by reapplying cap 10 until the lead-in portion 60 is located along the neck thread portion 66 between projections 54a and 54b. In this position, the spring portion 16 is compressed enough to provide a seal as well as a positive seating of the cap thread 34 against the neck thread 52. However, there are no locking faces in opposition and the cap 10 may easily be removed without special manipulation. Alternatively, where desired the cap 10 may be reapplied to the locked position. Optionally, the cap lid 12 may include an indicating means 31 on its upper surface above the locking face 50 so that the cap lid 12 may be pressed downwardly only at that point to unlock the cap. In this manner, much lower pressures are required to unlock the cap without compromising its intended child resistant use.
Referring now to FIGS. 14 to 16, there is shown an alternative method for producing the spring portion 16 of cap 10 wherein the curling tool 26a has peripherally spaced cutting edges 72 located in groove 28. As shown in FIG. 15, as the rim 30 of preform wall 18 enters the groove 28, it meets the cutting edges 72 which slit it axially so that after the curl 24 has been formed virtually all its hoop strength has been removed by its peripherally spaced slits 74. In this manner, the resiliency of the spring 16 may be further enhanced while relying on a separate linerless plug seal for sealing.
In FIG. 17 there is shown an alternative method for producing peripheral slits in the spring portion 16 wherein the curl 24 is produced as illustrated by FIGS. 6 and 7 and in a sequential operation the tool 26a of FIGS. 14 to 16 is pressed against the already formed curl 24 so that the slits 74 occur only in the intermediate spring portion 76.
Referring now to FIGS. 18 to 20, there is illustrated a cap 10 including an integral spring portion 16 having a curled free end 24 with a sealing portion 32 and lugs 90 used to secure the cap to a container neck 38. Disposed about the periphery of rim 40 of neck 38 are lugs 92 shaped with a recess 96 to receive and coact with the lugs 90 of the cap 10. The recess 96 has a stopping face 94 and a locking face 98 to prevent cap removal without first pressing the cap downwardly to free the cap lug 90 from the container lug recesses 96.
FIGS. 21 to 23 illustrate an alternative spring portion 16 to the cap 10 illustrated in FIGS. 18 to 20 in which generally horizontal flaps 78 are attached to the lid 12 through a short annular wall 20 and coact in a cantilevered manner with the rim 40 of container neck 38. The flaps 78 are separated by slots 74 which may be molded in or formed subsequently. FIGS. 22 and 23 show how the spring portion .6 formed by bending the flaps 78 outwardly and upwardly from the as-molded position which forms a generally conical structure 79 employing the tool 26b. Heat may optionally be employed to reduce the strain created by bending at the hinge portion 75. The flaps 78 may also be long enough so that they will be held in a generally horizontal position by the abutment of their rims 30 with the skirt 14. Preferably, the generally horizontal, flaps of spring portion 16 range from 0 to 30 degrees above the horizontal although it will perform adequately outside of this range.
FIGS. 24 and 25 illustrate how the as-molded conical structure 79 of FIGS. 21 to 23 may be employed as a spring portion 16 without reforming to a generally horizontal position. Since the slits 7.4 have removed almost all of the hoop strength and, therefore, resistance to spread deformation of the conical structure 79, the structure can operate effectively as a spring portion 16 at a much greater angle from the horizontal. As a result, the conical structure 79 is suitable for use as spring portion 16 in shapes and wall angles suitable for molding and withdrawal from molds without subsequent bending or curling, which would not be possible without the inclusion of the slits 75 therein. This makes possible conical walls more closely approaching the vertical in one direction as well as the horizontal in the other. Preferred wall angles for conical structure 79 with slits 74 when used for the spring portion 16 as molded and without reforming may therefore be preferably about 0 to 70 degrees from the horizontal. Also shown in FIGS. 24 and 25 is the curled plug seal 80 which shares its attachement with the spring portion 16 to lid 12 through upper wall 20. During the curling operation which forms the plug seal 80, the flaps 78 may be bent upwardly to a more horizontal position as a result of the upward pressure by the curl 84 of the plug seal 80 as it is being formed. Alternatively, the curling tool 26 may also directly bend the flaps 78 upwardly during the formation of the plug seal curl 84.
Referring now to FIGS. 26 and 27, there is shown a container neck 38 similar to that described in FIGS. 18 to 20 except that the lug 92 has two recesses 96 and 97. Recess 96 is the locking lug described in FIGS. 18 to 20 with a stopping face 94 and a locking face 98. In contrast, recess 97 has beveled restraining faces 91 and 93 which allow the cap 10 of FIG. 18 to engage the container neck 38 securely but without requiring an axial pressure to unlock it before uncapping. In this manner, the closure may alternatively or optionally be used in a locked or unlocked mode as individually desired.
FIG. 28 shows the cap 10 as described in FIGS. 18 to 20 as one side of a two sided cap wherein its opposing side is a snap cap including a bead 95 which is used to engage the lugs 92 of the container neck 38 described in FIG. 19.
FIG. 29 shows the cap 10 described in FIGS. 18 to 20 as one side of a two sided cap wherein its opposing side is similar, except that its lugs 90a have a restraining face 99 which is beveled and which will not be locked by the opposing locking face 98 on the container neck 38.
Referring now to FIGS. 30 and 31 there is illustrated an embodiment of the invention wherein the container neck 37 described in FIG. 9 has been adapted to include a curled portion 16 at its rim. The curled portion 16 has a "U" shape cross section with an end 20 integral with the top 40 of the neck finish and a free end 22 with a curved intermediate portion 21 which provides a spring action upon axial compression. FIG. 31 shows the engagement of the neck 37 with a cap 10 having a lid 12 and one depending annular ring 18 which is a plug seal for engagement with the intermediate portion 21 of the curled spring portion 16, and a second depending annular ring 41 which is adapted to depress the free end 22 in a spring engagement to unlock the cap thread 34 from the neck thread 52. In this manner, the container curled spring portion 16 provides both an effective seal and an effective spring action for the practice of the invention. Alternatively, the curled spring portion 16 may be produced in the original molding of the container neck 37 using suitable shaped blow, injection or other molds without a subsequent curling operation as described for the curled spring portion 16 in FIGS. 6 and 7.
The curled portion is adapted to provide significant axial compression of at least about 0.030, preferably about 0.030 to 0.070 inches to allow for a significant butressing area on the locking and stopping surfaces and significant axial motion to effect their engagement and disengagement.
Referring now to FIG. 32, there is shown another bottle neck 37 of the invention similar to the bottle neck 37 of FIGS. 30 and 31 except that it has a spring portion 16 which is an inwardly directed horizontal flange 43 integral with the neck lip 40. The cap lid 12 has a depending wall 41 which engages the spring portion 16 to create a seal and through which the spring portion 16 urges the cap and neck threads 34 and 52 together. The threads are separated to unlock the cap when the cap is depressed and the spring portion 16 yields.
Referring to FIG. 33 there is shown another bottle neck 37 similar to that illustrated by FIGS. 30 and 31 except that its spring portion 16 is inwardly curled. When the cap 10 is depressed, the spring portion 16 yields and moves down to unlock the cap 10 from the neck 37.
Referring now to FIG. 34, there is shown another embodiment wherein the cap 10 is similar to that described in FIG. 22 except that the generally horizontal flaps 78 used as spring portions-are integral with the cap skirt 14. The flaps are separated by slots 4 which facilitate their operation as cantilevered springs by significantly reducing the hoop strength of the generally conical structure 79 of the array of flaps 78. The neck rim 40 is slanted downwardly and outwardly to facilitate the spring action by placing the flap bearing surface 71 further from its attachment site 20 at the skirt 14.
In the production of the invention, the size of the caps typically can range from about 20 mm to 120 mm and bottle and/or jar sizes range from about 2 ounce to 128 ounce capacity. Larger capacity containers such as drums or kegs are also suitable for the practice of the invention as are smaller vials and other containers.
Useful plastics which can be used for forming the caps of the invention include polypropylene, polyethylene, polystyrene, acrylonitrile-styrene-butadiene polymers, and other semi-rigid to rigid plastic materials.
The caps also can include combinations of materials, e.g., caps having metal lid portions or portions utilizing different plastics. The caps of the invention can be used to close and seal a wide variety of containers for a wide variety of products and foods including:
beverages, including carbonated soft drinks and pasteurized beverages such as beer;
foods, especially those where container sealing performance is critical, including oxygen sensitive foods such as mayonnaise, peanut butter and salad oil, and including corrosive foods such as vinegar, lemon juice; and
househould chemicals, including bleaches and detergents, drugs and cosmetics and other products requiring the highest integrity seal and reseal under the widest range of distribution and use conditions.
Further, the caps of the present invention can be used in conjunction with other features for caps, such as breakaway rings, including the caps having the breakaway or separable rings disclosed in my U.S. patent application, Ser. No. 809,057, the entire disclosure of which is hereby incorporated by reference.
The invention in its broader aspects is not limited to the specific described embodiments and departures may be made therefrom within the scope of the accompanying claims without departing from the principles of the invention and without sacrificing its chief advantages.
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A cap for a container having a depending wall with a free end adapted to constantly urge engaging means of the cap and the container together upon engagement therebetween. Preferably, the free end of the cap has low hoop stress when axially compressed to provide spring means which perform the required function. In forming the cap, preferably one end is attached at the top wall of the cap, its other end is free to move relative to the cap and a substantial horizontal intermediate element is provided therebetween. In use, the free end has a bearing surface at or beyond the horizontal element thereof.
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