description
stringlengths 2.98k
3.35M
| abstract
stringlengths 94
10.6k
| cpc
int64 0
8
|
|---|---|---|
BOTANICAL/COMMERCIAL CLASSIFICATION
[0001] Rosa hybrida /Shrub Rose Plant
VARIETAL DENOMINATION
[0002] cv. Radtko
SUMMARY OF THE INVENTION
[0003] The new variety of Rosa hybrida landscape shrub rose plant of the present invention was created by artificial pollination wherein two parents were crossed which previously had been studied in the hope that they would contribute the desired characteristics. The female parent (i.e., the seed parent) was a seedling of the ‘Bucbi’ variety (U.S. Plant Pat. No. 4,225). The ‘Bucbi’ variety is marketed under the CAREFREE BEAUTY trademark. The male parent (i.e., the pollen parent) of the new variety was a seedling of the ‘Razzle Dazzle’ variety (U.S. Plant Pat. No. 3,995). The parentage of the new variety can be summarized as follows:
‘Bucbi’ seedlingבRazzle Dazzle’ seedling.
[0004] Such parental plants are the same as those used when creating the ‘Radrazz’ variety (U.S. Plant Pat. No. 11,836).
[0005] The seeds resulting from the above pollination were sown and small plants were obtained which were physically and biologically different from each other. Selective study resulted in the identification of a single plant of the new variety.
[0006] It was found that the new variety of landscape shrub rose plant of the present invention possesses the following combination of characteristics:
[0007] (a) abundantly and substantially continuously forms attractive double blossoms that are red in coloration and possess significantly more petals than the ‘Radrazz’ variety (U.S. Plant Pat. No. 11,836),
[0008] (b) exhibits a round and bushy growth habit,
[0009] (c) forms vigorous vegetation,
[0010] (d) forms attractive ornamental green foliage with a satiny finish, and
[0011] (e) exhibits excellent resistance to blackspot.
[0012] The blooming cycle is believed to be one of the longest observed to date and is generally comparable to that of the ‘Radrazz’ variety. Also, the winter hardiness has been very good during observations to date.
[0013] The new variety well meets the needs of the horticultural industry. It can be grown to advantage as attractive ornamentation in parks, gardens, public areas, and in residential settings. It is particularly well suited for growing in the landscape. The bright red blossoms having an increased number of petals contrast nicely with the satiny green foliage.
[0014] The new variety of the present invention can be readily distinguished from the ‘Radrazz’ variety. More specifically, the blossoms of the new variety are double and display substantially more petals than the single blossoms of the ‘Radrazz’ variety. For example, the blossoms of the new variety commonly display approximately 23 petals on average while those of the ‘Radrazz’ variety and commonly display approximately 10 petals on average. The growth habit of the new variety tends to be slightly more compact and dense than that of the ‘Radrazz’ variety. Also, winter hardiness has been observed to be superior to that of the ‘Radrazz’ variety.
[0015] The new variety of the present invention also can be readily distinguished from its ancestors. More specifically, the new variety of the present invention forms deep red blossoms while those of the ‘Bucbi’ variety are pink, forms new foliage having flushes of deep burgundy which are lacking in the ‘Bucbi’ variety, and forms darker green mature foliage than the ‘Bucbi’ variety. The deep red blossom coloration of the new variety is present on both surfaces of the petals. The ‘Razzle Dazzle’ variety is a Floribunda that forms blossoms that are blood red on the inner surface and near white on the outer surface, and lacks flushes of deep burgundy on the new foliage.
[0016] The characteristics of the new variety have been found at Waso, Calif., U.S.A., to be homogeneous and stable and are strictly transmissible by asexual propagation such as budding, grafting, and the rooting of cuttings from one generation to another. The new variety reproduces true to type by such asexual propagation.
[0017] The new variety has been named the ‘Radtko’ variety.
BRIEF DESCRIPTION OF THE PHOTOGRAPHS
[0018] The accompanying photographs show, as nearly true as it is reasonably possible to make the same in color illustrations of this character, typical specimens of the new variety. The rose plants of the new variety illustrated herein were approximately five years of age and were observed during mid-May, 2004, while growing outdoors near West Grove, Pa., U.S.A. Such plants had undergone no spraying and were budded on ‘Dr. Huey’ understock.
[0019] FIGS. 1 and 2 each illustrate a group of three specimens of the new variety while abundantly flowering. The attractive bright red double blossoms and the neat, dense and compact growth habit are shown.
DETAILED DESCRIPTION
[0020] The chart used in the identification of colors is that of The Royal Horticultural Society (R.H.S. Colour Chart), London, England. The description is based on the observation of two year-old specimens of the new variety during October while growing outdoors on their own roots near West Grove, Pa., U.S.A.
Class: Landscape Shrub Rose. Plant:
Height.— approximately one meter on average at the end of the growing season. Width.— approximately one meter on average at the end of the growing season. Habit.— round, and bushy.
Branches:
Color.— young stems: near Yellow-Green Group 144B with some highlights of Red Group 53A. — adult wood: Yellow-Green Group 144B suffused with Greyed-Purple Group 184A. Texture.— stems bear a smooth surface texture when young and when mature. Thorns.— size: approximately 1 to 1.5 cm in length on average with some smaller bristles/prickles near the peduncle. — quantity: commonly approximately 18 per branch on average. — shape: oblong at the base and tapering to a fine point at the apex. — color: Greyed-Orange Group 176C when immature, and Greyed-Purple Group 184B when mature.
Leaves:
Stipules.— approximately 15 mm in length, approximately 4 mm in width, parallel with the auricle facing outward, and Yellow-Green Group 144B in coloration. Petioles.— upper surface: Yellow-Green Group 144A with highlights of Greyed-Purple Group 184A and some prickles. — under surface: Yellow-Green Group 144B. — length: commonly approximately 24 mm on average. — rachis: commonly approximately 20 mm in length on average, and Yellow-Green Group 144B in coloration on the upper and under surfaces with a hint of Red Group 53A. Leaflets.— number: 3, 5, and 7. — shape: ovate with a serrulate margin, rounded base, and an acuminate tip. — margins: serrulate. — texture: smooth. — leaflet size: commonly approximately 5 cm in length and approximately 3.2 cm in width on average for a terminal leaflet, and approximately 3 cm in length and approximately 1.7 cm in width for other leaflets. — overall leaf size: commonly approximately 9.5 cm in length including the petiole and approximately 8 cm in width on average for a three-leaflet leaf, and approximately 12 cm in length including the petiole and approximately 8.7 cm in width on average for a five-leaflet leaf. — overall appearance: very dense, leathery, and medium green in coloration, with a satiny finish. — color (young foliage): upper surface: Greyed-Purple Group 187A with highlights of Green Group 141D. under surface: Greyed-Purple Group 187B. — color (adult foliage): upper surface: commonly between Yellow-Green Group 147A and Green Group 137A. under surface: Yellow-Green Group 147B with some Yellow-Green Group 148D.
Inflorescence:
Number of flowers.— commonly approximately 4 or 5 blooms on average in a cluster. Peduncle.— medium green, Green Group 141D, with some prickles, approximately 6 cm in length on average, approximately 2.1 mm in diameter, and possesses superior strength with the flowers being held upright. Sepals.— upper surface: between Yellow-Green Group 144A and Yellow-Green Group 144B. — under surface: Yellow-Green Group 144B with areas of White Group 155D and some pubescence. — number: five. — size: approximately 27 mm in length on average and approximately 7 mm in width on average at the widest point. — margin: commonly bears some fine hairs at the edges. — apex: acuminate. Buds.— shape: slender. — length: approximately 2.5 cm on average. — size: small to medium. — color (when opening): upper surface: commonly between Red Group 52A and Red Group 55C. under surface: commonly between Red Group 53C and Red Group 53D. Flower.— form: double and informal. — diameter: approximately 8 cm. on average. — color (when opening begins): upper surface: Crimson, near Red Group 52A. under surface: between Red Group 52B and Red Group 53D. — color (when blooming): upper surface: Red Group 53D and Yellow Group 2C at the base. under surface: Red Group 45A changing to near Yellow Group 2C at the center. — color (at end of blooming): upper surface: between Red Group 53D and Red Group 54A and near Yellow Group 4D at the base. under surface: Red Group 55A with highlights of Red Group 55B and near Yellow Group 4D at the base. — fragrance: mild spice. — petal form: wedge-shaped with a curled apex. — petal size: commonly approximately 43 mm in length on average and approximately 35 mm in width on average. — petal number: approximately 23 on average. — petaloids: none observed. — lasting quality: blossoms commonly last approximately two weeks on the plant and approximately three weeks when cut and placed in a vase. — petal drop: very good, the petals drop cleanly and freely. — stamen number: approximately 113 on average. — anthers: approximately 3 mm in length on average, approximately 1.8 mm in width on average, and Yellow Group 11A in coloration. — filaments: approximately 6.3 mm in length on average, and Red Group 48D in coloration. — pistils: are separate and free, and number approximately 36 on average. — stigmas: approximately 0.75 mm in size on average, and Yellow Group 13C in coloration. — styles: approximately 5.5 mm in length on average, and Red Group 45B in coloration. — receptacle: smooth, generally rounded, approximately 13 mm in length, approximately 9 mm in width, Yellow-Green Group 144B in coloration, and with achenes standing on the bottom and wall.
Development:
Vegetation.— vigorous and strong. Blossoming.— abundant and substantially continuous. Hardiness.— very good and believed to be somewhat superior to that of the ‘Radrazz’ variety. The new variety has successfully over-wintered at Greenfield, Wis., U.S.A. Resistance to diseases.— excellent with respect to blackspot and rust. Formation of hips/seeds.— sparse.
|
A new and distinct variety of landscape shrub rose plant is provided which forms in abundance on a substantially continuous basis attractive double blossoms that are red in coloration and possess significantly more petals than the ‘Radrazz’ variety (U.S. Plant Pat. No. 11,836). The vegetation is vigorous and the growth habit is round and bushy. Attractive ornamental satiny green foliage is formed. Excellent disease resistance to blackspot is exhibited as well as very good winter hardiness. The new variety is particularly well suited for growing as distinctive ornamentation in the landscape.
| 0
|
BACKGROUND OF THE INVENTION
This invention relates to a vehicle windscreen cleaner and more particularly to a vehicle windscreen cleaner having a partially open container for containing water-soluble, cleaning and/or rinsing agent, preferably in a solid form, the container having means to attach the container releasably in position at a point in front of a vehicle windscreen.
The words cleaning and/or rinsing agent are used in this Specification to mean any suitable detergent or anti-smear agent that may be applied to a vehicle windscreen to improve visibility through the windscreen.
Windscreen cleaners of the kind spcified above are as a rule releasably attached to the windscreen wiper blade, and use a comb-shaped applicator to transfer the cleaning or rinsing agent, which may be released by rain or splashes, or other water applied to the windscreen, from the container to the windscreen. The cleaning and rinsing agent then acts to dissolve and release layers of dirt and grease and protein-containing coatings from the windscreen and eliminates smears which spoil visibility during driving.
It has been proposed to provide a windscreen cleaner in which the cleaning and rinsing agent can be transferred to the windscreen without causing wear or stressing of the surface of the screen and without scratching the screen. In this proposal the container for the cleaning and/or rinsing agent is attached, at a distance from the vehicle windscreen, by attaching elements neither to a moving part of the windscreen wiper, or to a stationary part of the vehicle, so that the slipstream generated when the vehicle moves along can directly or indirectly flow into the inside of the said container, through its open side, scavenging the cleaning or rinsing agent and thus entraining drops of the agent in the slipstream, and causing the drops to impinge on the windscreen. The only mechanical connection of the container to parts of the motor vehicle is constituted by the attaching elements. The special advantage of this arrangement is the elimination of a mechanical applicator, which, in previously known windscreen cleaners was the cause of both wear and scratches on the surface of the windscreen. The Application of the entrained drops is performed uniformly and automatically, and the drops are always generated during the periods in which the windscreen wiper must be actuated to remove moisture deposited on the windscreen, since moisture deposited on the windscreen is also deposited on the cleaning and/or rinsing agent. The cleaning and rinsing agent is distributed over the whole width of the windscreen firstly by the action of the windscreen wiper and additionally by the action of the slipstream, due to the inclined curved nature of the windscreen.
In prior proposed cleaners the container for receiving the cleaning and/or rinsing agent took the form of a trough, open on one side, which was filled by the manufacturer with a pasty or solid cleaning and/or rinsing agent. The inside of the container had projections for retaining the pasty or solid cleaning or rinsing agent in place. In the prior art windscreen cleaners it was a relatively laborious operation to refill the trough with the concentrate of cleaning and/or rinsing agent. For instance, the trough of the windscreen cleaner had to be released from its mounting, which might be on the windscreen wiper blade, and either a new block of solid cleaning and/or rinsing agent had to be inserted in position or a generally pasty concentrate of the agent had to be distributed uniformly in the trough, smoothed, and more particularly forced tightly in to the inner corners of the trough. Hitherto, as a rule, people using these prior proposed cleaners have avoided these operations, and instead have substituted a fresh windscreen cleaner, filled by the manufacturer with the cleaning and/or rinsing agent, instead of re-filling the trough of the old cleaner. Moreover, the projections provided in the trough for retaining the rinsing agent are effective only to a limited extent, since they must not completely close the open side of the trough. For this reason, in the prior art containers, the cleaning agent tends to be washed out of the container as lumps or pasty masses before it has become completely used up. Thus not all the cleaning and/or rinsing agent is used, and some of the agent is washed.
OBJECT OF THE INVENTION
It is therefore an object of the invention to provide a windscreen cleaner which can be simply manufactured and can be readily mounted in position, for example on a windscreen wiper arm, in front of a vehicle windscreen, and which has a container for receiving an element of a preferably solid, water-soluble cleaning and/or rinsing agent, which can be replaced very simply and inexpensively the container being adapted so that only a minimum of the agent is wasted.
SUMMARY OF THE INVENTION
According to this invention there is provided a vehicle windscreen cleaner device having at least one partially open container, in which a cavity is formed to receive a water-soluble, substantially solid or pasty concentrate of cleaning agent or the like, the container being at least partly defined by a movable or removable member which can be moved or removed to permit an element of said cleaning agent or the like to be inserted into the cavity and mounting means, connected to the container, for the mounting of the windscreen cleaner at a distance in front of the vehicle windscreen.
Preferably the container comprises: a bearer part; a closure part which can be fitted to the bearer part; and means for releasably connecting the bearer part and the closure part being so formed that in the assembled position they enclose and bound the cavity, the closure part constituting said movable or removable member.
It has been appreciated that the reason for the laborious topping up of the container of the prior proposed device was the one-piece construction of the prior device, and it is the design of the device which makes it necessary that the cleaning and/or rinsing agent concentrate must be made to adhere to the walls of the container. In a preferred embodiment of this invention the replacement of the cleaning and/or rinsing agent concentrate is straightforward in that the concentrate can be laid loosely in a practically solid rod in the container and can be retained therein in a usable position.
When a preferred embodiment of a windscreen cleaner device in accordance with the invention, preferably retained on a windscreen wiper arm, is used, a rod-shaped cleaning and rinsing concentrate insert is completely enclosed and fixed by the interengaging or interlocked bearer and closure parts of the container. Due to the grid-shaped or cage-shaped wall zone of the container, on the one hand the slipstream and together therewith the splashed water or rainwater can penetrate into the inside of the container to release the concentrate and on the other hand the dissolved cleaning and/or rinsing agents can escape from the container on to the windscreen. A fresh inserted rod of concentrate can be introduced by a few movements of the hand, the catch or locking device holding the bearer and closure parts together being released and the two parts being opened to such an extent that the rod of concentrate can be introduced into the container, the two component parts of the container finally being reclosed, latched or locked, the inserted rod lying firmly or loosely between the two parts of the container.
In a preferred embodiment of the invention the container cavity has an elongate shape, suitable for receiving a rod-shaped solid cleaning and/or rinsing agent concentrate, and has a periphery which is always substantially parallel to the axis, the bearer part and closure part each comprising an element having an open side, the two parts being joined together by their open sides in a dividing plane which is substantially parallel with the axis. The closure part can have two longitudinal struts which adjoin the dividing plane and extend parallel with one another, and transverse ribs which connect the longitudinal struts, extend substantially arcuately and are spaced out from one another, the apertures for the passage of the liquid being formed between the transverse ribs.
Preferably the closure part is made of resilient deformable plastics material and can be deformed to such an extent that the catch device operative between the two component parts of the container can be engaged and released. In one embodiment of the invention the adjacent end faces of the closure part and bearer part are formed with catch elements interengaging in pairs for the releasable retention of the closure part. In this embodiment the closure part can first be slightly compressed for release, and lifted from the bearer part, whereafter it is forced back again into its latching position on the bearer part with renewed slight deformation.
In an alternative embodiment the receiving container is a one-piece injection moulding of resiliently deformable plastics material, the closure part being moulded on to the bearer part, with provision for pivoting, at a lateral edge, via a thinned folding place, forming a resilient joint, and the bearer part and closure part being formed with co-operating catch elements at a place at a distance from the resilient joint. For replacing the inserted concentrate rod, the closure part is hinged upwards from the bearer part and then closed again over the inserted rod.
In another embodiment of the invention the bearer part is an integral, elongate hollow member having a grid-shaped or cage-shaped peripheral portion and a closed second peripheral portion, the closure part taking the form of a lid such as a pivotable lid closing an end face of the hollow member. Thus the container is substantially cylindrical and the movable or removable lid member is movable or removable to provide an access aperture in one end wall of the cylindrical container. In this embodiment the inserted concentrate rod is pushed into the hollow member through the aperture closable by the lid.
In a preferred further development of the invention at least some of the ribs forming the grid-shaped or cage-shaped peripheral portion of the receiving container have a substantially triangular cross-section. one edge of the section being turned towards the inside of the container. In this way the inserted rod of cleaning and rinsing agent engages relatively sharp, engaging edges, which provide the inserted rod with an additional, more particularly axial, hold in the inside of the container.
In a preferred embodiment of the invention the inside of the container is covered by a closed outer surface of the bearer part which forms the top side of the container. When the windscreen cleaner device is attached at a distance from the windscreen and without means for the mechanical application of the cleaning and rinsing agent, this closed cover wall prevents the inserted rod of concentrate being released, for instance by the rain, and used up when the vehicle is stationary.
Preferably an outwardly projecting, two-armed clamp, which acts as an attaching means for the releasable attachement of the windscreen cleaner device to a windscreen wiper, is mounted on said container, the clamp having at least one pivoting arm which can be moved to embrace a carrier arm of a windscreen wiper, the clamp being lockable in the closed windscreen wiper carrier arm embracing position by a closure.
In an alternative embodiment the bearer part can be formed integrally with the windscreen wiper arm and is preferably punched from sheet metal and shaped. The closure part can be made either of plastics or of a resiliently deformable metal.
BRIEF DESCRIPTION OF DRAWINGS
In order that the invention may be more readily understood and so that further features thereof may be appreciated the invention will now be described by way of example with reference to the accompanying drawings, in which:
FIG. 1 is a diagrammatic and elevation on an enlarged scale, of one embodiment of a two-part windscreen cleaner device in accordance with the invention;
FIG. 2 is a plan view of the inside of a first part of the windscreen cleaner illustrated in FIG. 1;
FIG. 3 is a view of the inside of the second part of the windscreen cleaner illustrated in FIG. 1;
FIG. 4 is a sectional view, taken along the line IV--IV in FIG. 3;
FIG. 5 is a view of the inside of an alternative form of second part, which is a variant of that illustrated in FIG. 3, and which is rigidly connected via a resilient joint on one side to the first part, and
FIG. 6 is a diagrammatic side elevation of an embodiment of a two part windscreen cleaner which is a variant of that illustrated in FIG. 1, and in which the first part is integral with a windscreen wiper arm.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIG. 1 a windscreen cleaner device 10 comprises two shell-shaped parts, which when assembled together completely enclose a cylindrical inner space 13. The two parts 11, 12 are resiliently deformable plastics mouldings. Moulded on the first part 11, which in this Specification will be termed the bearer part, is a mounting clamp 14 having a first arm 15, and a second arm 16 which takes the form of a pivoting arm which can be pivoted about a thin portion or hinge web 17, acting as a resilient joint, about an axis parallel with the axis 18 (FIGS. 2 and 3) of the cylindrical inner space of the container formed by the parts 11, 12. Formed on the free end of the pivoting arm 16 is a catch attachment 19 which in the closure position of the clamp 14 illustrated in phantom in FIG. 1, engages behind a catch shoulder 20 moulded on the outside of the bearer part 11.
In the embodiment illustrated in FIG. 1, the windscreen cleaner can be attached to the carrier arm of a windscreen wiper by the clamp 14, the arm 15 being located under the windscreen wiper carrier arm, and the pivoting arm 16 being pivoted over the windscreen wiper carrier arm into the latched position shown in phantom in FIG. 1, the clamp 14 thus embracing the windscreen wiper arm. Moulded on the side of the fixed arm 15 adjacent the pivotable arm 16, parallel with the axis 18 are two projections 21 which, when the windscreen cleaner device 10 is attached to a windscreen wiper carrier arm formed of U-sectioned channel engage in the longitudinal recess defined by the U-shaped channel and prevent undesired pivoting movements of the windscreen cleaner device 10 relative to the windscreen wiper arm.
Over the major part of the outer surface of the device 10 namely approximately from the point of connection of the attaching clamp 14 to the point of connection to a comb-like row of tines 22, the container comprising the bearer part 11 and closure part 12 is closed, being substantially open over the rest of its outer surface. In particular, the outer surface formed by the second part 12, herein termed the closure part, is substantially open. When mounted on a windscreen wiper carrier arm, the closed outer surface of the container forms substantially the top side and protects the internal space 13 and therefore a rod of a solid cleaning and rinsing agent concentrate (not shown) located within space 13, from the rain. On the other hand the closure part 12 is grid-shaped, having a large number of apertures therein. As can be seen from FIG. 3 the part 12 is formed from two longitudinal struts 23 which lie immediately adjacent the edges of the part 11, and arcuate transverse ribs 24 connecting the longitudinal struts 23. In cavity 13 defined between the shell-shaped bearer and closure parts 11, 12 there is space to accommodate rod of a rising and cleaning agent concentrate. In use of the windscreen cleaning device with a rod of concentrate in position water enters from outside the cavity 13 and the rinsing and cleaning agent released by rain or splashes emerges, more particularly through the apertures between the transverse ribs 24, the rod-shaped concentrate element being retained at all times inside the container.
As shown in FIGS. 3 and 4, the transverse ribs 24 each have a substantially triangular cross-section with a sharp or pointed edge 25 pointing towards the cavity 13 with the container formed by the parts 11,12. A rod of rinsing agent disposed in the cavity 13 within the container formed by the parts 11, 12 is gripped to minimise axial movement thereof by the sharp or pointed edges 25 of the transverse ribs 24.
To ensure a sufficient release of concentrate from the rod in cavity 13 the outwardly open portion of the cavity is further increased by a series of spaced-out teeth 26 which are moulded on the closed peripheral portion 27 of the bearer part 11 and extend by their face ends as far as the closure part 12. Thus further apertures are formed by the spaces between the teeth 26, the spaces being partly bounded by the struts 23. In the embodiment illustrated in FIGS. 2 to 4, the teeth 26 are spaced out by the same axial distance as the transverse ribs 25 of the closure part 12, and when the closure part is applied to the first part 11 the teeth 26 are substantially aligned with such ribs 25. However, the teeth 23 are optional.
A comb-like series of tines 22, is moulded on the bearer part 11, substantially at the point of attachment of the series of teeth 26, catches drops of water carried along by the slipstream and leads them, due to adhesion and capillary effect, and under the influence of the slipstream into the inside 13 of the container 11, 12. The cleaning and rinsing agent released by water is also atomised by the slipstream, and is entrained by the slipstream and flows out of the container 11, 12 through the part of the outer surface of the container formed with the above described aperture on to the adjacent windscreen.
The closure part 12 is releasably connected to the bearer part 11 by means of snap-fastening means 27 at each end of the member 12. The snap fasteners 27 project beyond the plane containing the struts 23 and engage behind latching recesses formed in the end walls 28 of the bearer part 11. Projections 29 formed on each end face of the closure part 12 form abutments for supporting the closure part 12 on the adjacent edge of the end wall 28 of the bearer part 11. As a result the closure part 12 can be removed from the bearer part 11 in a very simple manner since the closure part, made of a resilient deformable material, can be compressed in the direction of the axis of the cavity 13 to such an extent that the snap fasteners 27 on the two end faces are released from engagement.
FIG. 5 shows a modified closure part 112 of an alternative embodiment of the invention in which the closure part does not have the catch device provided on both sides in the embodiment previously described, but is moulded, with provision for pivoting, at one end, via a resilient joint 30 on the bearer part (not shown in FIG. 5). At the other end the previously described snap fastening device is provided with the snap fastener 27 and the two projections 29. To place a fresh concentrate rod in the cavity of a device provided with such a closure part 112, the closure part 112 is grasped by two handle attachments moulded on the longitudinal struts 123, the snap fastener 27 is released, accompanied by the bending of the closure part, and the closure part is hinged upwards around the pivoting axis formed by the resilient joint 30, so that a large enough unobstructed aperture is created for the insertion of the fresh rod. After insertion, the closure part 112 is closed again and so is the snap fastener 27 is reengaged.
In the case of the closure part illustrated in FIG. 5, the gaps 34 between adjacent transverse webs 124 are substantially narrower than in the embodiment illustrated in FIG. 4. In operation the narrower opening cross-section results in a more economic or slower rate of removal of concentrate and an even more complete utilization of the inserted concentrate rod, since the rod will have to disintegrate into very small parts before any of the rod can fall out of the container and be wasted.
The embodiments described with reference to FIGS. 1 to 5 are made of plastics material mouldings which can be manufactured very simple since, due to the dividing plane between two parts 11, 12, in the cylinder axis 18, each part can be completely moulded without undue difficulty.
In a modified embodiment (not shown) the zone of outer surface formed with apertures and the closed zone of the outer surface are formed in one piece, and in the region of one end wall an aperture is provided through which a fresh concentrate rod can be introduced axially. The aperture is closed by a pivoting flap or a separately applied closure flap.
FIG. 6 shows an embodiment, a modification of that illustrated in FIG. 1, of a windscreen cleaner 10' in which the bearer part 11' is unitary with a windscreen wiper arm 40, which is shown in cross-section. Since, in operation, a windscreen wiper arm 40 may be heavily loaded as a rule it is made of sheet metal which is relatively resistant to bending. Thus the bearer part 11' of the windscreen cleaner device 10', mounted on the side of the windscreen wiper arm 40, is therefore also made of sheet metal. Both the windscreen wiper arm 40 and also the bearer part 11' integral therewith can be made in conventional manner by cold forming, end-face flaps 42 also being formed by cold-forming to take the place of the end wall 28 described in the first embodiment. Basically the closure part 12' can be constructed in the same way as illustrated in FIGS. 3 and 4. For aesthetic reasons the closure part 12' in FIG. 6 has a cross-sectional shape corresponding to that of the bearer part 11', which apertures 34, similar in shape to those shown in FIG. 5, being formed merely in the closure part 12'. FIG. 6 shows the closure part 12' closed over rod of concentrate 50 shown by a chain-dot line. The crosssection of a fresh inserted concentrate rod 50 is such that it fits neatly into the cavity 13' formed between the sheel-shaped bearer and closure parts 11', 12'. In operation the material of the rod 50 is released by liquid entering and leaving via the aperture gap 34 and the released cleaning and rinsing agent is distributed over the windscreen as in the above described embodiments.
Although preferred embodiments of the invention have been described and are illustrated in the drawings, it must be expressely pointed out that men skilled in the art can readily make modifications and changes within the scope of the invention. For instance, the catch means or fastener to connect the two parts can be disposed in the region of the longitudinal edges of the part 12 or in the region of the side wall of the bearer part 11. For instance, one or more press buttons could be used as the catch elements. The particular advantages of the invention reside in the fact that the windscreen wiper arm, or if the bearer part is unitary therewith, directly on the windscreen wiper arm retaining system. To replace the concentrate rod all that must be done is to hinge or lift off the closure part, or pivoting flap or closure flap to provide access to the cavity, insert a fresh rod and release the closure part of flap after the fresh rod has been inserted.
It should be noted that the size of the openings is not critical for the performance of the apparatus but they should be kept as small as possible to make the most economical use of the cleaning agent.
|
A vehicle windscreen cleaner device comprises a container which can be fastened to or is made integral with a windscreen wiper arm. The container is cylindrical and a portion of one side wall is grid-like with apertures. Either a part of the side wall or part of the end wall are removable to permit the insertion of a stick or rod of cleaning agent. In use, when the vehicle is used in the rain water is entrained into the container by the slipstream, dissolves some of the cleansing agent and is entrained onto the windscreen.
| 1
|
BACKGROUND OF THE INVENTION
1. Field of the invention
The present invention relates to a miniature air pump with an innovative structure, and more particularly, to a miniature air pump which can optionally choose the number of air bladders, and improve pump structure so as to stabilize the air output of the pump.
2. Description of the Prior Art
A conventional miniature air pump can only produce compressed air, and perform air intake and output function with a defined air chamber. Such a simply constructed miniature air pump often causes an unsmooth air flow due to its inherent shortcomings in the structural design.
For example, a well known conventional electronic sphy gmomanometer in the world requires installation of an outer check valve to refuse back flow of high pressure air into the pump so as to prevent measurement error.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a miniature air pump which can optionally choose the number of air chambers, and improve pump structure and function.
It is another object of the present invention to provide a miniature air pump which can be formed into a compact size and many pleasant contours for customers free choice.
It is still another object of the present invention to provide a miniature air pump whose bladders are able to sequentially output pressurized air from an air output hole after introducing the air into the pump via an air pathway, and also able to prevent the back flow of air with a membrane functioning as a check valve.
These and other objects of the miniature air pump according to the present invention comprises a motor unit, a compression unit, and an air collection unit.
Wherein, the motor unit further includes a main motor portion, a base, and a rotor portion. A rotating shaft which being extended out of the main motor portion tunnels through the base and is coupled with the rotor portion whereat an eccentric hole is provided. Several air inlet apertures are formed at the side of the base.
The compression unit further includes a compression vane, a fixture, and several compression chambers. A follower rod which being extended out of the center of the compression vane is inserted into the eccentric hole formed on the rotor portion with a predetermined offset angle. The compression chamber is composed of a bladder, a flow check membrane, and a leak proof gasket. Each compression chamber is conjoined with the compression vane by a tenon formed at the rear of each bladder mated with a corresponding mortise eye formed on the compression vane after tunneling through the fixture. A first check valve is installed on the fixture facing to the flow check membrane for each compression chamber.
The air collection unit has several flow pathways corresponding to the bladders, several membranes functioning as second check valves are equipped at each exit side of the flow pathway, several guide slots each formed between the first check valve and the bladder, and an air output port is formed at the topmost end thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
To enable a further understanding of the innovative and technological content of the invention herein, refer to the detailed description of the invention and the accompanying brief description of the drawings appended below. Furthermore, the attached drawings are provided for purposes of reference and explanation, and shall not be con strued as limitations applicable to the invention herein.
FIG. 1 is a three dimensional exploded view of the present invention;
FIG. 2 is a schematic view of the motor unit of the present invention;
FIG. 3 is a schematic view of the compression unit of the present invention;
FIG. 4 is a schematic view of the collection unit of the present invention;
FIG. 5 is an assembly view of the miniature air pump of the present invention;
FIGS. 6 (A) to 6 (D) drawings illustrating various kinds of planar views whereby a compression chamber is configurated in the miniature air pump of the present invention;
FIGS. 7A to 7 B are drawings illustrating operational principle in the miniature air pump of the present invention;
FIGS. 8A and 8B are illustrating two different types of latching means used for conjoining all three units of the present invention together; and
FIG. 9 is a plan view illustrating relative positions among the compression chamber, the leak proof gasket, and the check flow membrane.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the three dimensional exploded view of the present invention shows that the contour of the miniature air pump is formed into a cylindrical configuration. The miniature air pump comprises a motor unit 10 , a compression unit 20 , and an air collection unit 30 . Several latch pins 40 are applied from outside to conjoin all three aforementioned units together.
The motor unit 10 further includes a main motor portion 101 , a base 103 , and a rotor portion 104 . FIG. 2 is its assembled view.
The compression unit 20 further includes a compression vane 201 , a fixture 204 , and several compression chambers 208 . A follower rod 202 is extended from the center of the compression vane 201 and inserted into an eccentric hole 105 formed on the rotor portion 104 with a predetermined offset angle. The compression chamber 208 is composed of a bladder 207 , a check flow membrane 209 , and a leak proof gasket 210 . In FIG. 1, three bladders disposed symmetrically apart from each other with 120° are used for improving compressed air output or particular requirement. The compression chambers 208 are conjoined with the compression vane 210 by tenons 206 each formed at the rear of respective bladder mated with corresponding mortise eye 203 formed on the compression vane 201 after tunneling through the fixture 204 . A first check valve 205 is installed on the fixture 204 facing to the check flow membrane 209 for each compression chamber 208 . The compression vane 201 is divided into three sub-blades each inclining upward with a predetermined angle.
The main motor portion 101 is engaged with its base 103 , a rotating shaft 102 is extended out of the main motor portion 101 , and after tunneling through the base 103 , is coupled with the rotor portion 104 . Several air inlet apertures 106 are formed at the side of the base 103 . After the motor unit 10 is energized, the rotor portion 104 rotates rapidly along with the follower rod 202 which being inserted into the eccentric hole 105 . Several steel balls are provided in the eccentric hole 105 for preventing excessive abrasion of the follower rod 202 caused by friction.
Referring to FIG. 3, this drawing shows the assembled view of the compression unit in which the follower rod 202 has been already inserted into the eccentric hole 105 of the rotor portion 104 . The follower rod 202 revolves eccentially by the motor unit 10 and drives the compression vane 201 to rotate which in turn sequentially equesszes all bladders 207 with a thrust force imparted from the follower rod. The bladders 207 then supplies the produced air into the air collection unit 20 . With such structure and the aid of the friction reducing steel balls in the eccentric hole 105 , the driving power can be saved a great deal.
For more detailed description about the operational principle of the present invention, reference should be made to FIGS. 7A and 7B together with FIGS. 3 and 4. FIGS. 7A and 7B illustrate operational principle of a two-bladder pump of the present invention. In the state shown in FIG. 7A, the upper bladder 207 is in full state, the upper first valve 205 is closed by inner pressure of the upper compression chamber 208 , and this same pressure forces the upper flow check membrane 302 to open and from a pathway 301 around its periphery such that air stored in the upper comprission chamer 208 is supplied to the air collection unit 30 therethrough and ejected out of the air output hole 303 . On the other hand, the lower bladder 207 is in squeezed and deformed state, the reduced inner pressure of the lower compression chamber 208 causes the lower first check valve 205 to open and allows the outside air to flow into the lower compression chamber 208 via the plurality of air inlet apertures 106 . On the other hand, in FIG. 7B, an exactly reversed state to that of FIG. 7A happens. Such motions are alternatively and repeatedly continued until the motor unit 10 stops driving the compression vane 201 .
By successively and sequentially squeezing all bladders 207 one by one, the air can continuously flow through the pathway 301 and is uniformly ejected out of the air output port 303 . The membrane 302 can function as a check valve to prevent back flow of air from the pathway 301 .
Referring to FIG. 5 the miniatuture air pump after assembling is engaged with several latch pins 40 from outside. The leak proof gasket 210 interposed between the compression unit 20 and the air collection unit 30 may preserve a constant pressure inside the pump and maintain a stable amount of air output as well.
According to operational principles described above, any number of bladders and any forms of arrangement for the bladders are optionally applicable as long as the compression chambers may be symmetrically disposed as shown in FIG. 9 . In FIG. 9, relative positions among the compression chamber 208 , the leak proof gasket 210 , and the flow check membrane are shown in a plan view. As it is clearly shown, each compression chamber 208 is disposed 120° apart from the adjacent one so that the arrangement fulfils the aforesaid principles of uniformity and symmetry. Besides, referring to FIGS. 6A through 6D, two or more than two bladders are employed with a contour configurated in square, ellipse, circle, or rectangle in planar view. Other corresponding parts can be designed to match for.
Finally, referring to FIG. 8A, for achieving pinless construction, a pair of U shaped shackles 50 are used to combine all units of the present invention together. Two hooks 51 flexed in opposite direction are stretched from two ends of the shackle 50 to hook respectively on two hasps 52 formed on the rim of the top surface of the assembly. In this way the component units of various sizes and shapes can be engaged together with two U shaped shackles 50 . FIG. 8A shows two U shaped shackles 50 are used to engage all three units of a cylindrical pump together by inlaying two shackle bodies 53 in the grooves 60 formed on the outer surface of the assembly. Similarly, FIG. 8B shows two U shaped shackles 70 are used to engage all three units of a pump formed in a rectangular prismatic contour by inlaying two shackle bodies 73 in the grooves 80 formed on the outer surface of the assembly, and engaging hooks 71 with the hasps 72 in similar way as that of FIG. 8 A.
From the above detailed description of the present invention, it will be clear that the miniature air pump according to the present invention has many advantages that the number of air chambers is optionally selective to form the pump structure into a compact size and many pleasant contours, and also can improve the pump function to supply compressed air stably and with a uniform flow.
Other embodiments of the present invention will become obvious to those skilled in the art in light of above disclosure. It is of course also understood that the scope of the present invention is not to be determined by the foregoing description, but only by the following claims.
|
An elaborately designed miniature air compressor is composed of a motor unit, a compression unit, and an air collection unit. Several bladders installed in the compression unit are sequentially actuated by a compression vane with a thrust and pulling force imparted from priston like motion caused by revolution of an eccentrically installed follower rod such that air is continuously supplied to the air collection unit and ejected out of an air output port uniformly, stably, and adequately. Besides, all component units of the miniature air pump are combined together by two shackles in stead of using latch pins.
| 5
|
This is a continuation of patent application Ser. No. 08/124,815, filed 21 Sep. 1993 now U.S. Pat. No. 5,488,741.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to devices for cleaning air.
More particularly, the present invention relates to air cleaning devices in close association with toilets, for removing malodor from the air.
In a further and more specific aspect, the present invention concerns retrofitting an air cleaning apparatus onto a toilet for cleaning malodorous air within the toilet bowl.
2. The Prior Art
From early times, people have considered their excremental functions private, and accordingly, have moved this event in from the open outdoors, to small closed rooms. While private, these small rooms lack the cleansing breezes of the more natural setting. Attempts have been made to compensate for this deficiency by providing windows, ventilating fans and the like. It has also been discovered that sulfur tends to counteract the offensive odor. Capitalizing on this phenomena, methods have been developed employing sulfur. Some of the simpler methods include lighting matches, candles, and even firing cap guns, although this would seem to draw unnecessary attention to the problem.
While effective, these techniques are not always possible. Many times, the toilets are placed with no access to the outside. In these situations, ducting is required to exchange fresh air with the tainted air. This can be expensive and the ventilation may be slow since the offensive odor is diffused throughout the room and generally evacuated through a small duct. This is less than ideal, since persons in the room will be subjected to the offensive odors for prolonged periods of time. Other situations which do not permit open windows or the use of matches, is in the very small rest rooms of airplanes. Obviously windows cannot be opened, and due to recent regulations, matches cannot be used. Furthermore, the odoriferous air cannot simply be vented outside the aircraft, and certainly cannot be vented into the passenger compartment.
To overcome the problems associated with venting the closed rooms, commonly referred to as bathrooms, containing the toilet, devices directly associated with the toilet have been developed which filter the malodor from the air. Typically, many of the various devices require extensive modifications to be made to the toilet, or a toilet constructed to specification in order to remove the obnoxious air. These modifications include specially constructed toilet seats with air passages, lids and/or bowls.
After the foul air has been drawn from the bowl, it is then necessary to provide treatment devices packaged in a manner which will not detract from the decor of the bathroom. No matter how attractively the exhaust and deodorizing devices are housed, they remain a distraction and are often a nuisance. Generally, these devices are not esthetically pleasing, being large bulky and positioned on the floor next to the toilet. These devices, so placed are tasteless and detract from the overall decor of a bathroom as well being obstructive. Many require an electrical outlet as a power source, which may or may not be conveniently to hand.
It would be highly advantageous, therefore, to remedy the foregoing and other deficiencies inherent in the prior art.
Accordingly, it is an object of the present invention to provide an improved ventilated and deodorized toilet.
Another object of the present invention is to provide a new and improved apparatus for ventilating and deodorizing a toilet.
And another object of the present invention is to provide a ventilating and deodorizing apparatus which can be retrofitted onto a toilet.
Still another object of the present invention is to provide a ventilating and deodorizing apparatus which is adjustable to allow adaptation to substantially any toilet.
Yet another object of the present invention is to provide a ventilating and deodorizing apparatus which may be mounted to a toilet so as to be substantially unnoticeable.
Yet still another object of the present invention is to provide a self contained toilet ventilating and deodorizing apparatus.
A further object of the present invention is to provide a ventilating and deodorizing apparatus which prevents substantially all of the obnoxious odors from escaping the toilet.
And a further object of the present invention is to provide a ventilating and deodorizing apparatus which is easy to install and to maintain.
Yet a further object of the present invention is to provide a ventilating and deodorizing apparatus which is self contained.
And yet a further object of the present invention is to provide a reliable and relatively inexpensive ventilating and deodorizing apparatus for toilets.
SUMMARY OF THE INVENTION
Briefly, to achieve the desired objects of the present invention in accordance with a preferred embodiment thereof, provided is an odor collector mountable on a toilet bowl, for extracting air from the toilet bowl, a filter assembly for deodorizing the air extracted from the toilet bowl, and a neck adjustably coupling the filter assembly to the odor collector, with the odor collector and the neck supporting the filter assembly adjacent the toilet bowl. Further provided is a switch means carried by the odor collector for activating the filter assembly, a power source for supplying power to the assembly, and a power circuit coupling the power source to the filter assembly and the switch means.
More specifically, the odor collector includes a base attachable to the toilet bowl, an air intake carried by the base and positionable adjacent an interior of the toilet bowl, and a sleeve having an open end, carried by the base in gaseous communication with the air intake. The filter assembly includes an air duct having an inlet, an impeller assembly for providing air flow through the apparatus, the air duct is coupled to the filter assembly, and a filter is carried between the impeller assembly and the air duct. The neck has a first end removably and slidably received through the open end of the sleeve, and a second end coupled to the inlet of the air duct.
In accordance with a preferred embodiment thereof, the impeller assembly includes a housing having an inlet and an outlet, coupled to the air duct with the inlet in gaseous communication with an outlet of the air duct. A fan is carried within the housing for producing an air flow through the apparatus, and actuator means for rotating said fan, is carried within the housing. A socket extends from the housing about the inlet, for receiving the filter and for coupling the housing to the air duct.
Further in accordance with an embodiment thereof, the switch means includes a pressure switch carried by the base within a switch housing and covered by a cap over the switch housing and engaging the switch. The pressure switch includes a first contact member, a second contact member, a resilient member separating the first contact member from the second contact member, and a bridging member which couples the first contact member to the second contact member upon compression of the resilient member.
In yet a more specific embodiment, the power circuit includes internal leads, extending from the actuator means, internally to a battery case, and through the air duct, the neck and the odor collector, to the switch means. A contact assembly is mounted within the sleeve, electrically coupled to the switch and corresponding contacts are mounted on the neck, engagable and disengagable with the contact assembly. The corresponding contacts engage the contact assembly over an extended range, permitting inward and outward adjustments of the neck within the sleeve while maintaining electrical contact. The power circuit further includes a contact carried by the air duct and a corresponding contact carried by the housing of the impeller assembly, engagable and disengagable with the contact carried by the air duct.
In a further, more specific aspect, the power source includes a battery case containing a battery. The battery case is removably mountable to the housing of the impeller assembly by mounting brackets serving as contacts between the battery case and the impeller assembly.
The apparatus of the present invention may also include a filter assembly housing having an inlet, an outlet, and an access port. The outlet of the air duct is coupled to the inlet of the filter assembly housing. The filter assembly housing carries the impeller assembly with the socket engaging the outlet of the air duct. The filter assembly housing also carries the power source.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and further and more specific objects and advantages of the instant invention will become readily apparent to those skilled in the art from the following detailed description of a preferred embodiment thereof, taken in conjunction with the drawings, in which:
FIG. 1 is a partial perspective view, showing a toilet with the lid in a raised position, and a toilet ventilating apparatus constructed in accordance with the teachings of the present invention, mounted thereon;
FIG. 2 is a partial exploded perspective view, illustrating how the toilet ventilating apparatus is mounted on a toilet;
FIG. 3 is a partial top plan illustrating the adjustability of the toilet ventilating apparatus;
FIG. 4 is a partial side plan of the toilet and the toilet ventilating apparatus;
FIG. 5 is a partially cut-away perspective view of an inverted odor collector;
FIG. 6 is an enlarged cross sectional view of a portion of the odor collector of FIG. 5, showing inset wires;
FIG. 7 is an enlarged cut-away view of a portion of the odor collector of FIG. 5, illustrating a contact assembly;
FIG. 8 is a cross-sectional view of the odor collector with a neck of a filter assembly inserted therein;
FIG. 9 is an exploded perspective view of a switch assembly;
FIG. 10 is a cross-sectional view of the switch of FIG. 9 taken along line 10--10 of FIG. 2;
FIG. 11 is a partial cut-away perspective view of the neck of the filter assembly;
FIG. 12 is a cross-sectional side view of the toilet ventilating apparatus, showing air flow directions;
FIG. 13 is a sectional view taken along line 13--13 of FIG. 12;
FIG. 14 is a cross-sectional side view of the filter assembly taken along line 14--14 of FIG. 12;
FIG. 15 is an exploded perspective view, showing the filter assembly;
FIG. 16 is a partial cut-away view of the filter assembly and battery case;
FIG. 17 is a partial view illustrating electrical contact between a impeller assembly and an the air duct;
FIG. 18 is a cross-sectional view of the battery case;
FIG. 19 is a partial perspective view illustrating a first electrical and mechanical coupling between the battery case and the impeller assembly;
FIG. 20 is a partial perspective view illustrating a second electrical and mechanical coupling between the battery case and the impeller assembly;
FIG. 21 is a circuit diagram of the toilet ventilating apparatus;
FIG. 22 is a top plan view of the odor collector;
FIG. 23 is a top plan view of an alternate odor collector;
FIG. 24 if a cross-sectional view taken along line 24--24 of FIG. 23;
FIG. 25 is a partial exploded view of an alternate toilet ventilating apparatus constructed in accordance with the teachings of the present invention;
FIG. 26 is a partial cut-away side view of the toilet ventilating apparatus of FIG. 25, illustrating a battery compartment;
FIG. 27 is an exploded perspective view of a switch assembly;
FIG. 28 is a cross-sectional view of the switch illustrated in FIG. 27;
FIG. 29 is a partial cross-sectional view of the top of the battery compartment of FIG. 26;
FIG. 30 is a partial cross-sectional view of the bottom of the battery compartment of FIG. 26;
FIG. 31 is a perspective view illustrating an alternate neck;
FIG. 32 is a cross-sectional view taken along line 32--32 of FIG. 31;
FIG. 33 is a partial perspective view, showing a toilet with the lid in a raised position, and an alternate embodiment of a toilet ventilating apparatus constructed in accordance with the teachings of the present invention, mounted thereon;
FIG. 34 is a partial exploded perspective view, illustrating how the toilet ventilating apparatus of FIG. 33 is mounted on a toilet;
FIG. 35 is a partial top plan illustrating the adjustability of the toilet ventilating apparatus;
FIG. 36 is a partial side plan of the toilet and the toilet ventilating apparatus;
FIG. 37 is a partially cut-away inverted perspective view of an alternate embodiment of an odor collector;
FIG. 38 is a sectional view taken along line 38--38 of FIG. 37;
FIG. 39 is an enlarged cut-away view of a portion of the odor collector of FIG. 37, illustrating a contact assembly;
FIG. 40 is a cross-sectional view of the contact between the odor collector and the neck of a filter assembly inserted therein;
FIG. 41 is a cross-sectional view of an alternate embodiment of a switch assembly;
FIG. 42 is a partial cut-away perspective view of the neck of the filter assembly;
FIG. 43 is a partial sectional view of the sliding engagement between the neck and the sleeve;
FIG. 44 is a cross-sectional view taken along line 44--44 of FIG. 43;
FIG. 45 is an exploded perspective view of the filter assembly;
FIG. 46 is a sectional view illustrating means for securing the battery case within the housing of filter assembly;
FIG. 47 is a cross-sectional side view of the alternate toilet ventilation apparatus of FIGS. 33-46;
FIG. 48 is a partial sectional view of the impeller assembly;
FIG. 49 is a sectional view taken along line 49--49 of FIG. 47;
FIG. 50 is a perspective view illustrating the housing of the filter assembly; and
FIG. 51 is a circuit diagram of the alternate embodiment of the toilet ventilating apparatus.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning now to the drawings in which like reference characters indicate corresponding elements throughout the several views, attention is first directed to FIG. 1 which illustrates a toilet generally designated 10, onto which a toilet ventilating and deodorizing apparatus 12 is mounted. Toilet 10 may be substantially any toilet, and includes a base 13 supporting a toilet bowl 14 having a front 15 and back 17. Front 15 and back 17 of toilet 10 will provide directional reference throughout the ensuing descriptions. A toilet seat 18 and lid 19 are coupled to a top surface 20 of toilet bowl 14 by hinges at back 17 of toilet bowl 14. This hinge arrangement permits seat 18 and lid 19 to be lowered to a horizontal position with respect to top surface 20 of toilet bowl 14 or raised to an upright position with respect to top surface 20. The movement of seat 18 and lid 19 may be accomplished independently. A water tank 22 having a front surface 23, extends upward adjacent back 17 of toilet bowl 14.
Still referring to FIG. 1, toilet ventilating and deodorizing apparatus 12 includes an odor collector 24 mounted on top surface 20 of toilet bowl 14 at back 17, and a filter assembly 25 coupled to odor collector 24 and extending downwardly proximate back 17 of toilet bowl 14, partially concealed by water tank 22. In FIG. 1, seat 18 is in the lowered position wherein it rests on a pair of switches 27 and 28, only one of which is visible, extending from odor collector 24. Lid 19 is shown in the upright position, resting against front surface 23 of water tank 22. To operate toilet ventilating and deodorizing apparatus 12, a person sits on seat 18, compressing at least one of switches 27 and 28, thereby starting operation of filter assembly 25.
The detail of FIG. 2 illustrates the coupling of seat 18, lid 19 and odor collector 24 to toilet bowl 14. A pair of hinge posts 29 and 30 having threaded ends 32 and 33 respectively, are affixed to toilet bowl 14 by inserting threaded ends 32 and 33 through openings 34 and 35 (not visible) in toilet bowl 14 and securing them with nuts (not shown). A pin 37 passes between hinge posts 29 and 30 through a set of seat hinges 38 and a set of lid hinges 39 so that seat 18 and lid 19 may be independently rotated thereabout. The hinge arrangement as depicted is intended to be typical and is not provided as a limitation on the means for practicing the invention.
Still referring to FIG. 2, odor collector 24 includes a base 40, configured to be positioned between top surface 20 of toilet bowl 14 and seat 18. A pair of slots 41 and 42, corresponding to openings 34 and 35 in toilet bowl 14, are formed through base 40 and receive threaded ends 32 and 33 of hinge posts 29 and 30. Slots 41 and 42 are employed to allow forward and rearward adjustments to be made in positioning odor collector 24. Odor collector 24 further includes a pair of opposing legs 43 extending from the front of odor collector 24 and partially along top surface 20 of toilet bowl 14, terminating in switch housings 44 containing switches 27 and 28, an air intake 45 mounted centrally between slots 41 and 42, and a sleeve 47 extending the length of base 40, rearward of and coupled to air intake 45.
Filter assembly 25 is coupled to odor collector 24 by a neck 48 configured to be slidably received by sleeve 47, and includes an air duct 49 extending generally perpendicularly downward from neck 48, an impeller assembly 50 coupled to air duct 49 and a filter 52 (not visible) fitted between impeller assembly 50 and air duct 49. Power is supplied to impeller assembly 50 by batteries contained in a battery case 53 affixed to an outer edge of filter assembly 25.
Toilet ventilating and deodorizing apparatus 12 is intended to be substantially unnoticeable and blend into the overall appearance of toilet 10. To achieve this desired characteristic, filter assembly 25 is intended to be positioned adjacent back 17 of toilet bowl 14 under water tank 22 as can be seen in FIG. 3. Furthermore, the various components are adjustable since toilet ventilating and deodorizing apparatus 12 is intended to be retrofitted to substantially any toilet. Therefore, to accommodate toilets having different shapes and dimensions, neck 48 is slidably received within sleeve 47 to allow filter assembly 25 to be positioned at varying distance from odor collector 24, filter assembly 25 is pivotally attached to neck 48 allowing filter assembly 25 to be pivoted against the side of substantially any toilet, and slots 41 and 42 permit odor collector 24 to be properly positioned, with air intake 45 positioned to withdraw malodorous air from toilet bowl 14.
Toilet ventilating and deodorizing apparatus 12 is illustrated in FIG. 4, showing how it neatly and compactly fits against the side of toilet 10, with a large portion inconspicuously located under water tank 22. Battery case 53 unobtrusively couples to the rearward portion of filter assembly 25 under water tank 22. The coupling of battery case 53 will be described in greater detail below. An air outlet 54 from which deodorized air from toilet bowl 14 is expelled, can be seen extending downward from the bottom of impeller assembly 50.
Referring now to FIG. 5, odor collector 24 is illustrated in an inverted position. Base 40 includes a top 57 and a bottom 58 with a space 59 therebetween. A portion of bottom 58 is cut-away to show the inside of base 40. Sleeve 47 can be seen to be a substantially square tube extending the length of the rear of base 40, having an open end 60 for receiving neck 48 and a closed end 62. Air intake 45 extends from the front of base 40 to the back of base 40, having an inlet port 63, which is positioned to withdraw air from toilet bowl 14, and an outlet port 64 coupled in gaseous communication with sleeve 47. Odor collector 24 further includes a contact assembly 67 mounted within sleeve 47, fixed to a top 68 thereof, and a pair of leads 69 and 70 extending from contact assembly 67 through space 59 of base 40 to each of switch housings 44. While two pair of leads 69 and 70 are employed in this embodiment, each extending between one of switches 27 and 28 and contact assembly 67, it will be understood by one skilled in the art that only a single pair of leads 69 and 70 is required, coupled to a single switch. A redundant switch with associated pair of leads is employed to ensure that toilet ventilating and deodorizing apparatus 12 operates when a person sits on seat 18, even if that person sits off center depressing only one switch.
In order for neck 48 to slide freely within sleeve 47, each pair of leads 69 and 70 must be placed so as to avoid obstructing neck 48. As can be seen with additional reference to FIG. 6, leads 69 and 70 are recessed within a channel 72 formed in top 68. In this manner, leads 69 and 70 extend from contact assembly 67 along sleeve 47 to open end 60 and closed end 62 without interfering with neck 48.
Referring specifically to FIG. 7, contact assembly 67 consists of a contact pad 73 having a top surface 74 and bottom surface 75, constructed of a resilient insulating material such as rubber, and a pair of contacts 77 and 78 coupled to bottom surface 75. A pair of openings 79 and 80 are formed in the front and rear of contact pad 73 underneath contacts 77 and 78. Contact pad 73 is partially recessed into a depression 82 formed in top 68, with top surface 74 of contact pad 73 fastened to top 68 of sleeve 47. Each pair of leads 69 and 70 extend from channels 72 into depression 82. Lead 69 from each pair of leads 69 and 70 is received through one of openings 79 from top surface 74 and attached to contact 77, and lead 70 from each pair of leads 69 and 70 is received through one of openings 80 from top surface 74 and attached to contact 78.
Referring now to FIG. 8, neck 48 is shown inserted within sleeve 47. Neck 48 has a generally square cross-section, with a top surface 83, a rearward side 84, a forward side 85, and a bottom 87. A pair of contacts 88 and 89 corresponding to contacts 77 and 78 respectively, extend along top surface 83 (FIG. 11) and engage contacts 77 and 78 when neck 48 is received by sleeve 47. Contact pad 73 insures adequate engagement between contacts 77, 78 and 88, 89 by extending slightly out of depression 82. As neck 48 is inserted into sleeve 47, contacts 77 and 78 engage contacts 88 and 89 and compress contact pad 73 which, being resilient, forces contacts 77, 78 against contacts 88,89.
When neck 48 is inserted into sleeve 47, and contacts 77 and 78 firmly engage contacts 88 and 89, closing of one of switches 27 and 28 starts apparatus 12. Turning now to FIGS. 9 and 10, switch 27 is illustrated. Since switch 27 and switch 28 are identical, only one is described in detail. Switch 27 is mounted on bottom 58 of base 40 within switch housing 44. Switch housing 44 is a substantially square chamber formed from walls 90 extending upward from top 57 of base 40, terminating in a rim 92 defining an opening 93. Intermediate rim 92 and walls 90 is an inward sloping shoulder 94, whose purpose will be discussed presently.
Referring specifically to FIG. 9, a bottom contact strip 95 is mounted on bottom 58 with lead 69 coupled thereto. A top contact strip 97 with lead 70 coupled thereto, and having a bore 98 formed therethrough, is positioned over bottom contact strip 95, separated therefrom by a resilient ring 99, preferably composed of rubber. A compression member 100 having a threaded bore 102 formed therethrough and an outwardly directed shoulder 103 formed around the periphery thereof, is carried by top contact 97 with threaded bore 102 concentric with bore 98. Inwardly directed shoulder 94 of housing 44 engages outwardly directed shoulder 103 of compression member 100, retaining bottom contact 95, ring 99, top contact 97, and compression member 100 within housing 44. A screw 104 extends through an element 105 of an engagement pair and continues through compression member 100, bore 98 of top contact 97 and ring 99, terminating in a spaced apart relationship with bottom contact 95. The positioning of screw 104 with respect to bottom contact 95 may be adjusted by threading screw 104 farther through or unscrewing screw 104 from threaded bore 102 of compression member 100, but it is desirable that the head of screw 104 extend upward past rim 92 of switch housing 44. A cap 108 containing a complemental element 107 of the engagement pair, fits over switch housing 44 in a sliding engagement, secured to compression member 100 by the engaged element 105 and complemental element 107 of the engagement pair. Preferably the engagement pair consists of the hook and loop elements of Velcro®.
Switch 27 is closed by seat 18 pressing against cap 108 with sufficient force, such as when a person is seated thereon. Turning to FIG. 10, it will be seen that if sufficient force is applied to cap 108, compression member 100 is forced downward, compressing resilient ring 99 and bringing screw 104 into contact with bottom contact 95. When this occurs, the gap between bottom contact 95 and top contact 97 is bridged, closing the switch, and coupled lead 69 to 70, which extend back through space 59 of base 40 to contact assembly 67.
Referring now to FIG. 11, neck 48, as discussed previously in connection with FIG. 8, includes top surface 83 carrying contacts 88 and 89, rearward side 84 and forward side 85. Neck 48 further includes an insert end 110, and a pivot end 112. Insert end 110 is received within sleeve 47 as described previously, and pivot end 112 is pivotally coupled to filter assembly 25 and will be discussed infra. An opening 113 is formed in forward side 85 proximate insert end 110, allowing admittance of malodorous air from air intake 45. Opening 113 is somewhat elongate to allow adjustment of neck 48 while maintaining communication between opening 113 and outlet port 64. An opening 114 is formed in pivot end 112, through which malodorous air leaves neck 48 to enter filter assembly 25. A pair of leads 117 and 118 extend through opening 114 into neck 48 and are coupled to an end of contacts 88 and 89 respectively. An opposing end of contacts 88 and 89, positioned proximate insert end 110, is rounded so that contacts 88 and 89 will easily slide onto contact assembly 67 without catching an edge and causing damage.
Odor collector 24 is coupled in gaseous communication with filter assembly 25 by neck 48 extending between sleeve 47 and an inlet 119 of air duct 49, as can be seen with reference to FIG. 12. Operation of impeller assembly 50 draws offensive air from toilet bowl 14 (not shown) into odor collector 24 through air intake 45, and thence through opening 113 into neck 48. With additional reference to FIG. 13, pivot end 112 of neck 48 is received in a socket 120 formed within inlet 119 of air duct 49. Pivot end 112 of neck 48 is rounded to form a substantially sealing engagement with, and permit some rotation within socket 120. Rotation of pivot end 112 is halted by contact between neck 48 and air duct 49. As discussed supra, the rotation of filter assembly 25 with respect to neck 48 permits adjustment to accommodate a wide variety of toilet configurations.
Still referring to FIG. 12, malodorous air progresses through inlet 119 into air duct 49, out outlet 121 of air duct 49, and is subsequently drawn through filter 52, where the malodor is removed from the air, into impeller assembly 50. With additional reference to FIG. 14, impeller assembly 50 consists of a housing 122 enclosing a fan 123 having a hub 124. Fan 123 is driven by a motor 125 positioned in hub 124, powered by battery case 53 coupled to the outer surface of housing 122. Rotation of fan 123 draws filtered air through an opening 127 in housing 122 positioned adjacent to hub 124, and expels the filtered air through an outlet 128.
Referring now to FIG. 15, impeller assembly 50 further consists of a socket 130 extending from housing 122 and defining a receptacle 132 over opening 127. Socket 130 has an outer wall 133 and an inner wall 134 defining a space 135 therebetween. Inner wall 134 slopes outward to join outer wall 133 at a rim 137, opposite housing 122, and further includes a radially inwardly directed shoulder 138 proximate housing 122 for supporting filter 52, and a radially inwardly directed shoulder 139 proximate rim 137 for supporting air duct 49. Filter 52 is received within receptacle 132 of socket 130, covering opening 127. The slope of inner wall 134 provides a tight fit around the periphery of filter 52, preventing air flow around same. A ridge 140 extends from air duct 49 encircling outlet 121, configured to be received by socket 130 and engage shoulder 139. Air duct 49 is held securely in place by screws 142 inserted through socket 130 into ridge 140.
A battery case 53 is attached to outer wall 133 of socket 130, providing power to operate motor 125. Battery case 53 includes a body 143 for holding batteries, a cover 144 closing body 143, and clips 145 and 146 for coupling battery case 53 to socket 130. With additional reference to FIG. 18, battery case 53 preferably holds four D cell batteries 147, and includes conventional negative and positive terminal contacts 148 and 149 respectively, for receiving batteries 147, with the negative terminal contacts being compression coils to insure a secure fit and connection. Negative and positive terminal contact 148 and 149 are coupled in a conventional manner, and terminate at clips 145 and 146 respectively.
Still referring to FIG. 15, clips 145 and 146 function to mechanically and electrically coupled battery case 53 to impeller assembly 50. Clips 145 and 146 are configured to be received by brackets 150 and 152 carried by outer wall 133 of socket 130 respectively. Details of the connection between battery case 53 and impeller assembly 50 can be seen with additional reference to FIGS. 19 and 20. FIG. 19 illustrates clip 145 extending outward from an end of battery case 53, to be received within bracket 150, substantially parallel to outer wall 133. A lead 153 is coupled to bracket 150, extending through space 135 between inner wall 134 and outer wall 133, and terminating in a contact 154 extending from rim 137 (FIG. 15). FIG. 20 illustrates clip 146, extending parallel to battery case 53, being plugged into bracket 152 through a slot 155 formed in outer walls 133. A lead 157 is coupled to bracket 152, extending through space 135 between inner wall 134 and outer wall 133, and terminating in a contact 158 extending from rim 137 (FIG. 15).
The details of the electrical connections between battery case 53 and impeller assembly 50, and between impeller assembly 50 and air duct 49 are shown in FIG. 16. Battery case 53 is easily attached to impeller assembly 50 by sliding clip 145 into bracket 150, then plugging clip 146 into bracket 152 with battery case 53 flush against outer wall 133. Lead 153 extends from bracket 150 to motor 125 then terminates in contact 154 (FIG. 15). Lead 157 extends from bracket 152 and terminates in contact 158 (FIG. 15). Air duct 49 includes spring contacts 159 and 160, corresponding to contacts 154 and 158 respectively, attached adjacent ridge 140 and placed so as to engage contacts 154 and 158 respectively when air duct 49 is coupled to impeller assembly 50. Details of the connection between contacts 154 and 158 and spring contacts 159 and 160 are shown in FIG. 17. Spring contacts are preferred to insure a solid connection.
A diagrammatic representation of an operating circuit 162 of toilet ventilating and deodorizing apparatus 12 is illustrated in FIG. 21. Switches 27 and 28 having contacts 95 and 98 are coupled in parallel, each having leads 70 extending from contacts 98 which terminate at contact 78, and leads 69 extending from contacts 95 which terminate at contact 77. Progressing from switches 27 and 28 in a clock wise direction, contact 78, found in sleeve 47, is coupled to contact 89 of neck 48 when neck 48 is inserted into sleeve 47. Lead 118 extends from contact 89, terminating in spring contact 160 mounted on air duct 49. Spring contact 160 disengageably engages contact 158 on rim 137 when air duct 49 is fitted to impeller assembly 50. Lead 157 extends from contact 158 and is disengageably coupled to the positive terminal of batteries 147 by mounting battery case 53 onto impeller assembly 50, thereby engaging contacts 152 and 146. The negative terminal of batteries 147 are coupled to motor 125 through lead 153 when battery case 53 is mounted, coupling contacts 145 and 150. Lead 153 then couples motor 125 to switches 27 and 28 by two disengageable couplings. Lead 154 terminates in contact 154 on rim 137 which, when air duct 49 is fitted to impeller assembly 50, engages spring contact 159. Lead 117, extending from contact 159 terminates in contact 88 of neck 48. Contact 88 engages contact 77 of sleeve 47, coupling lead 117 to leads 69. Upon closing of either or both switches 27 and 28, circuit 162 is completed and motor 125 is powered.
Detachable coupling are provided, coupling each of the removable parts, specifically sleeve 47, neck 48, air duct 49, impeller assembly 50 and battery case 53, so that an individual can easily install system 12 with little thought to wiring, battery case 53 can be removed for battery changes, and air duct 49 can be removed to change or clean filter 52 without the need to worry about disconnecting wiring. Furthermore, in this manner, the wiring is entirely contained within system 12 to enhance appearance and prevent accidental disconnections.
Turning now to FIG. 22, an alternate embodiment of an odor collector generally designated 170 is illustrated. Odor collector 170 is generally identical to and shares in common with odor collector 24, elements, including base 40, air intake 45 and slots 41 and 42. In contrast, odor collector 170 differs from odor collector 24 in that a sleeve 172 is substantially straight for receiving a straight neck 173, as opposed to the slightly convex sleeve 47 and corresponding neck 48 of odor collector 24.
Referring now to FIG. 23, a further embodiment of an odor collector generally designated 180 is illustrated. Odor collector 180 is generally identical to and shares in common with odor collector 24, elements, including air intake 45 switches 27 and 28, and slots 41 and 42. In contrast, odor collector 180 differs from odor collector 24 in that a sleeve 182 is concave for receiving a corresponding neck 183, as opposed to the slightly convex sleeve 47 and corresponding neck 48 of odor collector 24. Furthermore, with additional reference to FIG. 24, odor collector 180 includes a base 184 having a raised air dam 185 extending along the inner edge thereof, between switches 27,28 and air intake 45. Air dam 185 prevents air outside bowl 14 from being drawn between seat 18 and top surface 20 into air intake 45.
An alternate embodiment of a toilet ventilating and deodorizing apparatus generally designated 212, is illustrated in FIGS. 25 and 26. Apparatus 212 is substantially similar to apparatus 12 including an odor collector 213 and a filter assembly 214, mounted onto a toilet in a manner generally identical to that discussed above in connection with apparatus 12, and will not be discussed in great detail here.
Odor collector 213 includes a base 215 having a top surface 217, a bottom surface 218, a front edge 219 and a back edge 220. Base 215 is coupled to a toilet by hinge posts (not shown) extending through slots 222 and 223 formed through base 215. Base 215 further includes a sleeve 224 extending along back edge 220 on top surface 217, an air intake 225 extending from front edge 219 between slots 222 and 223 and abutting sleeve 224, and a tab 227 extending from front edge 219 carrying a switch 228. Apparatus 212 employs a single switch 228 instead of two as was employed in apparatus 212 for purposes of illustration. Air intake 225 has an inlet port 229 formed through base 215 from bottom surface 218, and extending upward into air intake 225. One skilled in the art will understand that while inlet port 229 is directed downward in this embodiment, an inlet port may be used extending horizontally inward from the front of the odor collector as was shown in apparatus 12.
Filter assembly 214 is coupled to odor collector 213 by a neck 230 configured to be slidably received by sleeve 224, and includes an air duct 232 extending generally perpendicularly downward from neck 230, an impeller assembly 233 coupled to air duct 232 and a filter (not visible) fitted between impeller assembly 233 and air duct 232 in a manner generally similar to that described above in connection with embodiment 12. Impeller assembly 233 and air duct 232 are generally similar to impeller assembly 50 and air duct 49 of apparatus 12, and are therefore not described in detail.
Air duct 232 includes an inlet (not visible) defined by an extension 237, and an outlet (not visible). Air duct 232 further includes a battery case 239 which will be discussed in more detail below. Impeller assembly 233 includes a fan, and a motor (not visible) which are generally identical to that described above, contained in a housing 243 having an inlet 244 (not visible) and an outlet 245. The motor driving the fan is powered by batteries 247 contained in battery case 239. Air flow through apparatus 212 is generally similar to that described above, and is therefore omitted here.
Sleeve 224 is in gaseous communication with air intake 225, and receives neck 230. Neck 230 is a generally tubular member having a forward side 248, an insert end 249 and a pivot end 250 extending from filter assembly 214. Insert end 249 is received within sleeve 224 as described previously, and pivot end 250 is pivotally coupled to filter assembly 214 and will be discussed infra. An opening 252 is formed in forward side 248 proximate insert end 249, allowing admittance of malodorous air from air intake 225. Opening 252 is somewhat elongate to allow adjustment of neck 230 while maintaining communication between opening 252 and air intake 225. An opening 253 is formed in pivot end 250, through which malodorous air leaves neck 230 to enter filter assembly 214.
Toilet ventilating and deodorizing apparatus 212 is intended to be substantially unnoticeable and blend into the overall appearance of a toilet. To achieve this desired characteristic, filter assembly 214 is intended to be positioned adjacent the back of a toilet bowl under the water tank as was discussed previously in connection with apparatus 12. Furthermore, the various components are adjustable since toilet ventilating and deodorizing system 212 is intended to be retrofitted to substantially any toilet. Therefore, to accommodate toilets having different shapes and dimensions, neck 230 is slidably received within sleeve 224 to allow filter assembly 214 to be positioned at varying distance from odor collector 213, filter assembly 214 is pivotally attached to neck 230 allowing filter assembly 214 to be pivoted against the side of substantially any toilet, and slots 222 and 223 permit odor collector 213 to be properly positioned, with air intake 225 in communication with a toilet bowl.
Operation of impeller assembly 233 draws offensive air from the toilet bowl (not shown) into odor collector 213 through air intake 225, and thence through opening 252 into neck 230. Pivot end 250 of neck 230 is received over extension 237 extending from the top of air duct 232 (visible in FIG. 26), defining an inlet (not visible). Pivot end 250 of neck 230 is rounded to form a substantially sealing engagement with, and permit some rotation about extension 237. Rotation of pivot end 250 is limited by a set screw 254 extending through a slot 255 formed in pivot end 250 into extension 237. Rotation of neck 230 is limited by the length of slot 255 which moves about set screw 254. As discussed supra, the rotation of filter assembly 214 with respect to neck 230 permits adjustment to accommodate a wide variety of toilet configurations. Malodorous air progresses through air duct 232 and is subsequently drawn through the filter, where the malodor is removed from the air, into impeller assembly 233 and is expelled from outlet 245.
Power is supplied to impeller assembly 233 by batteries 247 held in battery case 239 formed along an edge of air duct 232. Battery case 239 consists of a tubular body 258 running vertically along the side of air duct 232 configured to contain batteries 247 stacked end to end. Tubular body 258 preferably includes a top end cap 256 carrying a positive terminal contact 259 and closing the top of tubular body 258, and a bottom end cap 261 carrying a negative terminal contact 260 and closing the bottom of tubular body 258. A lead 262 extends from negative terminal contact 260, and is coupled to the motor in housing 243 by a releasable coupling 263. A lead 264 and 265 extends from the motor (not shown) and positive terminal contact 259 respectively, and terminate in a connector 267. Switch 228 carried on tab 227 of base 215 includes a connector 268 which receives connector 267, coupling switch 228 into the circuit. While external leads are shown in this embodiment, one skilled in the art will understand that internal wiring, such as those described in embodiment 12 above, may be employed.
Referring to FIGS. 27 and 28, switch 228 includes a contact strip 270 mounted onto tab 227. A block 272 of resilient material is carried upon contact strip 270 and extends in a vertical direction. A horseshoe contact 273 is received about the upper portion of block 272 with lower ends 274 spaced apart from contact strip 270 when switch 228 is open. A housing 275 having an opening 277 defined by an upwardly directed rim 278 is mounted onto tab 227, covering contact strip 270, with block 272 and horseshoe contact 273 projecting upward through opening 277. A cover 279 engages horseshoe contact 273 and extends down terminating above housing 275. Application of a downward force to cover 279, such as by engagement with a toilet seat, compresses block 272 allowing contact between lower ends 274 of horseshoe contact 273 and contact strip 270, closing switch 228. Leads 280 and 282 extend from contact strip 270 and horseshoe contact 273 respectively, terminating in connector 268.
In contrast to apparatus 12, an external connection is made between switch 228 and batteries 247. While installation of apparatus 212 requires the additional step of coupling connectors 267 and 258, manufacturing the apparatus with external leads and connections is less costly than internal leads and connectors.
Finally, removal and insertion of batteries 247 in apparatus 212 may be simplified by securing end caps 256 and 261 in tubular body 258 using Dins 283 and 284 as illustrated in FIG. 29 and 30. Referring specifically to FIG. 29, pin 283 extends through tubular body 258 into top end cap 256. To install batteries 247, pin 283 is removed, allowing removal of cap 256. Batteries 247 are then simply dropped into tubular body 258 and cap 256 replaced, secured by pin 283. Referring specifically to FIG. 30, pin 284 extends through tubular body 258 into bottom end cap 261. To remove batteries 247, pin 284 is removed, allowing removal of cap 261. Batteries 247 will then simply dropped out of tubular body 258. Cap 261 is then replaced and secured by pin 284.
An alternate embodiment of a neck generally designated 287 is illustrated in FIGS. 31 and 32. In general similarity to previously described embodiment 48, the immediate embodiment includes in common, an insert end 110, a pivot end 112, and a forward side 85 having an opening 113. Other commonalties will be readily apparent to one skilled in the art.
In contrast to neck 48, neck 287 includes a top surface 288 in which parallel channels 289 and 290 are formed. A pair of contacts 292 and 293 analogous to contacts 88 and 89 are partially recessed within channels 289 and 290 respectively. Contacts 292 and 2)3 are constructed of coiled conductive material imparting a rough surface and resilience to the portion extending out of channels 289 and 290, differing from the planar strips of contacts 88 and 89. The roughness helps remove oxidation from the opposing contacts in the sleeve, and the resilience allows compression of the contacts insuring a good connection.
An alternate embodiment of a toilet ventilating and deodorizing apparatus generally designated 312 is illustrated in FIGS. 33. Apparatus 312 is illustrated mounted on toilet 10 replacing apparatus 12. Toilet 10 has been described above as including toilet bowl 14, having front 15 and back 17, toilet seat 18 and lid 19 coupled to top surface 20 of toilet bowl 14 by hinges at back 17 of toilet bowl 14, and a water tank 22 having a front surface 23. Front 15 and back 17 of toilet 10 will again provide directional reference throughout the ensuing descriptions.
Still referring to FIG. 33, toilet ventilating and deodorizing apparatus 312 includes an odor collector 324 mounted on top surface 20 of toilet bowl 14 at back 17, and a filter assembly 325 coupled to odor collector 324 and extending downwardly proximate back 17 of toilet bowl 14, partially concealed by water tank 22. In FIG. 33, seat 18 is in the lowered position wherein it rests on a pair of switches 327 and 328, only one of which is visible, extending from odor collector 324. Lid 19 is shown in the upright position, resting against front surface 23 of water tank 22. To operate toilet ventilating and deodorizing apparatus 312, a person sits on seat 18, closing at least one of switches 327 and 328, thereby starting operation of filter assembly 325.
As in FIG. 2, the detail of FIG. 34 illustrates the coupling of seat 18, lid 19 and odor collector 324 to toilet bowl 14. This is accomplished in the same manner as described above, with threaded ends 32 and 33 inserted through openings 34 and 35 in toilet bowl 14 and securing them with nuts (not shown). The hinge arrangement has already been described previously, and will not be described further.
Still referring to FIG. 34, odor collector 324 includes a base 340, configured to be positioned between top surface 20 of toilet bowl 14 and seat 18. A pair of slots 341 and 342, corresponding to openings 34 and 35 in toilet bowl 14, are formed through base 340 and receive threaded ends 32 and 33 of hinge posts 29 and 30. Slots 341 and 342 are employed to allow forward and rearward adjustments to be made in positioning odor collector 324. Odor collector 324 further includes a pair of opposing legs 343 extending from the front of odor collector 324 and partially along top surface 20 of toilet bowl 14, terminating in switch housings 344 containing switches 327 and 328, an air intake 345 mounted centrally between slots 341 and 342, and a sleeve 347 extending the length of base 340, rearward of and coupled to air intake 345.
Filter assembly 325 is coupled to odor collector 324 by a neck 348 configured to be slidably received by sleeve 347, and includes a generally hemispherical air duct 349 coupled to neck 348, an impeller assembly 350 and a filter 352 (not visible) carried within a filter assembly housing 351 and coupled thereby to air duct 349. Power is supplied to impeller assembly 350 by batteries contained in a battery case 353 (not visible) carried within housing 351.
Toilet ventilating and deodorizing apparatus 312 is intended to be substantially unnoticeable and blend into the overall appearance of toilet 10 as is apparatus 12 and 212. To achieve this desired characteristic, filter assembly 325 is intended to be positioned adjacent back 17 of toilet bowl 14 under water tank 22 as can be seen in FIG. 35. Furthermore, the various components are adjustable since toilet ventilating and deodorizing apparatus 312 is intended to be retrofitted to substantially any toilet. Therefore, to accommodate toilets having different shapes and dimensions, neck 348 is slidably received within sleeve 347 to allow filter assembly 325 to be positioned at varying distance from odor collector 324, housing 351 is pivotally attached to air duct 349 allowing filter assembly 325 to be pivoted against the side of substantially any toilet, and slots 341 and 342 permit odor collector 324 to be properly positioned, with air intake 345 positioned to withdraw malodorous air from toilet bowl 14.
Toilet ventilating and deodorizing apparatus 312 is illustrated in FIG. 36, showing how it neatly and compactly fits against the side of toilet 10, with a large portion inconspicuously located under water tank 22. Apparatus 312 closely conforms to the lines of toilet 10 without interfering with the operation of seat 18 and lid 19.
Referring now to FIG. 37, odor collector 324 is illustrated in an inverted position. Base 340 includes a top 357 and a bottom 358 with a space 359 therebetween. A portion of bottom 358 is cut-away to show the inside of base 340. Sleeve 347 can be seen to be a substantially square tube extending the length of the rear of base 340, having an open end 360 for receiving neck 348 and a closed end 362. Air intake 345 extends from the front of base 340 to the back of base 340, having an inlet port 363, which is positioned to withdraw air from toilet bowl 14, and an outlet port 364 coupled in gaseous communication with sleeve 347. Odor collector 324 further includes a contact assembly 367 mounted within sleeve 347, fixed to a top 368 thereof, and a pair of leads 369 and 370 extending from contact assembly 367 through space 359 of base 340 to each of switch housings 344. While two pair of leads 369 and 370 are employed in this embodiment, each extending between one of switches 327 and 328 and contact assembly 367, it will be understood by one skilled in the art that only a single pair of leads 369 and 370 is required, coupled to a single switch. A redundant switch with associated pair of leads is employed to ensure that toilet ventilating and deodorizing apparatus 312 operates when a person sits on seat 18, even if that person sits off center depressing only one switch. While apparatus is shown having internal wiring for purposes of illustration, as is apparatus 312, one skilled in the art will understand that external wiring as employed in embodiment 212 may be used instead.
In order for neck 348 to slide freely within sleeve 347, each pair of leads 369 and 370 must be placed so as to avoid obstructing neck 348. As can be seen with additional reference to FIG. 38, leads 369 and 370 are recessed within a channel 372 formed in top 368. In this manner, leads 369 and 370 extend from contact assembly 367 along sleeve 347 to open end 360 and closed end 362 without interfering with neck 348. At open end 360 and closed end 362, additional channels 371 are formed coupling channel 372 to base 340.
Referring specifically to FIG. 39, contact assembly 367 consists of a contact pad 373 having a top surface 374 and bottom surface 375, constructed of a resilient insulating material such as rubber, and a pair of contacts 377 and 378 coupled to bottom surface 375. Contacts 377 and 378 each have ends angled toward top surface 374. Angled ends of contacts 377 and 378 extend from bottom surface 375 of contact pad 373, terminating adjacent top surface 374. A pair of openings 379 and 380 are formed in the front and rear of contact pad 373 underneath contacts 377 and 378. Contact pad 373 is partially recessed into a depression 382 formed in top 368, with top surface 374 of contact pad 373 fastened to top 368 of sleeve 347. Each pair of leads 369 and 370 extend from channels 372 into depression 382. Lead 369 from each pair of leads 369 and 370 is received through one of openings 379 from top surface 374 and attached to contact 377, and lead 370 from each pair of leads 369 and 370 is received through one of openings 380 from top surface 374 and attached to contact 378.
Referring now to FIG. 40, neck 348 is shown inserted within sleeve 347. Neck 348 has a generally square cross-section, with a top surface 383, a rearward side 384, and a forward side 385. A pair of contacts 388 and 389 corresponding to contacts 377 and 378 respectively, extend along top surface 383 (FIG. 42) and engage contacts 377 and 378 when neck 348 is received by sleeve 347. Contact pad 373 insures adequate engagement between contacts 377, 378 and 388, 389 by extending slightly out of depression 382. As neck 348 is inserted into sleeve 347, contacts 377 and 378 engage contacts 388 and 389 and compress contact pad 373 which, being resilient, forces contacts 377, 378 against contacts 388,389.
When neck 348 is inserted into sleeve 347, and contacts 377 and 378 firmly engage contacts 388 and 389, closing of one of switches 327 and 328 starts apparatus 312. Turning now to FIG. 41, switch 327 is illustrated. Since switch 327 and switch 328 are identical, only one is described in detail. Switch 327 is mounted on top 357 of base 340 within switch housing 344. Switch housing 344 is a substantially square chamber formed from walls 390 extending upward from top 357 of base 340, terminating in an inwardly directed rim 392 defining an opening 393. A bottom contact strip 395 is mounted on top 357 with lead 369 coupled thereto. A top contact 397 with lead 370 coupled thereto, and having a bore 398 formed therethrough, is positioned over bottom contact strip 395, separated therefrom by a resilient ring 399, preferably composed of rubber. A compression member 400 having a threaded bore 402 formed therethrough and an outwardly directed shoulder 403 formed around the periphery thereof, is carried by top contact 397 with threaded bore 402 concentric with bore 398. Inwardly directed rim 392 of housing 344 engages outwardly directed shoulder 403 of compression member 400, retaining bottom contact 395, ring 399, top contact 397, and compression member 400 within housing 344. A screw 404 extends through an element 405 of an engagement pair and continues through compression member 400, bore 398 of top contact 397 and ring 399, terminating in a spaced apart relationship with bottom contact 395. The positioning of screw 404 with respect to bottom contact 395 may be adjusted by threading screw 404 farther through or unscrewing screw 404 from threaded bore 402 of compression member 400. A cap 408 containing a complemental element 407 of the engagement pair, fits over switch housing 344 in a sliding engagement, secured to compression member 400 by the engaged element 405 and complemental element 407 of the engagement pair. Preferably the engagement pair consists of the hook and loop elements of Velcro®.
Switch 327 is closed by seat 18 pressing against cap 408 with sufficient force, such as when a person is seated thereon, to depress compression member 400. It will be seen that if sufficient force is applied to cap 408, compression member 400 is forced downward, compressing resilient ring 399 and bringing screw 404 into contact with bottom contact 395. When this occurs, the gap between bottom contact 395 and top contact 397 is bridged, closing the switch, and coupling lead 369 to 370, which extend back through space 359 of base 340 to contact assembly 367.
Referring now to FIG. 42, neck 348, as discussed previously in connection with FIG. 40, includes top surface 383 carrying contacts 388 and 389, rearward side 384 and forward side 385. Neck 348 further includes an insert end 410 receivable within sleeve 347 as described previously, and an opposing end 412 coupled to air duct 349. An opening 413 is formed in forward side 385 proximate insert end 410, allowing admittance of malodorous air from air intake 345. Opening 413 is somewhat elongate to allow adjustment of neck 348 while maintaining communication between opening 413 and outlet port 364. An opening 414 is formed in opposing end 412, through which malodorous air leaves neck 348 to enter filter assembly 325. A pair of leads 417 and 418 extend through opening 414 into neck 348 and are coupled to an end of contacts 388 and 389 respectively. An opposing end of contacts 388 and 389, positioned proximate insert end 410, is rounded so that contacts 388 and 389 will easily slide onto contact assembly 367 without catching an edge and causing damage.
Odor collector 324 is coupled in gaseous communication with filter assembly 325 by neck 348 extending between sleeve 347 and an inlet 419 of air duct 349, as can be seen with reference to FIG. 43. With additional reference to FIG. 44, neck 348 is shown received within sleeve 347, with leads 417 and 418 passing inside neck 348 to continue on to air duct 349, and leads 369 and 370 depressed within channel 372 avoiding interference with neck 348.
Turning now to FIG. 45, housing 351 of filter assembly 325 includes endwalls 422, sidewalls 423, a top 424, and an open bottom 425, configured to receive impeller assembly 350 and battery case 353. Air duct 349 is rotatably coupled to top 424 of housing 351 the details of which will be described below. Impeller assembly 350 includes a housing 427 containing a fan 428, and has an inlet 429 (not visible) and an outlet 430. A socket 432 extends from housing 427 and defines a receptacle 433 over inlet 429. Filter 352 is received within receptacle 433 of socket 432, covering inlet 429. The walls of socket 432 slope radially outward to provides a tight fit around the periphery of filter 352, preventing air flow around same. A ridge 434 extends from and encircles the top end of filter 352, configured to be received by housing 427, with an o-ring 435 sealing the engagement. A pair of contact posts 437 and 438 extend upward from housing 427, terminating in contacts 439 and 440 respectively. The purpose of posts 437 and 438 will be discussed in greater detail presently. Impeller assembly 350 is held securely in place by screws 442 inserted through housing 351 into housing 427.
Battery case 353 is a box having braces 443 and a center post 444 securely retaining batteries. Battery case 353 preferably holds four D cell batteries 445. Battery case 353 is received within housing 351 adjacent impeller assembly 350 and secured by securing means preferably consisting of an easily engageable and disengageable detent 447 received by a corresponding opening 448 formed in sidewall 423 of housing 351. With additional reference to FIG. 46, means for securing battery case 353 within housing 351 is illustrated. While those skilled in the art will understand that various known securing apparatus may be used, preferably, a biasing member 449 from which detent 447 extends, is attached to the inner surface of battery case 353 with detent 447 extending out through an opening 450. To insert battery case 353 into housing 351, detent 447 is forced inward, back into battery case 353 through opening 450 against the bias of bias member 449 as indicated by broken lines. Battery case 353 will then freely enter housing 351 from open bottom 425. Once properly positioned, opening 450 will align with opening 448 in housing 351 and detent 447 will be forced concurrently through openings 450 and 448 securing battery case 353 in place.
A detailed view of the inner workings of filter assembly 325 is illustrated in FIG. 47. Malodorous air enters filter assembly 325 through neck 348 into air duct 349. Housing 351 further includes an opening 452 defined by in turned lips 453 formed in top 424 which receives o-ring 435 and the upper edge of socket 432 thereagainst. Air duct 349 is constructed of an inner member 454 and an outer member 455 rotatably coupled thereto. Inner member 454 has an outwardly flared lower edge 457 which is inserted through opening 452 and engage inwardly directed lip 453. Outer member 455, from which neck 348 extends, has a lower edge 458 extending outside of housing 351. The malodorous air passes through air duct 349 into filter 352, being drawn by rotation of fan 428. Fan 428 is driven by a motor 459 positioned within a hub 460 thereof, powered by batteries 445 within case 353.
Still referring to FIG. 47, with additional reference to FIGS. 49 and 50, alternating pairs of cross-connected terminal contacts are mounted within battery case 353 and housing 351. Positive terminal contacts 462 alternately mounted within battery case 353 and housing 351 oppose negative terminal contacts 463. Negative and positive terminal contacts 463 and 462 respectively, are conventional terminal contacts for receiving batteries 445, with the negative terminal contacts 463 being compression coils to insure a secure fit and connection. Negative and positive terminal contact 463 and 462 are coupled in a conventional manner, with negative terminals 463 coupled by a lead 464 to a contact 465 mounted inside housing 351 on top 424, and positive terminals 462 coupled to lead 418 extending from contact 389 in neck 348, through air duct 349, between inner and outer members 454 and 455. Lead 417 from neck 348 parallels lead 418 and terminates in a contact 467 mounted inside housing 351 on top 424 spaced apart from contact 465.
FIG. 48 illustrates a lead 468 coupled to motor 459 extending up post 437 and terminating in contact 439. It will be understood that another lead 469 extends from motor 459 up post 438, to terminate in contact 440. Posts 437 and 438 with corresponding leads 468 and 469 respectively, can be seen with additional reference to FIG. 49. When impeller assembly 350 is secured within housing 351, contacts 439 and 440 on posts 437 and 438 engage contacts 465 and 467 respectively. At this point, closing of one of switches 327 and 328 completes the circuit, and starts operation of toilet ventilating and deodorizing apparatus 312.
A diagrammatic representation of an operating circuit 470 of toilet ventilating and deodorizing apparatus 312 is illustrated in FIG. 51. Switches 327 and 328 having contacts 395 and 397 are coupled in parallel, each having leads 370 extending from contacts 397 which terminate at contact 378, and leads 369 extending from contacts 395 which terminate at contact 377. Progressing from switches 327 and 328 in a clock wise direction, contact 378, found in sleeve 347, is coupled to contact 389 of neck 348 when neck 348 is inserted into sleeve 347. Lead 418 extends from contact 389 and is coupled to the positive terminal of batteries 445 by mounting battery case 353 onto impeller assembly 350. The negative terminal of batteries 445 are coupled to motor 459 through leads 464 and 469 when impeller assembly 350 is mounted coupling contacts 465 and 440. Lead 468 then couples motor 459 to switches 327 and 328 by two couplings. Lead 468 terminates in contact 439 on post 437 which, when impeller assembly 350 is fitted to housing 351 engages contact 467. Lead 417, extending from contact 467 terminates in contact 388 of neck 348. Contact 388 engages contact 377 of sleeve 347, coupling lead 417 to leads 369. Upon closing of either or both switches 327 and 328, circuit 470 is completed and motor 459 is powered.
Various changes and modifications to the embodiments herein chosen for purposes of illustration will readily occur to those skilled in the art. To the extent that such modifications and variations do not depart from the spirit of the invention, they are intended to be included within the scope thereof which is assessed only by a fair interpretation of the following claims.
|
A toilet bowl ventilating and deodorizing apparatus comprises an odor collector for extracting air from a toilet bowl, a filter assembly for deodorizing the air extracted from the toilet bowl, and a neck coupling the filter assembly to the odor collector, with the odor collector and the neck supporting the filter assembly adjacent the toilet bowl. The odor collector includes a base attachable to the toilet bowl, an air intake carried by the base and positionable adjacent an interior of the toilet bowl, and a sleeve carried by the base in gaseous communication with the air intake. The filter assembly includes an air duct, an impeller assembly for providing air flow through the apparatus, the air duct is coupled to the filter assembly, and a filter is carried between the impeller assembly and the air duct. A switch is carried by the odor collector for activating the filter assembly, a power source for supplying power to the impeller assembly, and a power circuit coupling the power source to the impeller assembly and the switch.
| 4
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to the use of water-based lubricants for textile machines, in particular, the use as needle oils and/or sinker oils in textile knitting machines.
[0003] 2. Description of Related Art
[0004] Lubricants that must meet high requirements are used for lubricating textile knitting machines. The compositions of a needle oil or sinker oil should have a constant viscosity at different machine speeds and temperatures. In this case, the operating viscosity of the lubricant should lie in the range of ISO VG 15-ISO VG 100. The compositions of the needle or sinker oils, moreover, should be resistant to aging.
[0005] The lubricants are to be present in the form of a colorless and clear solution as possible. These colorless lubricants are to have a good-to-excellent scourability, i.e., washing out ability; in particular, it should be possible to scour the lubricants at low temperatures. When a lubricant can be scoured only incompletely, it results in problems in the subsequent treatments of knit fabrics. In particular, a uniform dyeing of the knit goods is no longer possible, and irreversible color defects are the result.
[0006] In addition, the lubricants are also to have a long shelf life even at low temperatures without the formation of precipitates. The formation of precipitates can result in the clogging of the oil supply systems of the knitting machines.
[0007] The lubricant also must not have a tendency toward phase separation over the overall service temperature range of 0° C. to 80° C. The phase separation of the lubricant can result in a deficient lubrication of the machine parts, and thus, can result in unevenness of the knit fabric, which also can result in defects in the knitwear in the subsequent color treatment.
[0008] In addition to good protection against wear and tear and erosion, the lubricant must also provide the lowest possible level of friction. This results in a considerable energy savings and in reducing the noise level, which in turn results in improving work conditions.
[0009] In addition, the lubricant has to be slightly biodegradable, since the lubricant can get into the waste water via the scouring process and correspondingly has to be treated and decomposed via the clarification process.
[0010] The textile oils that are used over time, which are present in the form of an emulsion, in most cases are composed of more than 80% mineral oil, to which the usual wear-protecting and corrosion-protecting additives are added. In addition, emulsifiers are added to improve the scourability. In this connection, both anionic emulsifiers (e.g., sulfonates) and nonionic emulsifiers (e.g., fatty alcohol ethoxylates or else NPE), as well as cationic emulsifiers (e.g., quaternary ammonium compounds) can be used. At times, small amounts of water (less than 1%) have to be added to emulsifier-containing textile oils to stabilize them or reduce their tendency toward precipitation. Higher concentrations of water result in unacceptably high cloudiness by forming an emulsion, which results in phase separation, or can produce hydrolysis of the additives that are used.
[0011] In addition, it is known to apply a lubricating agent to textile yarns by a roller, which runs over the corresponding yarn, being immersed in a lubricating agent emulsion to facilitate the processibility of the yarns. To this end, a composition that contains 50 to 80 parts by weight of poly(oxyethylene-oxy-1,2-propylene)glycol, 10 to 40 parts by weight of emulsifier, and 10 to 40 parts by weight of an ester is described in U.S. Pat. No. 3,338,830. This mixture is present as a concentrate and is diluted with water, so that 1 to 25% by weight of non-aqueous components is present and is used in the form of an aqueous emulsion. From German Patent DE 30 08 500 C2 and corresponding U.S. Pat. No. 4,250,046, a water-soluble metal-working fluid that contains diethanol disulfide and one or more water-soluble polyoxyalkylene glycols are known. This liquid is used for working metals, whereby maximum pressure and anti-friction properties are ensured by preparing a sufficient amount of liquid.
DETAILED DESCRIPTION OF THE INVENTION
[0012] The object of this invention is to prepare a liquid water-based lubricant for textile machines, with which the above-mentioned drawbacks, which develop when a mineral oil is used, are overcome, and which is present in the form of a solution.
[0013] So that the lubricant can be used in textile machines, it should be biodegradable, and it should be scourable at the lowest possible temperatures as well as used in an overall service temperature range without phase separation, should offer good protection against wear and tear and corrosion, and should have as low a friction level as possible.
[0014] According to the invention, a water-based lubricant for textile knitting machines, which contains 5 to 50% by weight of water-soluble polymer and/or 5 to 50% by weight of emulsifier add water up to 100% by weight, is therefore used.
[0015] In addition, the lubricant can also contain 0 to 15% by weight, in particular 2 to 5% by weight, of corrosion-reducing and protecting, respectively agent; 0 to 10% by weight, in particular 0.2 to 5% by weight, of wear-reducing and protecting, respectively agent; 0 to 1% by weight, in particular 0.01 to 0.75% by weight, of biocide; and 0 to 50% by weight, in particular 2 to 25% by weight, of an anti-icing agent.
[0016] The water-soluble polymer that is contained in the lubricant is selected from the group that consists of polyalkylene glycols, in particular polyethylene glycol with molar masses of 1,000 to 35,000, water-soluble esters, polyacrylates, polymethacrylates, polyvinyl pyrrolidones, polyacrylamides, carboxymethyl cellulose, polyanionic cellulose, hydroxy cellulose, and hydroxyethyl cellulose.
[0017] The emulsifier that is contained in the lubricant is selected from the group that consists of nonionic, anionic and cationic emulsifiers, in particular alkylene oxide polymers, sulfonates, carboxylic acid and dicarboxylic acid derivatives with a chain length of 6 to 16 carbon atoms, phosphate esters, and quaternary ammonium compounds.
[0018] The corrosion-protecting and wear-protecting agent that is contained in the lubricant is selected from the group that consists of water-soluble phosphorus and/or sulfur compounds, and nitrogen compounds, the biocide is benzoic acid, and the anti-icing agent is selected from the group that consists of low-molecular glycols, in particular ethylene glycol, propylene glycol, trimethylene glycol, glycerol, salts or ionic liquids.
[0019] The lubricant according to the invention can also be used in the form of a concentrate. In this case, primarily the reduced goods traffic is advantageous, since the finished formulation can be produced directly by customers by dilution with water. Moreover, the storage space that is required at the user site is reduced. Besides, the user can adjust the lubricant directly to the desired viscosity for its application.
[0020] To ensure that the lubricant is biodegradable, can be scoured, i.e. washed out at the lowest possible temperatures, can be used in the overall service temperature range without phase separation, offers good protection against wear and tear and corrosion, and has as low a friction level as possible, water is used as a carrier liquid. Special water-soluble additives, such as polyalkylene glycol and/or water-soluble esters, are added to this carrier liquid, and then the corresponding operating viscosity is set between ISO VG 15-ISO VG 100.
[0021] In this connection, it is pointed out expressly that the examples below do not involve any emulsions, but rather true clear aqueous solutions. The application is exclusively the lubrication of machines or machine parts and not the lubrication/finishing of yarns.
[0022] The advantageous properties of the lubricant according to the invention are shown based on the subsequent examples and the comparison example.
EXAMPLE 1
[0023] The lubricant has the following composition:
[0000]
Distilled water
68.0% by weight
Water-soluble polymer, polyglycol 8000 S, Clariant
22.0% by weight
Co.
Alcohol polyalkylene glycol ether, Marlowet 5056,
5.0% by weight
Sasol Co.
Boric acid ester and alkanolamines, Hostacor Bl,
2.0% by weight
Clariant Co.
Sulfurized fatty acid, LUBIO EP 1, Schäfer Additive
3.0% by weight
Systems GmbH
[0024] Table 1 shows the results of the studies of the properties of the lubricating agent according to the invention in accordance with the invention compared to that of a known mineral-oil-based lubricating agent.
[0000]
TABLE 1
Comparison Example
Based on Mineral Oil
(Kluber Oil Tex 1-22 N)
Example 1
Appearance,
Colorless Clear,
Colorless Clear,
Hazen Color Unit
Hazen <50
Hazen <50
Corrosion Protection on
Very Good
Very Good
Knitting Needles,
KLM Test
Scourability at 65° C. with
Very Good
Very Good
Washing Agent
DIN EN ISO 105-A01
Scourability at 30° C.
Poor
Very Good
without Washing Agent
DIN EN ISO 105-A01
Kin. Viscosity at 40° C.
22 cst
22 cst
Protection Against Wear
Very Good
Very Good
and Tear (SRV) DIN
51834-1; DIN 51834-2
Friction Coefficient (SRV)
0.10
0.06
Biodegradability
—
Very Good
[0025] The KLM test is performed as follows:
[0026] In a Petri dish (diameter 80 mm), an acetone-purified knitting needle (length 44 mm) is placed on a round filter (filter paper with a diameter of 55 mm, Whatman) and covered with 10 ml of aqueous textile oil. After 48 hours of storage at room temperature, the needle (black spots) and the filter paper (yellow-red coloring) are checked for corrosion.
[0027] The study results shown in Table 1 can be summarized as follows. The lubricant that is produced according to the invention is a virtually colorless, limpid solution. The complete scourability is itself added without washing agents at low temperatures, which makes possible a considerable savings in energy. The friction level that is drastically reduced in comparison to the conventional needle oils allows one to expect a clearly improved energy efficiency as well as a lower noise level and extended holding times during operation. By the exchange of mineral oil or a basic oil corresponding to the latter by water, a greater focus is placed on durability with the lubricant of this invention.
EXAMPLE 2
[0028]
[0000]
Distilled water
68.0% by weight
Water-soluble polymer, polyglycol 20000 S, Clariant
22.0% by weight
Co.
Alcohol polyalkylene glycol ether, Marlowet 5056,
5.0% by weight
Sasol Co.
Boric acid ester and alkanolamines, Hostacor Bl,
2.0% by weight
Clariant Co.
Sulfurized fatty acid, LUBIO EP 1,
3.0% by weight
Schäfer Additive Systems GmbH
EXAMPLE 3
[0029]
[0000]
Distilled water
68.0% by weight
Water-soluble polymer, polyglycol 8000 S, Clariant
22.0% by weight
Co.
Alcohol polyalkylene glycol ether, Marlowet 5056,
5.0% by weight
Sasol Co.
Tolyl triazole, Rheinchemie Co.
2.0% by weight
Sulfurized fatty acid, V 345, Schäfer Additive Systems
3.0% by weight
GmbH
[0030] In Table 2, the properties of the formulations of Example 2 and 3 are listed.
[0000]
TABLE 2
Example 2
Example 3
Appearance,
Colorless Clear,
Colorless Clear,
Hazen Color Unit
Hazen <50
Hazen <50
Corrosion Protection on
Very Good
Very Good
Knitting Needles,
KLM Test
Scourability at 65° C. with
Very Good
Very Good
Washing Agent
DIN EN ISO 105-A01
Scourability at 30° C.
Very Good
Very Good
without Washing Agent
DIN EN ISO 105-A01
Kin. Viscosity at 40° C.
46 cst
22 cst
Protection Against Wear
Very Good
Very Good
and Tear (SRV) DIN
51834-1; DIN 51834-2
Friction Coefficient (SRV)
0.07
0.06
[0031] Also here, the comparison with the comparison example shows the excellent properties of the use according to the invention of a water-based lubricant according to Examples 2 and 3.
EXAMPLE 4
[0032]
[0000]
Distilled water
60.0% by weight
Water-soluble dicarboxylic acid ethoxylate
35.0% by weight
Sulfurized fatty acid
3.0% by weight
Boric acid ester and alkanolamines
2.0% by weight
EXAMPLE 5
[0033]
[0000]
Distilled water
60.0% by weight
Water-soluble dicarboxylic acid ethoxylate
17.0% by weight
Water-soluble polyethylene glycol
18.0% by weight
Sulfurized fatty acid
3.0% by weight
Boric acid ester and alkanolamines
2.0% by weight
[0034] In Table 3, the properties of the formulations of Examples 5 and 6 are listed.
[0000]
TABLE 3
Example 5
Example 6
Appearance,
Colorless Clear,
Colorless Clear,
Hazen Color Unit
Hazen <50
Hazen <50
Corrosion Protection on
Very Good
Very Good
Knitting Needles,
KLM Test
Scourability at 65° C. with
Very Good
Very Good
Washing Agent
DIN EN ISO 105-A01
Scourability at 30° C.
Very Good
Very Good
without Washing Agent
DIN EN ISO 105-A01
Kin. Viscosity at 40° C.
22 cst
22 cst
Protection Against Wear
Very Good
Very Good
and Tear (SRV) DIN
51834-1; DIN 51834-2
Friction Coefficient (SRV)
0.11
0.10
[0035] Advantageously, the water that is used can be used both in the distilled, demineralized form and as tap water, which simplifies a possible application in the form of a concentrate.
[0036] To achieve the required operating viscosity of ISO VG 15-ISO VG 100, it may be necessary to adjust the aqueous lubricant to a lower viscosity. By evaporating a portion of the water at the friction site, the target viscosity is then achieved.
[0037] The emulsifiers that are optionally contained in the lubricant comprise all non-ionic, anionic and cationic systems from the cleaning agent industry and the metal-working industry.
[0038] Examples of the nonionic emulsifiers that are used are alkylene oxide polymers, such as alcohol ethoxylates that consist of, e.g., ethylene oxide and/or propylene oxide with alkylene oxide units of 5-50 and linear or branched alkyl radicals with a chain length of C 10 to C 20 .
[0039] Examples of anionic emulsifiers are sulfonates, carboxylic acid and dicarboxylic acid derivatives with a chain length of 6 to 16 carbon atoms, as well as phosphate esters.
[0040] Examples of cationic emulsifiers are quaternary ammonium compounds.
[0041] Water-soluble polymers comprise polyalkylene glycols, whereby polyethylene glycols with molar masses of 1,000 to 35,000 are preferred. Moreover, water-soluble esters, such as, for example, polyacrylates or polymethacrylates, can be used, as well as polyvinyl pyrrolidones or polyacrylamide, cellulose or sugar derivatives, in particular carboxymethyl cellulose, polyanionic cellulose, hydroxycellulose, and hydroxyethyl cellulose. The desired viscosities can be set by different molecular weights of the polymers.
[0042] Typical usable corrosion- and wear-protecting additives originate from the (cool)lubricant industry and comprise phosphorus-containing and/or sulfur-containing water soluble compounds as well as boron compounds, such as boric acid derivatives, or nitrogen compounds, such as, e.g., triazole derivatives or VCIs (volatile corrosion inhibitors, e.g., secondary amines).
[0043] To avoid bacterial growth in the aqueous solution accompanied by sludge formation, bactericides can be added, e.g., benzoic acid. To improve the low-temperature behavior, anti-icing agents, such as low-molecular glycols, in particular ethylene glycol, propylene glycol, trimethylene glycol, glycerol, salts or ionic liquids, can be used.
[0044] The advantages of the lubricant according to the invention can be listed as follows:
[0045] They can be scoured, i.e., washed out with tap water at room temperature without washing agents, thus energy is saved in the washing process,
[0046] Water pollution is significantly reduced by the elimination of mineral oil and washing agent; a clarifying step can be eliminated.
|
The present invention relates to water-based lubricants for textile machines, especially to such lubricants for use as needle oil and/or lifter oil as well as the use thereof as a needle oil and/or lifter oil.
| 2
|
BACKGROUND OF THE INVENTION 1. FIELD OF INVENTION
The present invention is directed to treatment of liquid compositions that are useful as biomedical adhesives and sealants, particularly methods of sterilizing them. More particularly, the present invention relates to a method using electron beam irradiation to sterilize monomeric liquid adhesive compositions, for example 1,1-disubstituted ethylene monomers. 2. Description of Related Art
Several methods are known for sterilizing monomeric and polymeric compositions.
U.S. Pat. No. 5,530,037 to McDonnell et al. discloses sterilizing cyanoacrylates using gamma radiation. Additionally, several other methods are disclosed including ionizing radiation. However, most of these methods are said to be unsuitable in their applicability to cyanoacrylate adhesives. In particular, the '037 patent states that electron beam accelerators have relatively low penetration and are effective only in sterilizing the outer surface of a container.
U.S. Pat. No. 2,904,392 to Pomerantz et al. discloses a method of packaging various chemicals, gasoline, polymerized plastics, or polymerizable monomers in film-formed bags and subjecting the bags to high intensity ionizing irradiation to effect sterilization. The radiation is obtainable from beams of high energy electrons produced by high voltage electron accelerators. In the case of monomers, irradiation at a suitable dosage level can be utilized to initiate polymerization without the assistance of a chemical catalyst or promoter. In this manner, polymerization can be achieved at low temperatures and the resultant polymer is essentially pure.
U.S. Pat. No. 3,704,089 to Stehlik discloses a process for the sterilization of monomeric esters of α-cyanoacrylic acids. The sterilization is carried out by ionizing irradiation (e.g., Co 60-gamma irradiation) after the esters have cooled, preferably to below their solidification points.
U.S. Pat. No. 2,921,006 to Schmitz et al. discloses polymerization of organic compounds with high energy electrons and, more particularly, polymerization of such compounds in the liquid or solid state by irradiation with high energy electrons. The organic compounds are contained in a receptacle covered with an aluminum sheet.
U.S. Pat. No. 3,122,633 to Steigerwald discloses an apparatus for polymerization of liquid materials by subdividing a polymer organic material into small volumes and irradiating the material while in the subdivided state with an electron beam source.
U.S. Pat. No. 3,780,308 to Nablo discloses surface sterilization and/or surface treatment of containers and other articles, the walls of which have a high specific energy absorption for relatively low energy electrons. The electron beam slightly penetrates container walls to effect surface sterilization, while substantially absorbing the electrons within the walls to minimize x-ray generation.
SUMMARY OF THE INVENTION
The present invention is directed to methods for sterilizing a liquid adhesive composition, preferably a monomeric composition, in a container using electron beam irradiation. The liquid adhesive composition of the present invention may comprise a 1,1-disubstituted ethylene monomer.
The present invention uses electron beam irradiation to sterilize liquid adhesive compositions inside their containers. In preferred embodiments, there is substantially no initiation of polymerization of monomeric liquid adhesive compositions that affects the utility of the monomer or monomers. Benefits of electron beam irradiation include the ability to sterilize the liquid composition on a production line without initiating any substantial polymerization, in a few seconds and at a lower penetration than gamma irradiation. The sterilized liquid adhesive compositions have good shelf life and excellent stability. The temperature levels of the liquid adhesive compositions during electron beam irradiation change only slightly from room temperature. In addition, post sterilization microbiological testing and a quarantine period are not required.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention is directed to sterilizing a liquid adhesive composition in a container using electron beam irradiation. In embodiments, the liquid adhesive composition is subjected to a dosage of about 0.5-10 MRad (5-100 kGy), preferably about 1.0-5.0 MRad (10-50 kGy), and more preferably 2-3 Mrad (20-30 kGy), of electron beam irradiation. The time of exposure is relative to the strength of the beam and is typically in the range of tenths of a second to seconds (depending on the conveyor speed) and is preferably less than one minute. Time of exposure will change from day to day depending on the beam strength at the time of setup. Dosimeters may be used to determine the exposure of the samples.
There are several sources for electron beam irradiation. The two main groups of electron beam accelerators are: (1) a Dynamitron, which uses an insulated core transformer, and (2) radio frequency (RF) linear accelerators (linacs). The Dynamitron is a particle accelerator (4.5 MeV) designed to impart energy to electrons. The high energy electrons are generated and accelerated by the electrostatic fields of the accelerator electrodes arranged within the length of the glass-insulated beam tube (acceleration tube). These electrons, traveling through an extension of the evacuation beam tube and beam transport (drift pipe) are subjected to a magnet deflection system in order to produce a "scanned" beam, prior to leaving the vacuum enclosure through a beam window. The dose can be adjusted with the control of the percent scan, the beam current and the conveyor speed.
The liquid adhesive composition may be in any type of at least partially electron beam permeable container, including, but not limited to, glass, plastic, and film-formed packages. In embodiments of the present invention, the container may be sealed or have an opening. Examples of glass containers include, but are not limited to, ampules, vials, syringes, pipettes, applicators, and the like. The penetration of electron beam irradiation is a function of the packaging. If there is not enough penetration from the side of a stationary electron beam, the container may be flipped or rotated to achieve adequate penetration. Alternatively, the electron beam source can be moved about a stationary package. In order to determine the dose distribution and dose penetration in product load, a dose map can be performed. This will identify the minimum and maximum dose zone within a product.
In embodiments, after the container containing the liquid adhesive composition is sterilized with electron beam irradiation, the container may be subjected to gamma irradiation. For example, the container may be placed in a kit with other components that need to be sterilized. The entire kit may then be sterilized. In addition to gamma irradiation, the entire kit may be sterilized by chemical (e.g., with ethylene oxide or hydrogen peroxide vapor), physical (e.g., dry heat) or other techniques such as microwave irradiation and electron beam irradiation.
The liquid composition in embodiments is preferably a monomeric adhesive composition. In embodiments, the monomer is a 1,1-disubstituted ethylene monomer, e.g., an alpha-cyanoacrylate. Preferred monomer compositions of the present invention and polymers formed therefrom are useful as tissue adhesives, sealants for preventing bleeding or for covering open wounds, and in other biomedical applications. They find uses in, for example, apposing surgically incised or traumatically lacerated tissues; retarding blood flow from wounds; drug delivery; dressing burns; and aiding repair and regrowth of living tissue.
Conventional surgical adhesive compositions have included plasticizers with the adverse effect of reducing the film strength. It has been discovered that, contrary to prior belief, the film strength (e.g., toughness) under certain conditions is not adversely reduced upon the addition of greater amounts of plasticizing agent. Depending on the particular acidic stabilizing agent and the purity of the monomer utilized in the adhesive composition, the addition of greater amounts of plasticizing agent may increase the toughness of the resulting bond formed on the wound. Acidic stabilizing agents do not significantly affect the polymerization of the monomer in the present composition and provide increased film strength with increasing amounts of plasticizing agents.
Monomers that may be used in this invention are readily polymerizable, e.g. anionically polymerizable or free radical polymerizable, to form polymers. Such monomers include those that form polymers, which may, but do not need to, biodegrade. Reference is made, for example, to U.S. Pat. No. 5,328,687, which is hereby incorporated by reference herein. As defined herein, "histotoxicity" refers to adverse tissue response, such as inflammation due to the presence of toxic materials in the tissue.
Useful 1,1-disubstituted ethylene monomers include, but are not limited to, monomers of the formula:
HRC═CXY (I)
wherein X and Y are each strong electron withdrawing groups, and R is H, --CH═CH 2 or, provided that X and Y are both cyano groups, a C 1 -C 4 alkyl group.
Examples of monomers within the scope of formula (1) include alpha-cyanoacrylates, vinylidene cyanides, C 1 -C 4 alkyl homologues of vinylidene cyanides, dialkyl methylene malonates, acylacrylonitriles, vinyl sulfinates and vinyl sulfonates of the formula CH 2 ═CX'Y wherein X' is --SO 2 R' or --SO 3 R' and Y' is --CN, --COOR', --COCH 3 , --SO 2 R' or --SO 3 R', and R' is H or hydrocarbyl.
Preferred monomers of formula (I) for use in this invention are alpha-cyanoacrylates. These monomers are known in the art and have the formula ##STR1## wherein R 2 is hydrogen and R 3 is a hydrocarbyl or substituted hydrocarbyl group; a group having the formula --R 4 --O--R 5 --O--R 6 , wherein R 4 is a 1,2-alkylene group having 2-4 carbon atoms, R 5 is an alkylene group having 2-4 carbon atoms, and R 6 is an alkyl group having 1-6 carbon atoms; or a group having the formula ##STR2## , wherein R 7 is ##STR3## wherein n is 1-10, preferably 1-5 carbon atoms and R 8 is an organic moiety.
Examples of suitable hydrocarbyl and substituted hydrocarbyl groups include straight chain or branched chain alkyl groups having 1-16 carbon atoms; straight chain or branched chain C 1 -C 16 alkyl groups substituted with an acyloxy group, a haloalkyl group, an alkoxy group, a halogen atom, a cyano group, or a haloalkyl group; straight chain or branched chain alkenyl groups having 2 to 16 carbon atoms; straight chain or branched chain alkynyl groups having 2 to 12 carbon atoms; cycloalkyl groups; aralkyl groups; alkylaryl groups; and aryl groups.
The organic moiety R 8 may be substituted or unsubstituted and may be straight chain, branched or cyclic, saturated, unsaturated or aromatic. Examples of such organic moieties include C 1 -C 8 alkyl moieties, C 2 -C 8 alkenyl moieties, C 2 -C 8 alkynyl moieties, C 3 -C 12 cycloaliphatic moieties, aryl moieties such as phenyl and substituted phenyl and aralkyl moieties such as benzyl, methylbenzyl and phenylethyl. Other organic moieties include substituted hydrocarbon moieties, such as halo (e.g., chloro-, fluoro- and bromo-substituted hydrocarbons) and oxy- (e.g., alkoxy substituted hydrocarbons) substituted hydrocarbon moieties. Preferred organic radicals are alkyl, alkenyl and alkynyl moieties having from 1 to about 8 carbon atoms, and halo-substituted derivatives thereof. Particularly preferred are alkyl moieties of 4 to 6 carbon atoms.
In the cyanoacrylate monomer of formula (II), R 3 is preferably an alkyl group having 1-10 carbon atoms or a group having the formula --AOR 9 , wherein A is a divalent straight or branched chain alkylene or oxyalkylene moiety having 2-8 carbon atoms, and R 9 is a straight or branched alkyl moiety having 1-8 carbon atoms.
Examples of groups represented by the formula --AOR 9 include 1-methoxy-2-propyl, 2-butoxy ethyl, isopropoxy ethyl, 2-methoxy ethyl, and 2-ethoxy ethyl.
The preferred alpha-cyanoacrylate monomers used in this invention are 2-octyl cyanoacrylate, dodecyl cyanoacrylate, 2-ethylhexyl cyanoacrylate, butyl cyanoacrylate, methyl cyanoacrylate, 3-methoxybutyl cyanoacrylate, 2-butoxyethyl cyanoacrylate, 2-isopropoxyethyl cyanoacrylate, or 1-methoxy-2-propyl cyanoacrylate.
The alpha-cyanoacrylates of formula (II) can be prepared according to methods known in the art. Reference is made, for example, to U.S. Pat. Nos. 2,721,858 and 3,254,111, each of which is hereby incorporated by reference herein. For example, the alpha cyanoacrylates can be prepared by reacting an alkyl cyanoacetate with formaldehyde in a non-aqueous organic solvent and in the presence of a basic catalyst, followed by pyrolysis of the anhydrous intermediate polymer in the presence of a polymerization inhibitor. The alpha-cyanoacrylate monomers prepared with low moisture content and essentially free of impurities are preferred for biomedical use.
The alpha-cyanoacrylates of formula (II) wherein R 3 is a group having the formula --R 4 --O--R 5 --O--R 6 can be prepared according to the method disclosed in U.S. Pat. No. 4,364,876 to Kimura et al., which is hereby incorporated by reference herein. In the Kimura et al. method, the alpha-cyanoacrylates are prepared by producing a cyanoacetate by esterifying cyanoacetic acid with an alcohol or by transesterifying an alkyl cyanoacetate and an alcohol; condensing the cyanoacetate and formaldehyde or para-formaldehyde in the presence of a catalyst at a molar ratio of 0.5-1.5:1, preferably 0.8-1.2:1, to obtain a condensate; depolymerizing the condensation reaction mixture either directly or after removal of the condensation catalyst to yield crude cyanoacrylate; and distilling the crude cyanoacrylate to form a high purity cyanoacrylate.
The alpha-cyanoacrylates of formula (II) wherein R 3 is a group having the formula ##STR4## can be prepared according to the procedure described in U.S. Pat. No. 3,995,641 to Kronenthal et al., which is hereby incorporated by reference herein. In the Kronenthal et al. method, such alpha-cyanoacrylate monomers are prepared by reacting an alkyl ester of an alpha-cyanoacrylic acid with a cyclic 1,3-diene to form a Diels-Alder adduct which is then subjected to alkaline hydrolysis followed by acidification to form the corresponding alpha-cyanoacrylic acid adduct. The alpha-cyanoacrylic acid adduct is preferably esterified by an alkyl bromoacetate to yield the corresponding carbalkoxymethyl alpha-cyanoacrylate adduct. Alternatively, the alpha-cyanoacrylic acid adduct may be converted to the alpha-cyanoacrylyl halide adduct by reaction with thionyl chloride. The alpha-cyanoacrylyl halide adduct is then reacted with an alkyl hydroxyacetate or a methyl substituted alkyl hydroxyacetate to yield the corresponding carbalkoxymethyl alpha-cyanoacrylate adduct or carbalkoxy alkyl alpha-cyanoacrylate adduct, respectively. The cyclic 1,3-diene blocking group is finally removed and the carbalkoxy methyl alpha-cyanoacrylate adduct or the carbalkoxy alkyl alpha-cyanoacrylate adduct is converted into the corresponding carbalkoxy alkyl alpha-cyanoacrylate by heating the adduct in the presence of a slight deficit of maleic anhydride.
Examples of monomers of formula (II) include cyanopentadienoates and alpha-cyanoacrylates of the formula: ##STR5## wherein Z is --CH═CH 2 and R 3 is as defined above. The monomers of formula (III) wherein R 3 is an alkyl group of 1-10 carbon atoms, i.e., the 2-cyanopenta-2,4-dienoic acid esters, can be prepared by reacting an appropriate 2-cyanoacetate with acrolein in the presence of a catalyst such as zinc chloride. This method of preparing 2-cyanopenta-2,4-dienoic acid esters is disclosed, for example, in U.S. Pat. No. 3,554,990, which is hereby incorporated by reference herein.
Preferred monomers are alkyl alpha-cyanoacrylates and more preferably octyl alpha-cyanoacrylates, especially 2-octyl alpha-cyanoacrylate. Monomers utilized in the present application should be very pure and contain few impurities (e.g., surgical grade).
The compositions of the present invention may include at least one plasticizing agent that imparts flexibility to the polymerized monomer formed on the wound or incision. The plasticizing agent preferably contains little or no moisture and should not significantly affect the polymerization of the monomer.
Other compositions are exemplified by U.S. Pat. Nos. 5,259,835 and 5,328,687 and U.S. patent application Ser. Nos. 08/609,921, 08/714,288, 08/909,845, 08/755,007, 08/920,876, and 08/488,411, all incorporated by reference herein in their entirety.
Examples of suitable plasticizers include acetyl tributyl citrate, dimethyl sebacate, triethyl phosphate, tri(2-ethylhexyl)phosphate, tri(p-cresyl) phosphate, glyceryl triacetate, glyceryl tributyrate, diethyl sebacate, dioctyl adipate, isopropyl myristate, butyl stearate, lauric acid, trioctyl trimellitate, dioctyl glutarate and mixtures thereof. Preferred plasticizers are tributyl citrate and acetyl tributyl citrate. In embodiments, suitable plasticizers include polymeric plasticizers, such as polyethylene glycol (PEG) esters and capped PEG esters or ethers, polyester glutarates and polyester adipates.
The compositions of the present invention may also include at least one acidic stabilizing agent that inhibits polymerization. Such stabilizing agents may also include mixtures of anionic stabilizing agents and radical stabilizing agents.
Examples of suitable anionic stabilizing agents include, but are not limited to, sultones (e.g., α-chloro-α-hydroxy-o-toluenesulfonic acid-γ-sultone), sulfur dioxide, sulfuric acid, sulfonic acid, lactone, boron trifluoride, organic acids, such as acetic acid or phosphoric acid, alkyl sulfate, alkyl sulfite, 3-sulfolene, alkylsulfone, alkyl sulfoxide, mercaptan, and alkyl sulfide and mixtures thereof. Preferable anionic stabilizing agents are acidic stabilizing agents of organic acids such as acetic acid or phosphoric acid. In embodiments, the amount of sulfur dioxide stabilizer is less than 100 ppm, preferably 5-75 ppm, and more preferably from about 20-50 ppm. The amount of sultone and/or trifluoracetic acid is about 500-3000 ppm.
Examples of suitable radical stabilizing agents include hydroquinone, hydroquinone monomethyl ether, catechol, pyrogallol, benzoquinone, 2-hydroxybenzoquinone, p-methoxy phenol, t-butyl catechol, butylated hydroxy anisole (BHA), butylated hydroxy toluene, and t-butyl hydroquinone. In embodiments, the amount of BHA is about 1,000-5,000 ppm.
Suitable acidic stabilizing agents include those having aqueous pK a ionization constants ranging from -12 to 7, about -5 to about 7, preferably from about -3.5 to about 6, and more preferably from about 2 to about 5.5. For example, suitable acidic stabilizing agents include: hydrogen sulfide (pK a 7.0), carbonic acid (pK a 6.4), triacetylmethane (pK a 5.9), acetic acid (pK a 4.8), benzoic acid (pK a 4.2), 2,4-dinitrophenol (pK a 4.0), formic acid (pK a 3.7), nitrous acid (pK a 3.3), hydrofluoric acid (pK a 3.2), chloroacetic acid (pK a 2.9), phosphoric acid (pK a 2.2), dichloroacetic acid (pK a 1.3), trichloroacetic acid (pK a 0.7), 2,4,6-trinitrophenol (picric acid) (pK a 0.3), trifluoroacetic acid (pK a 0.2), sulfuric acid (pK a -3.0) and mixtures thereof. In embodiments, the amount of trifluoroacetic acid is about 500-1,500 ppm.
When adding the above-mentioned acidic stabilizing agents to the adhesive composition, the addition of plasticizing agents in amounts ranging from about 0.5 wt. % to about 16 wt. %, preferably from about 3 wt. % to about 9 wt. %, and more preferably from about 5 wt. % to about 7 wt. % provides increased film strength (e.g., toughness) of the polymerized monomer over polymerized monomers having amounts of plasticizing agents and acidic stabilizing agents outside of the above ranges.
The concentration of the acidic stabilizing agents utilized may vary depending on the strength of the acid. For example, when using acetic acid, a concentration of 80-200 ppm (wt/wt), preferably 90-180 ppm (wt/wt), and more preferably 100-150 ppm (wt/wt) may be utilized. When using a stronger acid such as phosphoric acid, a concentration range of 20-80 ppm (wt/wt), preferably, 30-70 ppm (wt/wt) and more preferably 40-60 ppm (wt/wt) may be utilized. In embodiments, the amount of trifluoroacetic acid is about 100 to 3000 ppm, preferably 500-1500 ppm. In other embodiments, the amount of phosphoric acid is about 10-200 ppm, preferably about 50-150 ppm, and more preferably about 75-125 ppm.
Other compositions are exemplified by U.S. Pat. Nos. 5,624,669, 5,582,834, 5,575,997, 5,514,371, 5,514,372, 5,259,835 and 5,328,687, incorporated by reference herein in their entirety. The compositions of the present invention may also include at least one biocompatible agent effective to reduce active formaldehyde concentration levels produced during in vivo biodegradation of the polymer (also referred to herein as "formaldehyde concentration reducing agents"). Preferably, this component is a formaldehyde scavenger compound. Examples of formaldehyde scavenger compounds useful in this invention include sulfites; bisulfites; mixtures of sulfites and bisulfites; ammonium sulfite salts; amines; amides; imides; nitriles; carbamates; alcohols; mercaptans; proteins; mixtures of amines, amides, and proteins; active methylene compounds such as cyclic ketones and compounds having a b-dicarbonyl group; and heterocyclic ring compounds free of a carbonyl group and containing an NH group, with the ring made up of nitrogen or carbon atoms, the ring being unsaturated or, when fused to a phenyl group, being unsaturated or saturated, and the NH group being bonded to a carbon or a nitrogen atom, which atom is directly bonded by a double bond to another carbon or nitrogen atom.
Bisulfites and sulfites useful as the formaldehyde scavenger compound in this invention include alkali metal salts such as lithium, sodium and potassium salts, and ammonium salts, for example, sodium bisulfite, potassium bisulfite, lithium bisulfite, ammonium bisulfite, sodium sulfite, potassium sulfite, lithium sulfite, ammonium sulfite, and the like.
Examples of amines useful in this invention include the aliphatic and aromatic amines such as, for example, aniline, benzidine, aminopyrimidine, toluene-diamine, triethylenediamine, diphenylamine, diaminodiphenylamine, hydrazines and hydrazide.
Suitable proteins include collagen, gelatin, casein, soybean protein, vegetable protein, keratin and glue. The preferred protein for use in this invention is casein.
Suitable amides for use in this invention include urea, cyanamide, acrylamide, benzamide, and acetamide. Urea is a preferred amide.
Suitable alcohols include phenols, 1,4-butanediol, d-sorbitol, and polyvinyl alcohol.
Examples of suitable compounds having a b-dicarbonyl group include malonic acid, acetylacetone, ethylacetone, acetate, malonamide, diethylmalonate or another malonic ester.
Preferred cyclic ketones for use in this invention include cyclohexanone or cyclopentanone.
Examples of suitable heterocyclic compounds for use as the formaldehyde scavenger in this invention are disclosed, for example, in U.S. Pat. No. 4,127,382 (Perry) which is hereby incorporated by reference herein. Such heterocyclic compounds include, for example, benzimidazole, 5-methyl benzimidazole, 2-methylbenzimidazole, indole, pyrrole, 1,2,4-triazole, indoline, benzotriazole, indoline, and the like.
A preferred formaldehyde scavenger for use in this invention is sodium bisulfite.
In practicing the present invention, the formaldehyde concentration reducing agent, e.g., formaldehyde scavenger compound, is added in an effective amount to the cyanoacrylate. The "effective amount" is that amount sufficient to reduce the amount of formaldehyde generated during subsequent in vivo biodegradation of the polymerized cyanoacrylate. This amount will depend on the type of active formaldehyde concentration reducing agent, and can be readily determined without undue experimentation by those skilled in the art.
The formaldehyde concentration reducing agent may be used in this invention in either free form or in microencapsulated form. Other compositions are exemplified by U.S. patent application Ser. No. 08/714,288, incorporated by reference herein in their entirety.
When microencapsulated, the formaldehyde concentration reducing agent is released from the microcapsule continuously over a period of time during the in vivo biodegradation of the cyanoacrylate polymer.
For purposes of this invention, the microencapsulated form of the formaldehyde concentration reducing agent is preferred because this embodiment prevents or substantially reduces polymerization of the cyanoacrylate monomer by the formaldehyde concentration reducing agent, which increases shelf-life and facilitates handling of the monomer composition during use.
Microencapsulation of the formaldehyde scavenger can be achieved by many known microencapsulation techniques. For example, microencapsulation can be carried out by dissolving a coating polymer in a volatile solvent, e.g., methylene chloride, to a polymer concentration of about 6% by weight; adding a formaldehyde scavenger compound in particulate form to the coating polymer/solvent solution under agitation to yield a scavenger concentration of 18% by weight; slowly adding a surfactant-containing mineral oil solution to the polymer solution under rapid agitation; allowing the volatile solvent to evaporate under agitation; removing the agitator; separating the solids from the mineral oil; and washing and drying the microparticles. The size of the microparticles will range from about 0.001 to about 1000 microns.
The coating polymer for microencapsulating the formaldehyde concentration reducing agent should be polymers which undergo in vivo bioerosion, preferably at rates similar to or greater than the cyanoacrylate polymer formed by the monomer, and should have low inherent moisture content. Such "bioerosion" can occur as a result of the physical or chemical breakdown of the encapsulating material, for example, by the encapsulating material passing from solid to solute in the presence of body fluids, or by biodegradation of the encapsulating material by agents present in the body.
Examples of coating materials which can be used to microencapsulate the formaldehyde concentration reducing agent include polyesters, such as polyglycolic acid, polylactic acid, poly-1,4-dioxa-2-one, polyoxaltes, polycarbonates, copolymers of polyglycolic acid and polylactic acid, polycaprolactone, poly-b-hydroxybutyrate, copolymers of epsilon-caprolactone and delta-valerolactone, copolymers of epsilon-caprolactone and DL-dilactide, and polyester hydrogels; polyvinylpyrrolidone; polyamides; gelatin; albumin; proteins; collagen; poly(orthoesters); poly(anhydrides); poly(alkyl-2-cyanoacrylates); poly(dihydropyrans); poly(acetals); poly(phosphazenes); poly(urethanes); poly(dioxinones); cellulose; and starches.
Examples of the surfactant which can be added to the mineral oil include those commercially available under the designations Triton x-100, Tween 20 and Tween 80.
The composition of this invention may further contain one or more adjuvant substances, such as thickening agents, medicaments, or the like, to improve the medical utility of the monomer for particular medical applications.
Suitable thickeners include, for example, polycyanoacrylates, polylactic acid, poly-1,4-dioxa-2-one, polyoxalates, polyglycolic acid, lactic-glycolic acid copolymers, polycaprolactone, lactic acid-caprolactone copolymers, poly-3-hydroxybutyric acid, polyorthoesters, polyalkyl acrylates, copolymers of alkylacrylate and vinyl acetate, polyalkyl methacrylates, and copolymers of alkyl methacrylates and butadiene. Examples of alkyl methacrylates and acrylates are poly(2-ethylhexyl methacrylate) and poly(2-ethylhexyl acrylate), also poly(butylmethacrylate) and poly(butylacrylate), also copolymers of various acrylate and methacrylate monomers, such as poly(butylmethacrylate-co-methylacrylate).
To improve the cohesive strength of adhesives formed from the compositions of this invention, difunctional monomeric cross-linking agents may be added to the monomer compositions of this invention. Such crosslinking agents are known. Reference is made, for example, to U.S. Pat. No. 3,940,362 to Overhults, which is hereby incorporated by reference herein. Examples of suitable crosslinking agents include alkyl bis(2-cyanoacrylates), triallyl isocyanurates, alkylene diacrylates, alkylene dimethacrylates, trimethylol propane triacrylate, and alkyl bis(2-cyanoacrylates). A catalytic amount of an amine activated free radical initiator or rate modifier may be added to initiate polymerization or to modify the rate of polymerization of the cyanoacrylate monomer/crosslinking agent blend.
In embodiments, the adhesive compositions may additionally contain heat and/or light (e.g., visible or ultraviolet light) activated initiators and accelerators that initiate cross-linking of cyanoacrylate compositions containing compounds of formula (I).
Particular initiators for particular systems may be readily selected by one of ordinary skill in the art without undue experimentation. Suitable polymerization initiators for the cyanoacrylate compositions include, but are not limited to, detergent compositions; surfactants: e.g., nonionic surfactants such as polysorbate 20 (e.g., Tween 20™), polysorbate 80 (e.g., Tween 80™) and poloxamers, cationic surfactants such as tetrabutylammonium bromide, anionic surfactants such as benzalkonium chloride or its pure components, stannous octoate (tin (II) 2-ethylheaxanoate), and sodium tetradecyl sulfate, and amphoteric or zwitterionic surfactants such as dodecyldimethyl(3-sulfopropyl)ammonium hydroxide, inner salt; amines, imines and amides, such as imidazole, tryptamine, urea, arginine and povidine; phosphines, phosphites and phosphonium salts, such as triphenylphosphine and triethyl phosphite; alcohols such as ethylene glycol, methyl gallate, ascorbic acid, tannins and tannic acid; inorganic bases and salts, such as sodium bisulfite, magnesium hydroxide, calcium sulfate and sodium silicate; sulfur compounds such as thiourea and polysulfides; polymeric cyclic ethers such as monensin, nonactin, crown ethers, calixarenes and polymeric epoxides; cyclic and acyclic carbonates, such as diethyl carbonate; phase transfer catalysts such as Aliquat 336; and organometallics and manganese acetylacetonate and radical initiators. Cobalt naphthenate can be used as an accelerator for peroxide.
The compositions of the present invention may further contain fibrous reinforcement and colorants, i.e., dyes and pigments. Examples of suitable fibrous reinforcement include PGA microfibrils, collagen microfibrils, cellulosic microfibrils, and olefinic microfibrils. Examples of suitable colorants include 1-hydroxy-4-[4-methylphenyl-amino]-9,10 anthracenedione (D+C violet No. 2); disodium salt of 6-hydroxy-5-[(4-sulfophenyl)axo]-2-naphthalene-sulfonic acid (FD+C Yellow No. 6); 9-(o-carboxyphenyl)-6-hydroxy-2,4,5,7-tetraiodo-3H-xanthen-3-one, disodium salt, monohydrate (FD+C Red No. 3); 2-(1,3-dihydro-3-oxo-5-sulfo-2H-indol-2-ylidene)-2,3-dihydro-3-oxo-1H-indole-5-sulfonic acid disodium salt (FD+C Blue No. 2); and [phtha-locyaninato (2-)] copper.
Depending on the particular requirements of the user, the liquid compositions of the present invention can be applied by known means such as with a glass stirring rod, sterile brush or medicine dropper. However, in many situations a pressurized aerosol dispensing package is preferred in which the adhesive composition is in solution with a compatible anhydrous propellant.
EXAMPLES
The following Examples illustrate specific embodiments of the invention. These examples are intended to be illustrative only, and the invention is not limited to the materials, conditions or process parameters set forth in the Examples.
Table 1 shows the stabilizer concentrations for runs 1-20 in Tables 2-7. Table 8 shows the stabilizer concentrations for runs 1-27 in Tables 9-11.
Tables 2 and 5 show the initial viscosity for 2-octylcyanoacrylate monomeric compositions containing less than 5 ppm SO2 and without SO 2 respectively when sterilized by electron beam irradiation. Tables 3-4 show the change in viscosity over time (d=days) for 2-octylcyanoacrylate compositions containing less than 5 ppm SO 2 that have been sterilized by electron beam irradiation. Tables 6-7 show the change in viscosity over time for 2-octylcyanoacrylate compositions containing no SO 2 that have been sterilized by electron beam irradiation. The change in viscosity is a measure of polymerization and thus the stability of the liquid adhesive monomeric compositions.
Table 9 shows the initial viscosity for 2-octylcyanoacrylate monomeric compositions containing 1500 ppm hydroquinone and 27 ppm SO 2 when sterilized by electron beam irradiation. Tables 10-11 demonstrate that monomeric compositions containing stabilizing agents exhibit good stability as shown by the small change in containing stabilizing agents exhibit good stability as shown by the small change in viscosity when sterilized by electron beam irradiation. Table 12 demonstrates that n-butyl cyanoacrylate monomeric compositions also exhibit good stability when sterilized by electron beam irradiation.
In the Accelerated Stability Results conducted at 80° C. to analyze stability and self-life, 3 days at 80° C. is approximately 6 months at room temperature, 6 days at 80° C. is approximately 1 year at room temperature and 12 days at 80° C. is approximately 2 years at room temperature. N.D. means no data. Viscosity is measured at 25° C.
TABLE 1______________________________________Stabilizer Concentrations Run Sultone (ppm) BHA (ppm) TFA (ppm)______________________________________ 1 1000 3000 1500 2 1500 5000 500 3 500 5000 500 4 1000 1000 1000 5 1000 5000 1000 6 500 5000 1500 7 500 3000 1000 8 1000 3000 1000 9 1500 1000 500 10 1000 3000 500 11 1000 3000 1000 12 1000 3000 1000 13 500 1000 500 14 1000 3000 1000 15 1500 3000 1000 16 1000 3000 1000 17 1500 5000 1500 18 1500 1000 1500 19 1000 3000 1000 20 500 1000 1500______________________________________
TABLE 2______________________________________2OCA Formulations with SO2 Viscosity (cps) Run Control 20 kGy 30 kGy______________________________________ 1 6.1 7.8 9.5 2 6.2 7.6 9.2 3 6.3 7.0 8.4 4 6.2 7.1 7.9 5 6.3 6.8 7.9 6 6.3 7.7 9.9 7 6.4 7.3 N.D. 8 6.3 7.1 8.4 9 6.3 7.1 8.4 10 6.2 7.1 8.5 11 6.2 7.3 8.5 12 6.2 7.1 8.5 13 6.3 7.2 8.5 14 6.2 7.2 8.6 15 6.1 6.9 8.3 16 6.1 7.8 10.2 17 6.1 7.6 9.3 18 6.1 7.1 8.3 19 6.2 7.1 8.2 20 6.3 6.9 7.8______________________________________
TABLE 3______________________________________2OCA Formulations with SO2 20 kGy Exposed Samples Accelerated Stability Results (80° C.) Viscosity (cps)Run t = 0 t = 6 d t = 12 d______________________________________ 1 7.8 30 449 2 7.6 1000 1000 3 7.0 69 N.D. 4 7.1 25 401 5 6.8 1000 1000 6 7.7 28 1000 7 7.3 15 N.D. 8 7.1 54 1000 9 7.1 23 1000 10 7.1 37 1000 11 7.3 33 1000 12 7.1 53 1000 13 7.2 45 1000 14 7.2 23 1000 15 6.9 20 478 16 7.8 20 177 17 7.6 50 1000 18 7.1 22 1000 19 7.1 16 304 20 6.9 34 1000______________________________________
TABLE 4______________________________________2OCA Formulations with SO2 30 kGy Exposed Samples Accelerated Stability Results (80° C.) Viscosity (cps)Run Control t = 6 d t = 12 d______________________________________ 1 9.5 191 1000 2 9.2 1000 1000 3 8.4 540 1000 4 7.9 384 1000 5 7.9 1000 1000 6 9.9 97 1000 7 N.D. N.D. N.D. 8 8.4 242 1000 9 8.4 63 1000 10 8.5 111 1000 11 8.5 130 1000 12 8.5 552 1000 13 8.5 157 1000 14 8.6 63 1000 15 8.3 49 1000 16 10.2 59 1000 17 9.3 187 1000 18 8.3 50 1000 19 8.2 26 1000 20 7.8 87 1000______________________________________
TABLE 5______________________________________2OCA Formulations without SO2 Viscosity (cps) Run Control 20 kGy 30 kGy______________________________________ 1 6.1 8.2 9.8 2 6.2 7.9 9.1 3 6.2 7.5 8.3 4 6.1 7.2 7.9 5 6.1 6.6 7.8 6 6.3 7.8 9.6 7 6.1 7.4 8.1 8 6.1 7.3 8.0 9 6.1 7.4 8.3 10 6.2 7.5 8.3 11 6.1 7.5 8.2 12 6.3 7.4 8.2 13 6.0 7.3 8.3 14 6.2 7.5 8.1 15 6.2 7.3 7.8 16 6.0 8.6 10.7 17 6.1 8.6 11.0 18 6.1 7.7 8.6 19 6.1 7.4 8.0 20 6.2 7.2 7.5______________________________________
TABLE 6______________________________________2OCA Formulations without SO2 20 kGy Exposed Samples Accelerated Stability Results (80° C.) Viscosity (cps)Run Control t = 6 d t = 12 d______________________________________ 1 8.2 1000 1000 2 7.9 1000 1000 3 7.5 1000 1000 4 7.2 1000 1000 5 6.6 1000 1000 6 7.8 1000 1000 7 7.4 329 1000 8 7.3 1000 1000 9 7.4 345 1000 10 7.5 262 1000 11 7.5 520 1000 12 7.4 417 1000 13 7.3 198 1000 14 7.5 213 1000 15 7.3 428 1000 16 8.6 1000 1000 17 8.6 1000 1000 18 7.7 20 N.D. 19 7.4 16 92.0 20 7.2 37 N.D.______________________________________
TABLE 7______________________________________2OCA Formulations without SO2 30 kGy Exposed Samples Accelerated Stability results (80° C.) Viscosity (cps)Run Control t = 6 d t = 12 d______________________________________ 1 9.8 1000 1000 2 9.1 1000 1000 3 8.3 1000 1000 4 7.9 1000 1000 5 7.8 1000 1000 6 9.6 1000 1000 7 8.1 1000 1000 8 8.0 1000 1000 9 8.3 1000 1000 10 8.3 1000 1000 11 8.2 1000 1000 12 8.2 1000 1000 13 8.3 1000 1000 14 8.1 1000 1000 15 7.8 1000 1000 16 10.7 1000 1000 17 11.0 1000 1000 18 8.6 1000 1000 19 8.0 149 1000 20 7.5 240 1000______________________________________
TABLE 8______________________________________Stabilizer Concentrations Run Sultone (ppm) BHA (ppm) TFA (ppm)______________________________________ 1 0 500 0 2 0 500 750 3 0 500 1500 4 0 2000 0 5 0 2000 750 6 0 2000 1500 7 0 3500 0 8 0 3500 750 9 0 3500 1500 10 750 500 0 11 750 500 750 12 750 500 1500 13 750 2000 0 14 750 2000 750 15 750 2000 1500 16 750 3500 0 17 750 3500 750 18 750 3500 1500 19 1500 500 0 20 1500 500 750 21 1500 500 1500 22 1500 2000 0 23 1500 2000 750 24 1500 2000 1500 25 1500 3500 0 26 1500 3500 750 27 1500 3500 1500______________________________________
TABLE 9______________________________________Initial Results (t = 0) Viscosity (cps) Run Control 20 kGy 30 kGy______________________________________ 1 6.8 10.2 12.0 2 6.6 8.6 9.8 3 6.7 8.7 10.0 4 6.7 9.4 11.0 5 6.7 8.3 9.3 6 6.7 8.1 8.7 7 6.6 9.1 10.0 8 6.6 8.5 8.9 9 6.6 8.6 8.4 10 6.6 10.3 12.0 11 6.7 9.3 10.0 12 6.6 9.1 9.5 13 6.8 9.8 11.0 14 6.7 8.9 9.3 15 6.7 8.6 9.2 16 6.6 9.4 9.7 17 6.8 8.6 9.6 18 6.8 8.5 9.3 19 6.8 10.0 11.0 20 6.5 9.7 11.2 21 6.7 9.2 10.7 22 6.7 9.7 11.0 23 6.8 9.0 9.8 24 6.9 8.6 9.8 25 6.7 9.3 10.0 26 6.7 8.8 9.8 27 6.6 8.6 8.8______________________________________
TABLE 10______________________________________20 kGy Exposed Accelerated Stability Results (80° C.) Viscosity (cps) Run t = 0 t = 3d______________________________________ 1 10.2 13 2 8.6 14 3 8.7 16 4 9.4 11 5 8.3 11 6 8.1 16 7 9.1 11 8 8.5 11 9 8.6 13 10 10.3 12 11 9.3 13 12 9.1 15 13 9.8 11 14 8.9 11 15 8.6 14 16 9.4 11 17 8.6 11 18 8.5 12 19 10.0 13 20 9.7 13 21 9.2 14 22 9.7 12 23 9.0 11 24 8.6 12 25 9.3 11 26 8.8 11 27 8.6 13______________________________________
TABLE 11______________________________________30 kGy Exposed Accelerated Stability Results (80° C.) Viscosity (cps) Run t = 0 t = 3d______________________________________ 1 12.0 21 2 9.8 23 3 10.0 24 4 11.0 18 5 9.3 18 6 8.7 22 7 10.0 15 8 8.9 15 9 8.4 18 10 12.0 18 11 10.0 16 12 9.5 19 13 11.0 14 14 9.3 13 15 9.2 17 16 9.7 13 17 9.6 14 18 9.3 15 19 11.0 16 20 11.2 17 21 10.7 18 22 11.0 15 23 9.8 15 24 9.8 16 25 10.0 14 26 9.8 13 27 8.8 14______________________________________
TABLE 12______________________________________Weeks at Viscosity (cps)50° C. 0 kGy 10 kGy 20 kGy 30 kGy 40 kGy 50 kGy______________________________________0 3.0 4.1 5.0 8.9 22 153 1 3.1 4.2 5.0 9.4 24 375 4 3.2 4.2 7.7 8.8 1000 1000 8 3.0 5.5 15 129 1000 1000 12 3.5 8.7 119 1000 1000 1000 14 3.4 12 695 1000 1000 1000______________________________________
|
A method for sterilizing a liquid adhesive composition includes subjecting the composition to electron beam irradiation while it is enclosed in a container.
| 2
|
This application is a continuation of application Ser. No. 159,350 filed Feb. 23, 1988, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an optical recording medium for optically recording and reproducing information.
2. Related Background Art
In general, optical recording mediums, for example, optical discs and optical cards can record information in a high density by forming optically detectable pits of minute size, for example, of about 1 μm on a thin recording layer provided on a substrate having grooves of spiral, circular or linear form.
To write information in such an optical recording medium, a focused laser beam is scanned on the surface of a laser beam sensitive layer, whereby pits are formed only on the surface on which the laser beam was irradiated and the information is recorded The laser-beam-sensitive layer can absorb energy to form optically detectable pits thereon. For example, in a certain heat mode recording system, the laser-beam-sensitive layer absorbs a heat energy to form minute concaves. i.e., pits, on those energy-absorbed parts by evaporation or fusion. In another heat mode system, the absorption of the energy of the irradiated laser beam can form pits having an optically detectable density difference on those parts.
The information recorded on the optical recording medium in this manner can be detected by reading optical changes between the part on which the pits are formed and that part on which the pits are not formed.
Hitherto known laser beam-sensitive layers or recording layers used in such optical recording mediums include those in which inorganic materials are chiefly used, for example, those in which bismuth thin films, tellurium oxide thin films, chalcogenite type amorphous glass films or metal thin films such as aluminum or gold thin films are used as disclosed in Japanese Patent Publication No. 40479/1871, Japanese Patent Laid-open No. 27395/1981, etc. These thin films, however, have been disadvantageous such that they involve poor storage stability, low resolution power, low recording density, high production cost, etc.
Recently, also proposed in Japanese Patent Laid-open No. 187948/1985, Japanese Patent Laid-open No. 205841/1988, etc. is to use in the recording layer an organic coloring matter thin film whose physical properties can be changed by light of a relatively long wavelength, for example, of 780 nm or more. In this organic coloring matter thin film, the pits can be formed by use of a semiconductor laser beam having an oscillation wavelength, for example, of around 830 nm, thus eliminating the drawbacks possessed by the above mentioned thin films chiefly employing the inorganic materials. In general, however, organic coloring matters having absorption characteristics on the side of the long wavelength has the problem such that they have a low stability to heat and light.
An organic coloring matter that can solve the above problem is disclosed in Japanese Patent Laid-open No. 181690/1983. In the invention disclosed therein, the organic coloring matter has a great absorption band to a wavelength (750 to 850 nm) of conventional semiconductor lasers. Recent years, however, a semiconductor laser that can oscillate light of a shorter wavelength, for example, of a visible light region has been developed. Thus, an organic coloring matter having a great absorption band even to the light from such a semiconductor laser has been sought after.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an optical recording medium having an organic thin layer that has a greater absorption band not only to light from conventional semiconductor laser but also to light of a shorter wavelength, for example, near 680 nm, and also can be stable to heat and light, may suffer less light deterioration and reproduction deterioration, and has excellent storage stability.
According to the present invention, there is provided with an optical recording medium comprising an organic film, wherein said organic film contains at represented by Formulas (I), (II) and (III) shown below. ##STR1##
wherein A, B, D and E each represent a hydrogen atom, a substituted or unsubstituted alkyl group, a cyclic alkyl group, an alkenyl group, a substituted or unsubstituted aralkyl group, a substituted or unsubstituted aryl group, a substituted or unsubstituted styryl group, or a substituted or unsubstituted heterocyclic group; Y represents a divalent residual group having a group of atoms necessary for completing a ring of 5 or 6 members; R 1 , R 2 , R 3 and R 4 each represent a hydrogen atom, a halogen atom, or an alkyl group; m and n each represents an integer of 0, 1 or 2; Z.sup.⊖ represents ##STR2## X.sup.⊖ represents an anion.
In the present invention, since the compound has less number of carbon atoms in the main chain by two or more as compared with the one disclosed in Japanese patent Laid-open No. 181690/1983, the position of the absorption peak is shifted by about 50 nm or more to the short wavelength side. For this reason, it is possible to obtain an optical recording medium improved in the sensitivity to near infrared light from conventional semiconductor lasers or the like, and at the same time improved also in the sensitivity to light from a short wavelength semiconductor laser, for example, light of visible light region near 680 nm.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 to FIG. 4 are views schematically illustrating examples of the optical recording mediums according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In the compounds represented by the above Formulas (I), (II) and (III) used in the present invention, A, B, D and E each represent a hydrogen atom or an alkyl group (for example, a methyl group, an ethyl group, a n propyl group, an iso-propyl group, a n-butyl group, a sec-butyl group, an iso-butyl group, a t-butyl group, a n-amyl group, a t-amyl group, a n-hexyl group, a n-octyl group, t-octylgroup, etc.), including other alkyl groups, for example, substituted alkyl groups (for example, a 2-hydroxyethyl group, a 3-hydroxypropyl group, a 4-hydroxybutyl group, a 2-acetoxyethyl group, a carboxymethyl group, a 2-carboxyethyl group, a 3-carboxypropyl group, a 2-sulfoethyl group, a 3-sulfopropyl group, a 4-sulfobutyl group, a 3-sulfatopropyl group, a 4-sulfatobutyl group, a N-(methylsulfonyl)-carbamylmethyl group, a 3-(acetylsulfamyl) propyl group, a 4-(acetylsulfamyl) butyl group, etc.), cyclic alkyl groups (for example, a cyclohexyl group), alkenyl groups (for example, a vinyl group, an allyl group, a propenyl group, a butenyl group, a pentenyl group, a hexenyl group, a heptenyl group, an octenyl group, a dodecenyl group, a prenyl group, etc.), aralkyl groups (for example, a benzyl group, a phenethyl group, an α-naphthylmethyl group, a β-naphthylmethyl group, etc.), substituted aralkyl groups (for example, a o carboxybenzyl group, a sulfobenzyl group, a hydroxybenzyl group, etc.), etc.
A, B, D and E each further represent a substituted or unsubstituted aryl group (for example, a phenyl group, a naphthyl group, a tolyl group, a xylyl group, a methoxyphenyl group, a dimethoxyphenyl group, a trimethoxyphenyl group, an ethoxyphenyl group, a dimethylaminophenyl group, a diethylaminophenyl group, a dipropylaminophenyl group, a dibenzylaminophenyl group, a diphenylaminophenyl group, etc.), a substituted or unsubstituted heterocyclic group (for example, a pyridyl group, a quinolyl group, a lepidyl group, a methylpyridyl, a furyl group, a thienyl group, an indolyl group, a pyrrole group, a carbazolyl group, an N-ethylcarbazolyl group, etc.) or a substituted or unsubstituted styryl group (for example, a styryl group, a methoxystyryl group, a dimethoxystyryl group, a trimethoxystyryl group, an ethoxystyryl group, a dimethylaminostyryl group, a diethylaminostyryl group, a dipropylaminostyryl group , a dibenzylaminostyryl group, a diphenylaminostyryl group, a 2,2-diphenylvinyl group, a 2-phenyl-2-methylvinyl group, a 2-(dimethylaminophenyl)-2-phenylvinyl group, a 2-(diethylaminophenyl)-2-phenylvinyl group, a 2-(dibenzylaminophenyl)-2-phenylvinyl group, a 2,2-di(diethylaminophenyl)vinyl group, a 2,2-di(methoxyphenyl)vinyl group, a 2,2-di(ethoxyphenyl) vinyl group, a 2-(dimethylaminophenyl)-2-methylvinyl group, a 2-(diethylaminophenyl)-2-ethylvinyl group, etc.).
R 1 , R 2 , R 3 and R 4 each represent a hydrogen atom, a halogen atom (such as a chlorine atom and a bromine atom) or an alkyl group (such as a methyl group, an ethyl group, a propyl group, a butyl group and an amyl group).
Y represents a divalent hydrocarbon group (such as --CH 2 --CH 2 --, --CH 2 --CH 2 --CH 2 --, ##STR3## and --CH═CH--) that forms a substituted or unsubstituted 5-membered or 6-membered ring, and the 5-membered or 6-membered ring may be condensed with a benzene ring, a naphthalene ring or the like.
X.sup.⊖ represents an anion including, for example, a chloride ion, a bromide ion, an iodide ion, a perchlorate ion, a benzenesulfonate ion, a p-toluenesulfonate ion, a methylsulfate ion, an ethylsulfate ion, a propylsulfate ion, etc.
Typical examples of the polymethine compounds represented respectively by the above Formulas (I), (II) and (III) are shown below, but, in the present invention by no means limited to these.
Com-poundNo. For-mula B A D E R.sub.1 R.sub.2 R.sub.3 ##STR4## X (1) (I) ##STR5## ##STR6## ##STR7## ##STR8## H H H ##STR9## Cl (2) (I) H ##STR10## ##STR11## H CH.sub.3 CH.sub.3 CH.sub.3 ##STR12## Br (3) (I) ##STR13## ##STR14## ##STR15## ##STR16## Cl H H ##STR17## ClO.sub.4 (4) (I) ##STR18## ##STR19## ##STR20## ##STR21## Cl CH.sub.3 CH.sub.3 ##STR22## ClO.sub.4 (5) (I) ##STR23## ##STR24## ##STR25## ##STR26## H H H ##STR27## I (6) (I) ##STR28## ##STR29## ##STR30## ##STR31## Cl H H ##STR32## BF.sub.4 (7) (I) ##STR33## ##STR34## ##STR35## ##STR36## H C.sub.2 H.sub.5 C.sub.2 H.sub.5 ##STR37## ##STR38## (8) (I) ##STR39## ##STR40## ##STR41## ##STR42## Cl H H ##STR43## ClO.sub.4 Com-poundNo. For- mula A B D E R.sub.1 R.sub.2 R.sub.3 ##STR44## X (9) (I) ##STR45## ##STR46## ##STR47## ##STR48## H Cl Cl ##STR49## ClO.sub.4 (10) (I) ##STR50## ##STR51## ##STR52## ##STR53## H H H ##STR54## ClO.sub.4 (11) (I) ##STR55## ##STR56## ##STR57## ##STR58## Cl H H ##STR59## ClO.sub.4 (12) (I) ##STR60## H ##STR61## H CH.sub.3 H H ##STR62## I (13) (I) ##STR63## ##STR64## ##STR65## ##STR66## Cl Cl Cl ##STR67## BF.sub.3 (14) (I) ##STR68## ##STR69## ##STR70## ##STR71## H H H ##STR72## ClO.sub.4 (15) (I) ##STR73## ##STR74## ##STR75## ##STR76## Br Br Br ##STR77## ##STR78## (16) (I) ##STR79## ##STR80## ##STR81## ##STR82## H H H ##STR83## ClO.sub.4 (17) (I) ##STR84## ##STR85## ##STR86## ##STR87## Cl H H ##STR88## I (18) (I) ##STR89## ##STR90## ##STR91## ##STR92## Br CH.sub.3 CH.sub.3 ##STR93## ##STR94## (19) (I) ##STR95## CH.sub.3 ##STR96## CH.sub.3 H H H ##STR97## BF.sub.4 (20) (I) ##STR98## ##STR99## ##STR100## ##STR101## Cl H H ##STR102## ClO.sub.4 (21) (I) ##STR103## ##STR104## ##STR105## ##STR106## H H H ##STR107## ClO.sub.4 (22) (I) ##STR108## ##STR109## ##STR110## ##STR111## Cl H H ##STR112## I (23) (I) ##STR113## ##STR114## ##STR115## ##STR116## H H H ##STR117## ClO.sub.4 (24) (I) ##STR118## ##STR119## ##STR120## ##STR121## Br Br Br ##STR122## I (25) (I) ##STR123## ##STR124## ##STR125## ##STR126## H H H ##STR127## ClO.sub.4 (26) (I) ##STR128## ##STR129## ##STR130## ##STR131## H H H ##STR132## BF.sub.4 (27) (I) ##STR133## ##STR134## ##STR135## ##STR136## Cl Cl Cl ##STR137## ##STR138## (28) (I) ##STR139## ##STR140## ##STR141## ##STR142## Br H H ##STR143## ClO.sub.4 (29) (I) ##STR144## ##STR145## ##STR146## ##STR147## Cl H H ##STR148## BF.sub.4 (30) (I) ##STR149## ##STR150## ##STR151## ##STR152## H CH.sub.3 CH.sub.3 ##STR153## ClO.sub.4 (31) (I) ##STR154## ##STR155## ##STR156## ##STR157## H H H ##STR158## ClO.sub.4 (32) (I) ##STR159## ##STR160## ##STR161## ##STR162## Cl H H ##STR163## ClO.sub.4 (33) (II) ##STR164## ##STR165## ##STR166## ##STR167## H ##STR168## Cl (34) (II) ##STR169## H ##STR170## H Cl ##STR171## Br (35) (II) ##STR172## ##STR173## ##STR174## ##STR175## Cl ##STR176## ClO.sub.4 (36) (II) ##STR177## ##STR178## ##STR179## ##STR180## H ##STR181## ClO.sub.4 (37) (II) ##STR182## ##STR183## ##STR184## ##STR185## H ##STR186## I (38) (II) ##STR187## ##STR188## ##STR189## ##STR190## Cl ##STR191## BF.sub.4 (39) (II) ##STR192## ##STR193## ##STR194## ##STR195## CH.sub.3 ##STR196## ##STR197## (40) (II) ##STR198## ##STR199## ##STR200## ##STR201## Cl ##STR202## ClO.sub.4 (41) (II) ##STR203## ##STR204## ##STR205## ##STR206## H ##STR207## ClO.sub.4 (42) (II) ##STR208## ##STR209## ##STR210## ##STR211## H ##STR212## ClO.sub.4 (43) (II) ##STR213## ##STR214## ##STR215## ##STR216## Cl ##STR217## ClO.sub.4 (44) (II) ##STR218## H ##STR219## H Br ##STR220## I (45) (II) ##STR221## ##STR222## ##STR223## ##STR224## Cl ##STR225## BF.sub.3 (46) (II) ##STR226## ##STR227## ##STR228## ##STR229## H ##STR230## ClO.sub.4 (47) (II) ##STR231## ##STR232## ##STR233## ##STR234## Br ##STR235## ##STR236## (48) (II) ##STR237## ##STR238## ##STR239## ##STR240## H ##STR241## ClO.sub.4 (49) (II) ##STR242## ##STR243## ##STR244## ##STR245## Cl ##STR246## I (50) (II) ##STR247## ##STR248## ##STR249## ##STR250## Br ##STR251## ##STR252## (51) (II) ##STR253## CH.sub.3 ##STR254## CH.sub.3 H ##STR255## BF.sub.4 (52) (II) ##STR256## ##STR257## ##STR258## ##STR259## CH.sub.3 ##STR260## ClO.sub.4 (53) (II) ##STR261## ##STR262## ##STR263## ##STR264## H ##STR265## ClO.sub.4 (54) (II) ##STR266## ##STR267## ##STR268## ##STR269## Cl ##STR270## I (55) (II) ##STR271## ##STR272## ##STR273## ##STR274## H ##STR275## ClO.sub.4 (56) (II) ##STR276## ##STR277## ##STR278## ##STR279## Br ##STR280## I (57) (II) ##STR281## ##STR282## ##STR283## ##STR284## H ##STR285## ClO.sub.4 (58) (II) ##STR286## ##STR287## ##STR288## ##STR289## ##STR290## BF.sub.4 (59) (II) ##STR291## ##STR292## ##STR293## ##STR294## Cl ##STR295## ##STR296## (60) (II) ##STR297## ##STR298## ##STR299## ##STR300## Br ##STR301## ClO.sub.4 (61) (II) ##STR302## ##STR303## ##STR304## ##STR305## Cl ##STR306## BF.sub.4 (62) (II) ##STR307## ##STR308## ##STR309## ##STR310## H ##STR311## ClO.sub.4 (63) (II) ##STR312## ##STR313## ##STR314## ##STR315## H ##STR316## ClO.sub.4 (64) (II) ##STR317## ##STR318## ##STR319## ##STR320## Cl ##STR321## ClO.sub.4 Compound No. Formula A B D E R.sub.1 R.sub.2 R.sub.3 R.sub.4 Z m n (65) (III) ##STR322## ##STR323## ##STR324## ##STR325## H H H H Z.sub.1 1 1 (66) (III) ##STR326## H ##STR327## H CH.sub.3 H H CH.sub.3 Z.sub.2 2 2 (67) (III) ##STR328## ##STR329## ##STR330## ##STR331## -- -- -- -- Z.sub.1 0 0 (68) (III) ##STR332## ##STR333## ##STR334## ##STR335## H H H H Z.sub.1 1 1 (69) (III) ##STR336## ##STR337## ##STR338## ##STR339## H CH.sub.3 CH.sub.3 H Z.sub.2 2 2 (70) (III) ##STR340## ##STR341## ##STR342## ##STR343## -- -- -- -- Z.sub.1 0 0 (71) (III) ##STR344## ##STR345## ##STR346## ##STR347## H H H H Z.sub.2 1 1 (72) (III) ##STR348## ##STR349## ##STR350## ##STR351## -- -- -- -- Z.sub.2 0 0 (73) (III) ##STR352## ##STR353## ##STR354## ##STR355## CH.sub.3 H H CH.sub.3 Z.sub.1 1 1 (74) (III) ##STR356## ##STR357## ##STR358## ##STR359## -- -- -- -- Z.sub.1 0 0 (75) (III) ##STR360## ##STR361## ##STR362## ##STR363## H H H H Z.sub.2 1 1 (76) (III) ##STR364## H ##STR365## H H H H H Z.sub.1 2 2 (77) (III) ##STR366## ##STR367## ##STR368## ##STR369## H H H H Z.sub.1 1 1 (78) (III) ##STR370## ##STR371## ##STR372## ##STR373## -- -- -- -- Z.sub.2 0 0 (79) (III) ##STR374## ##STR375## ##STR376## ##STR377## H CH.sub.3 CH.sub.3 H Z.sub.1 1 1 (80) (III) ##STR378## ##STR379## ##STR380## ##STR381## H H H H Z.sub.1 1 1 (81) (III) ##STR382## ##STR383## ##STR384## ##STR385## -- -- -- -- Z.sub.2 0 0 (82) (III) ##STR386## ##STR387## ##STR388## ##STR389## H H H H Z.sub.1 1 1 (83) (III) ##STR390## CH.sub.3 ##STR391## CH.sub.3 H Cl Cl H Z.sub.1 1 1 (84) (III) ##STR392## ##STR393## ##STR394## ##STR395## -- -- -- -- Z.sub.1 0 0 (85) (III) ##STR396## ##STR397## ##STR398## ##STR399## H H H H Z.sub.2 1 1 (86) (III) ##STR400## ##STR401## ##STR402## ##STR403## H H H H Z.sub.2 1 1 (87) (III) ##STR404## ##STR405## ##STR406## ##STR407## H CH.sub.3 CH.sub.3 H Z.sub.1 2 2 (88) (III) ##STR408## ##STR409## ##STR410## ##STR411## -- -- -- -- Z.sub.1 0 0 (89) (III) ##STR412## ##STR413## ##STR414## ##STR415## H H H H Z.sub.2 1 1 (90) (III) ##STR416## ##STR417## ##STR418## ##STR419## -- -- -- -- Z.sub.1 0 0 (91) (III) ##STR420## ##STR421## ##STR422## ##STR423## CH.sub.3 H H CH.sub.3 Z.sub.1 1 1 (92) (III) ##STR424## ##STR425## ##STR426## ##STR427## H H H H Z.sub.2 1 1 (93) (III) ##STR428## ##STR429## ##STR430## ##STR431## -- -- -- -- Z.sub.1 0 0 (94) (III) ##STR432## ##STR433## ##STR434## ##STR435## H H H H Z.sub.1 1 1 (95) (III) ##STR436## ##STR437## ##STR438## ##STR439## H H H H Z.sub.1 0 0 (96) (III) ##STR440## ##STR441## ##STR442## ##STR443## -- -- -- -- Z.sub.2 0 0
The optical recording medium of the present invention can have the construction, for example, as shown in FIG. 1. The optical recording medium shown in FIG. 1 can be formed by providing an organic thin film 2 containing the compound selected from the compounds represented respectively by the above Formulas (I), (II) and (III), on a substrate 1.
In forming the organic thin film 2, the compounds represented respectively by the above Formulas (I), (II) and (III) can be used in combination of two or more kinds. At this time, the compounds to be used in combination may be the compounds having the same structure or compounds having different structure, and also may be mixed and dispersed with other dyes, for example, dyes of polymethine type, azulene type, pyrylium type, squarium type, croconium type, triphenylmethane type, xanthene type, anthraquinone type, cyanine type, phthalocyanine type, dioxazine type, tetrahydrocholine type, triphenothiazine type, phenanthlene type, metal chelate complex type, aminium salt type or diimonium salt type other than the compounds represented respectively by the above Formulas (I), (II) and (III), or with metals, metallic compounds or the like, for example, Al, Te, Bi, Sn, In, Se, SnO, TeO 2 , As, Cd, etc. Alternatively, the organio thin film 2 and a layer containing the dye other than the compounds of Formulas (I), (II), and (III), the metal or metallic compound may be laminated each other.
The compound selected from the compounds represented respectively by the above Formulas (I), (II) and (III) may also be contained in a binder in a dispersed state or dissolved state. Such a binder may include, for example, cellulose esters such as nitrocellulose, cellulose phosphate, cellulose sulfate, cellulose acetate, cellulose propionate, cellulose butyrate, cellulose myristate, cellulose palmitate, cellulose acetate propionate and cellulose acetate butyrate, cellulose ethers such as methyl cellulose, ethyl cellulose, propyl cellulose and butyl cellulose; vinyl resins such as polystyrene, polyvinyl chloride, polyvinyl acetate, polyvinyl butyral, polyvinyl acetal, polyvinyl alcohol and polyvinyl pyrrolidone: copolymer resins such as a styrene/butadiene copolymer, a styrene/acrylonitrile copolymer, a styrene/butadiene/acrylonitrile copolymer and a vinyl chloride/vinyl acetate copolymer, acrylic resins such as polymethyl methacrylate, polymethyl acrylate, polybutyl acrylate, polyacrylic acid, polymethacrylic acid, polyacrylamide and polyacrylonitrile, polyesters such as polyethylene terephthalate; polyacrylate resins such a poly(4,4'-isopropylidenediphenylene-co- 1,4-cyclohexylenedimethylene carbonate), poly(ethylenedioxy-3,3'-phenylene thiocarbonate), poly(4,4'-isopropylidenediphenylene carbonate coterephthalate), poly(4,4'-isopropylidenediphenylene carbonate), poly(4,4'-sec butylidenediphenylene carbonate) and poly(4,4'-isopropylidenediphenylene carbonate block oxyethylene), or polyamides, polyimides, epoxy resins, phenol resins, polyolefins such as polyethylene. polypropylene and chlorinated polyethylene, etc.
The organic thin layer 2 may also contain a surface active agent, an antistatic agent, a stabilizer, a dispersant, a flame retardant, a lubricant, a plasticizer, etc.
The organic thin film 2 can be formed by the vapor deposition, coating, spraying method or the like. However, it can be formed preferably by the coating method in view of the operation.
As an organic solvent that can be used when the organic thin film 2 is provided by coating, though variable depending on whether the above compounds are used in a dispersed state or a dissolved state, there can be used, in general, alcohols such as methanol. ethanol, isopropanol and diacetone alcohol; ketones such as acetone, methyl ethyl ketone and cyclohexanone; amides such as N,N -dimethylformamide; and N,N-dimethylacetamide; sulfoxides such as dimethylsulfoxide; ethers such as tetrahydrofuran, dioxane, and ethylene glycol monomethyl ether; esters such as methyl acetate, ethyl acetate and butyl acetate; aliphatic halogenated hydrocarbon such as chloroform, methylene chloride, dichloroethylene. carbon tetrachloride and trichloroethylene; aromatics such as benzene, toluene, xylene, monochlorobenzene and dichlorobenzene or aliphatic hydrocarbons such as n-hexane, cyclohexane and ligroin; etc.
The coating can be carried out by using coating methods such as dip coating, spray coating, spinner coating, beat coating, Meyer bar coating. blade coating, roller coating and curtain coating.
The organic thin film 2 may appropriately have a dry thickness or vapor deposited thickness of from 50 Å to 100 μm, preferably from 200 Å to μm.
The substrate I may be made of materials having a high transmittance to light used in instances in which recording and/or reproducing light is irradiated on the side of this substrate 1, and there can be used acrylic resins, polyester resins, polycarbonate resins, vinyl type resins, polysulfon resins, polyimide resins, polyacetal resins, polyolefin resins, polyamide resins, cellulose derivatives, etc. In instances in which recording and/or reproducing light is irradiated on the reverse side to the substrate 1, there may be used, in addition to the above, polyvinyl chloride, fluorine-substituted ethylene polymers, a vinyl chloride/vinyl acetate copolymer, polyvinylidene chloride, acrylic polymers such as polymethyl methacrylate, polystyrene, polyvinyl butyral, acetyl cellulose, a styrene/butadiene copolymer, polyethylene, polypropylene, polycarbonate, an epoxyacrylonitrile/butadiene/styrene copolymer, etc.
In some instances, it is possible to use various kinds or types depending on purposes, such as metallic sheets made of iron, stainless steel, aluminum, tin, copper, zinc, etc., synthetic paper, paper, fiber reinforced plastics, composite materials of metallic powder such as magnetic materials with plastics, and ceramics.
The present invention can also be made to have the construction that a subbing layer 3 and/or a protective layer 4 is/are provided as shown in FIG. 2 to FIG. 4.
The subbing layer is provided for the purpose of (a) improving the adhesion, (b) providing a barrier to water, gas, or the like, (c) improving the storage stability of the recording layers, (d) improving the reflectance, (e) protecting the substrates from solvents, (f) forming pregrooves; etc. With regard to the purpose (a), there can be used polymeric materials, for example, a variety of materials such as ionomer resins, polyamide resins, vinyl type resins, natural macromolecules, silicone and liquid rubber. With regard to the purposes (b) and (c), there can be used, in addition to the above polymeric materials, inorganic compounds, for example, SiO 2 , MgF 2 , SiO, TiO 2 , ZnO, TiN, SiN, etc., metals or semi-metals for example, Zn, Cu, S, Ni, Cr, Ge. Se, Cd, Ag, Al, etc. With regard to the purpose (d), there can be used metals, for example, Al, Ag. etc., or organic thin film of, for example, azulene dyes, methine dyes, etc. having a metallic gloss. And, with regard to the purposes (e) and (f), there can be used ultraviolet curing resins, thermosetting resins, thermoplastic resins, etc. The subbing layer may appropriately have a film thickness of from 50 Å to 100 μm, preferably from 200 Å to 30 μm.
The protective layer is provided for the purposes of protection from scratch, dust, soil, etc., improving the storage stability of the recording layers and improving the reflectance, and the materials that can be used therefor are the materials same as those for the subbing layer. The protective layer may appropriately have a film thickness of 50 Å or more, preferably 200 Å or more.
In this occasion, the above compounds represented by the above Formulas (I), (II) or (III) of the present invention may be contained in the subbing layer and/or the protective layer. The subbing layer and/or the protective layer may also contain stabilizers, flame retardants, lubricants, antistatic agents, surface active agents, plasticizers, etc.
In another constitution of the optical recording medium according to the present invention, the optical recording medium may have the so called air-sandwiched construction such that two pieces of the optical recording mediums of the constitution as shown in FIG. 1 to FIG. 4, or one piece of such optical recording medium and one piece consisting of the substrate only, are hermetically stuck together, with the interposition of spacers and with the organic thin film 2 facing inwardly.
There is no particular limitation in the shape of the optical recording medium according to the present invention, and there may be included, for example, disc- or card-like ones.
In the present invention, it is possible to carry out the recording on the organic film by irradiation with a gas laser beam such as an argon laser beam (oscillation wavelength: 488 nm), a helium/neon laser beam (oscillation wavelength: 633 nm), a helium/cadmium laser beam (oscillation wavelength: 442 nm), etc, but more suitable is a method in which the recording is carried out by irradiation with a laser beam preferably having an oscillation wavelength of 750 nm or more, inparticular, a laser beam having the oscillation wavelength at the near infrared or infrared region, such as a gallium/aluminum/arsenic semiconductor laser beam (oscillation wavelength: 830 nm).
The writing can also be performed with a good sensitivity even by irradiation from a semiconductor laser that oscillates light of the visible light region.
In the optical recording medium according to the present invention, the irradiation, for example, of the light as mentioned above causes changes in shape of the recording layer at the irradiated parts by fusion or sublimation, and thus the pits are formed.
For carrying out the reading, the above laser beams can also be used. Here, the writing and reading can be carried out with use of laser beams having the same wavelength, or can be carried out with use of laser beams having the different wavelength.
The optical recording medium and the process for preparing the same can bring about the effect as follows:
(1) The organic film has greater absorption bands at a long wavelength region such as the near infrared region and at a visible light region, and can achieve recording in a high sensitivity with use of semiconductor lasers or the like.
(2) Pits with good shape can be formed, and a high C/N ratio can be obtained.
(3) There can be achieved a high stability to heat and light, excellent storage stability, and less reproduction deterioration to be caused by reproducing light.
EXAMPLES
The present invention will be described below in greater detail in line with Examples, but the present invention is by no means limited to these.
EXAMPLE 1
On a polymethyl methacrylate (hereinafter referred to as "PMMA") substrate of 130 mm in diameter and 1.2 mm in thickness, a pregroove of 50 μm in thickness was provided by use of an epoxy/acrylate type ultraviolet curing resin and according to the 2P process (a photopolymer process), and a solution obtained by dissolving 2 parts by weight of the compound of Compound No. (16) listed above in 98 parts by weight of dichloroethane was coated thereon according to spinner coating, followed by drying to obtain an organic thin filmy recording layer of 800 Å.
The optical recording medium thus prepared was fitted on a turn table, and the turn table was rotated at 1,800 rpm with a motor. Information was written in the organic thin filmy recording layer from the substrate side by use of a semiconductor laser of an oscillation wavelength of 830 nm and with a spot size of 1.5 μm in diameter, recording power of 6 mW and recording frequency of 2 MHz, and reproduced with a read-out power of 1.0 mW. The thus reproduced wave form was subjected to spectrum analysis (a scanning filter; band width: 30 kHz) to measure the C/N ratio (carrier/noise ratio).
Next, in regard to the same recording medium, measured under the above measurement conditions was the C/N ratio after the recorded part was repeatedly read out 10 5 times.
Further measured were transmittance (830 nm measurement) and C/N ratio after a same recording medium prepared under the above conditions was left to stand for 2,000 hours under the conditions of 60° C. and 95% RH to carry out an environmental storage stability test. Also measured were transmittance (830 nm measurement) and C/N ratio after xenon lamp light of 1,000 W/m 2 (300 to 900 nm) was irradiated on the same recording medium for 70 hours to carry out a light-resisting stability test.
EXAMPLES 2 TO 27
Example 1 was repeated to prepare optical recording mediums of Examples 2 to 27, except that the compound No. (16) used in Example 1 was replaced by the above compound No. (3), (4), (11), (14), (20), (22), (24), (29), (42), (35), (36), (39), (41), (44), (48), (53), (58), (77), (67), (70), (71), (74), (81), (85), (87) and (89), respectively.
The every sort of test was carried out on the above optical recording mediums of Examples 2 to 27 in the same manner as in Example 1.
EXAMPLES 28 AND 29
The compound No. (97) shown below and the above compound No. (10) were mixed in dichloroethane in weight ratio of 1:1, and the resulting mixture was used to provide an organic thin filmy recording layer of 850 Å in dried thickness in the same manner as in Example 1 to prepare an optical recording medium of Example 28. Also prepared was a optical recording medium of Example 29 in the same manner as in Example 28 but using the compound No. (98) shown below in place of the compound No. (97) used in Example 28. On the optical recording mediums of Examples 28 and 29 thus obtained, the every sort of test was carried out in the same manner as in Example 1. ##STR444##
EXAMPLES 30 and 31
Optical recording mediums of Examples 30 and 31 were prepared in the same manner as in Examples 28 and 29 but using the compound No. (43) in place of the compound No. (10) used in the above Examples 28 and 29. On the optical recording mediums of Examples 30 and 31 thus obtained, the every sort of test was carried out in the same manner as in Example 1.
EXAMPLES 32 AND 33
Optical recording mediums of Examples 32 and 33 were prepared in the same manner as in Examples 28 and 29 but using the compound No. (75) in place of the compound No. (10) used in the above Examples 28 and 29. On the optical recording mediums of Examples 32 and 33 thus obtained, the every sort of test was carried out in the same manner as in Example 1.
EXAMPLE 34
A solution obtained by mixing 2 parts by weight of the compound of Compound No. (9) previously shown and 1 part by weight of nitrocellulose resin (OH-less Lacquer; available from Daisel Ltd.) in 97 parts by weight of methyl ethyl ketone was coated according to the spinner coating method on a PMMA substrate of 130 mm in diameter and 1.2 mm in thickness provided with a pregroove, to prepare an organic thin filmy recording layer of 1,000 Å in dried thickness.
The every sort of test was carried out on the resulting optical recording medium of Example 34 in the same manner as in Example 1.
EXAMPLES 35 to 46
Optical recording mediums were prepared in the same manner as in Example 12 but replacing the compound No. (9) used in Example 34 above by the compounds Nos. (6), (18), (25), (49), (37), (47), (61), (83), (68), (78) and (88), respectively, to prepare optical recording mediums of Examples 35 to 45.
On the optical recording mediums of Examples 35 to 45 above thus obtained, the every sort of test was carried out in the same manner as in Example 1.
EXAMPLES 46 AND 47
In a molybdenum boat 500 mg of the compounds of Compounds Nos. (1) and (19) previously shown were introduced and, after evacuation to 1×10 -6 mmHg or less, vapor deposition was carried out on PMMA substrates of 130 mm in diameter and 1.2 mm in thickness provided with a pregroove. While controlling the pressure in the vacuum chamber with use of a heater so as not to increase to 10 -5 more during the vapor deposition, organic thin filmy recording layers of 950 Å were formed to prepare optical recording mediums of Examples 46 and 47, respectively.
On the optical recording medium of Examples 46 and 47 thus obtained, the every sort of test was carried out in the same manner as in Example 1.
EXAMPLES 48 AND 49
Example 46 was repeated but using the compound No. (33) in place of the compound No. (1) used in Example 46 above, to prepare an optical recording medium of Example 48.
Example 46 was also repeated but using the compound No. (38) in place of the compound No. (19) used in Example 47 above, to prepare an optical recording medium of Example 49. On the optical recording medium of Example 49 thus obtained, the every sort of test was carried out in the same manner as in Example 1.
EXAMPLES 50 AND 51
Example 46 was repeated but using the compound No. (65) in place of the compound No. (1) used in Example 46 above, to prepare an optical recording medium of Example 50.
Example 46 was also repeated but using the compound No. (77) in place of the compound No. (19) used in Example 47 above, to prepare an optical recording medium of Example 51. On the optical recording medium of Example 51 thus obtained, the every sort of test was carried out in the same manner as in Example 1.
Results of the above are shown in Table 1.
TABLE 1__________________________________________________________________________ Environmental Light-resisting Repeated storage stability stability: Initial reproduction 60° C., 95% RH, xenon lamp 1,000Exam- Com- stage 10.sup.5 times after 2,000 hours W/m.sup.2 after 70 hrple pound X Y Y X Y X YNo. No. (%) (dB) (dB) (%) (dB) (%) (dB)__________________________________________________________________________ 1 (16) 25 50 47 27 48 29 45 2 (3) 24 48 45 27 46 30 42 3 (4) 24 52 49 26 49 28 46 4 (11) 23 52 48 27 48 29 45 5 (14) 25 50 46 29 47 30 41 6 (20) 25 49 45 29 45 32 40 7 (22) 24 50 47 26 47 29 44 8 (24) 26 47 42 29 40 33 38 9 (29) 23 51 47 26 48 28 4510 (42) 15 55 50 20 51 24 4611 (35) 12 56 51 16 51 20 4712 (36) 14 54 50 19 49 22 4613 (39) 18 52 49 21 46 24 4414 (41) 12 57 53 18 51 21 5015 (44) 15 54 51 19 51 22 4616 (48) 16 53 49 20 50 23 4717 (53) 21 50 47 24 48 28 4218 (58) 17 51 48 21 49 25 4519 (77) 21 55 50 23 54 29 4720 (67) l9 53 48 23 50 25 4521 (70) 19 54 48 24 51 26 4822 (71) 23 49 42 27 42 29 4023 (74) 18 56 53 21 54 23 5124 (81) 21 52 50 24 50 26 4825 (85) 20 55 52 21 53 25 5026 (87) 20 53 51 23 51 26 4827 (89) 24 50 48 25 46 29 45 (10) 22 54 50 26 45 29 4228 (97) (10) 17 57 53 20 52 25 4929 (98) (43) 20 51 47 25 47 28 4330 (97) (43) 15 56 52 18 51 21 4931 (98) (75) 21 52 49 24 48 27 4532 (97) (75) 18 56 54 20 54 22 5133 (98)34 (9) 24 53 50 26 48 29 4435 (6) 22 52 48 27 46 30 4236 (18) 26 48 44 29 43 31 4037 (25) 25 50 45 27 45 33 4238 (49) 16 53 50 19 49 23 4639 (37) 15 54 52 19 50 21 4840 (47) 12 57 51 16 52 19 4941 (68) 13 55 53 17 51 21 4842 (83) 22 55 51 25 52 27 5043 (68) 23 52 49 25 50 26 4844 (78) 21 53 51 26 49 26 4845 (88) 22 51 47 27 49 27 4646 (1) 25 50 46 27 48 29 4447 (19) 22 52 49 25 50 29 4548 (33) 21 49 47 24 48 28 4449 (38) 19 51 48 22 49 25 4650 (65) 25 50 47 28 48 29 4551 (77) 22 54 50 26 51 28 48__________________________________________________________________________ X: Transmittance Y: C/N ratio
EXAMPLE 52
On a polycarbonate (hereinafter referred to as "PC") substrate of 0.4 mm in thickness and of Wallet size, a pregroove was provided by hot pressing, and coated thereon by bar coating was a solution obtained by mixing 4 parts by weight of the compound of Compound No. (21) previously shown in 96 parts by weight of diacetone alcohol, followed by drying to obtain an organic thin filmy recording layer of 1,000 Å. Further provided thereon in close contact by a heated roll process through an ethylene-vinyl acetate dry film was a PC substrate of 0.3 mm in thickness and of wallet size to prepare an optical recording medium of Example 52 of close contact structure.
The optical recording medium of Example 52 thus prepared was fitted on a stage that drives in the direction of X - Y, and information was written in the organic thin filmy recording layer in the direction of Y, using a semiconductor laser of an oscillation wavelength of 830 nm, from the side of the PC substrate of 0.4 mm thick, and with a spot size of 3.0 μm in diameter, recording power of 4.0 mW and recording pulse of 80 μsec, which information was reproduced with a read out power of 0.4 mW, to measure the ratio of the contrast thus formed (A--B)/A; A=signal intensity at a non-recorded portion, B=signal intensity at a recorded portion.
The environmental storage stability test and light-resisting stability test were also carried out on this optical recording medium in the same manner as in Example 1, and thereafter the transmittance and contrast ratio were measured.
EXAMPLE 53
Example 52 was repeated but using the compound No. (48) in place of the compound No. (21) used in Example 52 above, to prepare an optical recording medium. On the optical recording medium of Example 53 thus obtained, the every sort of test was carried out in the same manner as in Example 52.
EXAMPLE 54
Example 52 was repeated but using the abovementioned compound No. (89) in place of the compound No. (21) used in Example 52 above, to prepare an optical recording medium. On the optical recording medium of Example 54 thus obtained, the every sort of test was carried out in the same manner as in Example 52.
Results of the above are shown in Table 2.
TABLE 2______________________________________ Evironmental Light- storage resisting stability: stability: 60° C., 95% RH, xenon lamp, Initial after 2,000 1,000 W/m.sup.2Exam- Com- stage hours after 70 hrple pound X X XNo. No. (%) Y' (%) Y' (%) Y'______________________________________52 (21) 20 0.70 23 0.66 28 0.5953 (48) 21 0.70 23 0.68 28 0.6054 (89) 17 0.72 20 0.70 25 0.65______________________________________ X: Transmittance Y': Contrast ratio
COMPARATIVE EXAMPLE 1
Using as a comparative example a mixture obtained by mixing only the compound No. (97) used in Example 28 in dichloroethane, an organic thin filmy recording layer of 850 Å in dried thickness was provided in the same manner as in Example 1 to prepare an optical recording medium of Comparative Example 1.
On the optical recording medium of Comparative Example 1 thus obtained, the every sort of test was carried out in the same manner as in Example 1. Results obtained are shown in Table 3.
TABLE 3__________________________________________________________________________ Environmental Light-resisting Repeated storage stability stability: Initial reproduction 60° C., 95% RH, xenon lamp 1,000 stage 10.sup.5 times after 2,000 hours W/m.sup.2 after 70 hrCompound X Y Y X Y X YNo. (%) (dB) (dB) (%) (dB) (%) (dB)__________________________________________________________________________Comparativeexample:1 (97) 21 47 41 35 36 41 32__________________________________________________________________________ X: Transmittance Y: C/N ratio
|
An optical recording medium comprises an organic film, wherein said organic film contains at least one compound selected from the compounds represented by Formulas (I), (II) and (III).
| 8
|
PRIOR APPLICATION DATA
[0001] The present application claims priority from prior UK application 0606965.2 filed Apr. 6, 2006, incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to video processing and display. For example, some embodiments aim to provide a viewer with a wider field-of-view—leading to a greater sense of immersion than a traditional video presentation—without requiring a larger television or display screen.
BACKGROUND OF THE INVENTION
[0003] Traditional television viewing in domestic environments usually includes a single, television monitor. In some situations, a flat-screen display or projector may be used to provide a larger viewing area. It is reasonably common for viewers to choose to augment or replace the audio capabilities of the display with an external stereo or surround sound hi-fi system.
[0004] One known system (Philips Ambilight FlatTV TM) includes a built in soft light, which emanates onto the wall surrounding the television and aims to provide a more relaxed viewing environment as well as to improve the perceived picture detail, contrast and color. The color of the surrounding light may be adjusted in line with prevailing colors in the screen image, but there is no further image information. Thus this may improve perception but does not provide any real sense of enhanced “immersion” in the scene, as it occupies only a small proportion of the viewer's visual field, and is only very weakly related to the picture content.
[0005] Watching a broadcast television program or a DVD film in the home thus provides a very different experience from viewing ‘real world’ scenes. The angle subtended by the video image to the eye is only a few degrees at either optimum or typical viewing distances. Much of the field of view of the eye is filled with the viewing environment—the living room furniture, wall decoration, and so on.
[0006] Conventional methods for achieving a wide-angle display, such as IMAX, require a very high-definition camera and display system, and are unsuitable for use in a domestic environment. The data rate required to deliver such a high-definition image over a broadcast link makes deploying such a system impractical.
[0007] Furthermore, were such a system to be set up in a domestic environment, any conventional TV set would have to be removed to make space, interfering with viewing of conventional TV.
SUMMARY OF THE INVENTION
[0008] Embodiments of the present invention seek to provide an improved viewing system alleviating the drawbacks of the above-mentioned systems. Advantageously, embodiments may be backwards compatible with existing television equipment.
[0009] In one aspect, an embodiment of the present invention includes a method of providing a video display comprising the steps of providing a primary video display in a primary display region; providing a surround video display in a region surrounding the primary display region, wherein the surround video display is of lower quality than the primary video display.
[0010] The primary video display may be provided by a primary display device having a dedicated screen area. The primary video display may be provided by a device having an active screen. The surround video display may be provided by projection onto at least one object surrounding the primary display device. An embodiment may compensate the projected surround video display based on the geometry of an object. Apparent motion of at least one object in the primary video display may be extrapolated into the surround video display.
[0011] In another aspect, an embodiment of the present invention includes a method of providing a video display comprising providing a primary video display in a primary display region; and providing a surround video display in a region surrounding the primary display region, wherein the surround video display is of lower resolution than the primary display and wherein the surround video display extends over a substantially larger field of view than the primary display.
[0012] The primary video display may be provided on a primary display device and the surround video display may be provided by projection onto at least one object surrounding the primary display device. An embodiment may receive at least one encoded video signal and provide a primary signal to cause the primary display device to display the primary video and a surround signal to cause a surround video projector to display the surround video. The surround signal may include information for use in synthesizing surround information based on the primary video signal Synthesizing at least a part of a surround video signal based on the content of a primary video signal may be performed Apparent motion of at least one object in the primary video display may be extrapolated into the surround video display. A surround video signal may be provided by transforming generic surround images in real time based on the geometry of the surroundings of the primary video display.
[0013] A primary representation may include a primary video signal and a surround representation may include a surround video signal which is more coarsely quantized or encoded at a lower bit rate than the primary video signal. In another aspect, an embodiment of the present invention includes a method of distributing video content, comprising supplying a primary representation of a first view of a scene which representation is decodable to provide a primary video display; and supplying a surround representation of a second view of the scene, being a wider angle view than said first view, which surround representation is separately decodable to provide a surround video display in a region surrounding the primary display region.
[0014] In another aspect, an embodiment of the present invention includes a method of distributing video content, comprising supplying a primary representation of a first view of a scene which representation is decodable to provide a primary video display; and supplying surround information which surround representation is separately decodable to provide a surround video display in a region surrounding the primary display region such that apparent motion of at least one object in the primary video display is extrapolated into the surround video display.
[0015] In another aspect, an embodiment of the present invention includes video processing apparatus comprising an input stage for receiving a video input; a primary display driver connected with the input stage and adapted to provide a primary video signal for a primary display on a screen in a room; and a surround video processor connected with the input stage and adapted to provide a surround video signal for a surround display projected onto surfaces of the room adjacent the screen, the surround video processor being adapted to hold geometrical parameters of said surfaces and to compensate in said surround video signal for said parameters.
[0016] The surround video processor may for example mask the area of the screen in the surround video signal. A masking area corresponding to the primary video display may be defined.
[0017] In another aspect, an embodiment of the present invention a includes video processing apparatus comprising an input stage for receiving a video input; a primary display driver connected with the input stage and adapted to provide a primary video signal for a primary display; a surround video processor connected with the input stage adapted to provide a surround video signal for a surround display in which the trajectory of moving objects represented in the primary display is extrapolated into the surround display.
[0018] In another aspect, an embodiment of the present invention includes a method of calibrating a video display apparatus including a primary video display and a surround video projector, the method comprising registering the projector and primary video display so that the projected surround video surrounds but does not substantially overlap the primary video display.
[0019] In another aspect, an embodiment of the present invention includes a method of calibrating a video display apparatus including a primary video display and a surround video projector, the method comprising storing data indicative of the geometry and/or reflectivity and/or color of the surroundings of the primary video display for use in modifying a surround video image to be projected onto the surroundings.
[0020] In another aspect, an embodiment of the present invention includes video processing apparatus means for receiving video information; means for outputting a signal to a primary video display; surrounding object information storage means, store, or memory; image transformation means for transforming surround video image data based on the stored surrounding object information and means for outputting a surround video signal to a surround projector.
[0021] In another aspect, an embodiment of the present invention includes a system comprising a primary display driver for outputting a signal to a primary video display; a surrounding object information store or memory; an image transformation processor for transforming surround video image data based on the stored surrounding object information; a surround video display driver for outputting a surround video signal; and a surround projector receiving the surround video signal.
[0022] In another aspect, an embodiment of the present invention includes video capture apparatus comprising; primary video capture means for capturing primary video corresponding to at least one broadcast standard for a primary field of view; surround video capture means for capturing surround video for a surround field of view surrounding the primary field of view. The surround video capture means may capture video overlapping with or encompassing the primary field of view.
[0023] In another aspect, an embodiment of the present invention includes a processor, computer program or computer program product or logic or video processing hardware configured to perform a method comprising the steps of receiving at least one encoded video signal; providing a primary signal to generate a primary video display on a primary display device; providing a surround signal to generate a surround video display by projection onto at least one object surrounding the primary display device wherein apparent motion of at least one object in the primary video display is extrapolated into the surround video display.
[0024] It will be appreciated that there is considerable correspondence between capture and playback and processing features. For conciseness features are generally identified herein in a single context; method features may be provided as apparatus features (or computer code or program features) and vice versa and features of the capture system may be applied to the playback system and vice versa unless otherwise explicitly stated or clearly implied by context.
[0025] Embodiments may fill a large portion of the eye's view—both the central and peripheral vision areas—and thereby increase the sense of immersion in the presented scene.
[0026] In a preferred embodiment it is proposed that, a secondary (high definition) camera fitted with a wide angle or fish-eye lens is associated with and, typically, rigidly mounted to the main camera. While the main camera records action as usual, the secondary camera records the surrounding scene. The fish eye lens may have close to 180° field of view. The precise field of view and other characteristics of the secondary camera are not critical to this invention.
[0027] Both main and secondary recordings may be made available as two separate but synchronous video streams. Those viewers with the required playback equipment can use the second ‘surround’ video stream to project an image onto the walls, floor and ceiling of their viewing environment and substantially fill their field of view. Real-time image manipulation software is preferably provided to remove the distortion imposed on the image by the geometry (or other characteristics) of the room. The portion of the projected image that would fall on the normal TV display is typically blanked, but may be at a lower intensity so as not to be problematic.
[0028] Thus, a high-resolution video image is displayed on a smaller screen in the centre of the viewer's gaze. The second ‘surround’ video is displayed over a much larger area filling the viewer's peripheral vision. Because of the large surface area over which the secondary stream is displayed, it is perceived as a lower resolution image.
[0029] Those with only regular viewing equipment are free to watch the standard video stream as usual.
[0030] In cases where it is impossible or impractical to capture a contemporaneous “surround” video recording (or for use with archive or other video that was not captured using a secondary camera as described above), embodiments of the present invention contemplate analysis of the main video image (and possibly also the audio soundtrack) to synthesize a surround video stream, which is related to the main video image spatially, by color and by motion (of main camera or of objects in the scene) as examples.
[0031] The ‘surround’ video image will generally be of lower quality than the main image: it will almost certainly be of lower spatial resolution, it is likely to be dimmer, and is likely to show some residual distortion due to failures to accurately compensate for the geometry of the walls. However, since the programme being viewed will have been shot so as to put the main focus of interest on the conventional display (as the programme will generally be shot to look sensible for viewers without the benefit of the surround image), the viewer's attention will usually be concentrated on this display. The main task of the ‘surround’ image is to provide information for the viewer's peripheral vision, where requirements for resolution and other aspects of image quality are generally lower.
[0032] A mode selector may allow selecting at least one synthetic surround video signal or no signal in the absence of received or stored information providing the surround video signal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] The principles and operation of embodiments of the present invention may be better understood with reference to the drawings, and the following description, it being understood that these drawings are given for illustrative purposes only and are not meant to be limiting, wherein:
[0034] FIG. 1 shows a capture system;
[0035] Fig. 2 shows a playback system;
[0036] FIG. 3 shows a recording and delivery system;
[0037] FIG. 4 illustrates extrapolation from a primary image; and
[0038] FIG. 5 illustrates alternative extrapolation from a primary image.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0039] The following description is presented to enable one of ordinary skill in the art to make and use the invention as provided in the context of a particular application and its requirements. Various modifications to the described embodiments will be apparent to those with skill in the art, and the general principles defined herein may be applied to other embodiments. Therefore, the present invention is not intended to be limited to the particular embodiments shown and described, but is to be accorded the widest scope consistent with the principles and novel features disclosed. In some cases, well-known methods, procedures, and components have not been described in detail so as not to obscure the present invention.
[0040] Referring to FIG. 1 , two cameras 10 and 11 are used which are rigidly mounted together in a frame. The cameras can be handheld, mounted on a tripod or supported in any other appropriate manner. The main camera 10 is free to be moved to frame shots as usual; the second camera 11 may be fitted with a fish-eye lens, such that it captures a very much wider field of view than the main camera and is used to record the surround video stream The surround video stream captures the environment in which the scene was recorded, putting it into better context.
[0041] The cameras are frame-synchronized. A clapperboard may be used, as is common in television and film productions; the synchronism could equally be provided electronically using genlock and time code.
[0042] Referring to FIG. 2 , an existing video playback system (which is assumed to comprise of a video display, with internal or external audio capabilities) is supplemented with a projector The standard display system is used to present the main video stream, as usual. This may comprise a “conventional” television, which term is intended to encompass without limitation a cathode ray tube, plasma screen, liquid crystal display and may be analogue, digital, high definition. It may also include a video projection screen onto which an image is projected by a video projector, which may or may not be integrated with the projector to be described below.
[0043] In one example of a system according to this invention, a projector 20 is used to project the wide field-of-view video stream onto the walls ( 40 a - d ), ceiling and floor of the viewing environment. The wide-angle projection is obtained by using a conventional video projector 20 and a curved mirror 21 .
[0044] Referring to FIG. 3 , there is provided a system for recording a surround video stream, delivering said stream to a user and displaying the stream The image capture system comprises two cameras as before—one for the main image 10 and a second 11 , with a fish-eye lens; this provides the video stream The video is then processed in editing and post-production 41 . When the zoom of the main camera changes, the scale factor for the surround image may be adjusted accordingly. Image-based analysis 42 can occur by, for example:
[0045] i analyzing the main and surround images in order to deduce their relative scale factors (many techniques in the field of image processing are known which could be used for this task, for example correlation-based methods, object matching or recognition, or motion estimation) or
[0046] ii analyzing data from sensors attached to the camera lenses that indicated their focal length.
[0047] Similar techniques could be used to determine or specify the relative positioning of the main and surround video (for example, the surround video may be centered on the main image, or it may be centered a little way above, to give a more extensive view of objects above the camera rather than below). This analysis could also be carried out later at the end-user. The video stream is delivered via broadcast or physical media 50 to the user. Upon delivery, geometric correction is performed to correct distortions due to the viewing environment 43 ; in addition image-based analysis may be carried out, especially in cases where no surround video stream was recorded. Real-time video manipulation software may be used to remove the distortion imposed on the image by the fixed geometry of the room. This software performs additional scaling of the surround image, such that it correctly matches the scale of objects shown in the main video. Re-timing of the two video streams occurs 44 in order to compensate for processing delays. The main image is displayed on a video display 30 such as an LCD monitor. The peripheral image is projected onto the viewing environment 40 by a projector 20 or projecting system as depicted in FIG. 2 .
[0048] For cases where no surround video stream was recorded, the video may be analyzed to synthesize a surround video stream. A number of example algorithms are suggested here; any one of these or combinations or modifications may be used.
[0049] 1. Edge Color Extrapolation
[0050] To provide a wider surround view from existing video material it is proposed to synthesize a surround video signal. This signal contains aspects of the motion and the predominant color from the edges of the original image. The use of the predominant edge color allows the extended view to match the background color in the video and so providing a basic sense of being surrounded by the scene Motion in the original image is represented in the synthesized view to give extra movement cues to the viewer so that movement on the. conventional display is also represented on the surrounding view.
[0051] To extract basic motion and color from the edges of the conventional image, the average color is taken from blocks of pixels from around the edge of the image and replicate them to fill the larger surround image.
[0052] Referring to FIG. 4 , this averaging process is done for each pixel along a border 33 within the edge of the image 31 . This border is smaller than the picture size to take into account any letterboxing or pillar boxing black borders of the image. For each pixel along the line of this border the n×n block of pixels 32 containing the border pixel is averaged together to find the average color for the block. The resulting color for the block is then replicated within the surround video image 32 across a line 35 from where original pixel lines up within the larger surround image to the edge of the projected view.
[0053] The area within the surround image that the conventional display fills is then set to black in the image This stops light from the projected surround image landing on the conventional display. The brightness of the synthetic image can also be adjusted so that pixels get darker the further they are from the centre of the image to fade out the surround view.
[0054] This approach works well for the sides of the display. Motion within the synthetic view matches well with the original image and appears somewhat like the change of reflected light caused by the movement of the foreground objects. The extent to which motion and textural detail are represented in the surround view can be controlled by the size of the averaging blocks. The sizing of the averaging border also can be used to control the extent to which objects within the foreground of the scene occur within the surround image.
[0055] However, this approach may have limitations at the corner areas of the surround view as a single pixel block value is replicated to fill an entire corner area of the larger image. To minimize the effect of this, filtering may be performed on the entire synthesized view to the smooth the transition between the sides and the corners of the surround image.
[0056] 2. Radial Color Extrapolation
[0057] An alternative synthesis algorithm—presented in FIG. 5 —uses the averaging technique as described above, but generates the ‘Surround Video’ image 32 by extrapolating the location of each pixel in the ‘Surround’ image back to the centre of the original video image 31 and coloring it according to the color of the pixel on the edge of the original image which lies closest to the line 36 extrapolated between the centre pixel and the ‘Surround Video’ pixel.
[0058] 3. Measurement of Object or Camera Motion to Render a Moving Texture Pattern
[0059] Motion cues can be one of the more important cues to come from peripheral vision. Therefore one method of synthesizing the surround video is to generate an image with motion properties that match those of the main image. For example, a pseudo-random texture could be generated, which is moved in accordance with the estimated movement of the camera. Thus, when the camera pans left, the texture is moved to the left at a rate that matches the movement in the main image. Alternatively, instead of using a pseudo-random texture, some features of the image (such as fine detail) could be extracted and replicated to fill the surround image, in such a way that motion in the main image results in the replicated texture moving at a matching speed in the surround image.
[0060] By taking just the fine detail from the image, the replication process can be substantially hidden, resulting in a texture with an apparently random appearance, but which moves in largely the same way as the content of the main image. The low frequencies in the surrounding image could be synthesized using one of the color extrapolation methods described above.
[0061] 4. Extrapolation of Image Texture Using Object or Camera Movement
[0062] Having analyzed object movement in a video image (extracting object size and position over time to derive its speed, direction and possibly its acceleration), a representation of moving objects can be synthesized in the surround video image.
[0063] The analyzed movement properties are applied to the object being rendered in the surround image, giving the impression that it continues traveling off to the sides (or top or bottom) of the main image. Similar techniques could be applied to camera rather than object movement (that is, by measuring the apparent movement of the background), to build up a wide-angle image using a method similar to the well-known ‘image stitching’ approach used to build panoramic images from a series of overlapping still images. This kind of processing would preferably process an entire image sequence before producing any synthesized surround video, because information for a given frame may usefully be taken from both preceding and following points in time. It thus may be more applicable as a pre-processing stage, implemented by the broadcaster to generate a surround video channel before the video was delivered. Alternatively, the processing could take place using stored content in a domestic device (such as a PC with a DVD drive) to generate the surround video for a programme or film before viewing it
[0064] An example of the steps involved in this image synthesis process is as follows:
1. For each video frame, segment it into objects having different motions. Methods are known to achieve such segmentation, see for example Chung, H Y. et al “Efficient Block-based Motion Segmentation Method using Motion Vector Consistency”. In Proc. IAPR Conference on Machine Vision Applications (MVA2005), pages 550-553, Tsukuba Science City, Japan, May 2005 (http://www csis.hku.hk/˜kykwong/publications/hychung —mva 05.pdf) 2. For each object, look through the list of objects that have been seen before, and identify a corresponding object, by matching parameters such as object size, location, and direction of movement. Update the stored motion vector, size, shape and image information associated with the matching object, using the information from the current frame. If parts of the object are no longer visible due to having moved outside the image or having moved behinds another object, leave the shape and image information for these parts unchanged. If no corresponding object has been seen before, create a new object on the list of observed objects. 3. For all objects in the list, delete those that were expected to be seen in the current frame and were not. For those that were not expected to be seen (i.e. those that lie wholly outside the image), update their location by assuming they continue moving at constant velocity. 4 Synthesize an initial surround video image using one of the methods mentioned earlier, such as Edge Color Extrapolation. 5. For each object in the list that lies partly or wholly outside the image, draw the object using its stored location and image data at the appropriate position into the synthesized surround video image. Optionally, the objects may be drawn with a transparency level or degree of low-pass filtering that increases in accordance with the length of time since the object disappeared from the main image, or the distance it has traveled.
[0070] A number of alternative implementations are possible and the embodiments described above are in no way exhaustive or limiting. Some possibilities for modification include:
Using a projector rather than CRT or flat-screen display to present the main video stream. Using a projector with a wide angle lens to present the surround video image Using any other future video display device (such as electronic wallpaper) to show either the main or surround video image. In the case of proposals such as electronic wallpaper (which can be based on liquid crystal display technology), driving of the wallpaper shall be construed as “projection” onto the surrounding objects. Using a single high-resolution camera with wide-angle lens to capture the footage, and electronically extracting a centre portion to create the main video stream.
[0075] Other known techniques could be incorporated to enhance a projection-based surround video system. For example, methods are known to perform accurate compensation of projected images when projecting onto irregular surfaces with varying reflectivity, such as may be found in a typical home environment. An example of such a method is described in “Bimber, O et al. Enabling View-Dependant Stereoscopic Projection in Real Environments., Fourth International Symposium on Mixed and Augmented Reality, October 5-8, Vienna, Austria, pp. 14-23”.
[0076] To apply such a method, one approach would be to use a camera to capture images of a series of projected calibration patterns. The camera should preferably be placed at the position of a typical viewer's head (e.g. someone sitting in the middle of the sofa in a living room), although alternatively for convenience it could be integrated into the projector unit. The calibration patterns could consist of a series of lines, dots or squares in different positions in the projected image. By analyzing the captured image of each projected pattern, it is possible to calculate the geometric, brightness and color corrections that should be applied to the projected image in order to compensate for the non-ideal geometry and reflectivity of the walls onto which the image is being projected. The captured images could also be analyzed to determine the location and size of the main display screen, which would allow the scaling and positioning of the projected image to be adjusted to match.
[0077] The foregoing description of the embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. It should be appreciated by persons skilled in the art that many modifications, variations, substitutions, changes, and equivalents are possible in light of the above teaching. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.
|
To supplement a video display on a conventional television, a surround video stream may be projected onto wall and other surfaces adjacent the television. The surround video stream may derive from a wide angle lens camera positioned alongside the main camera. The surround video stream may be processed in a local processor to compensate for departures from planar geometry in the wall surfaces. Where no surround video stream is received, a video processor may synthesize a surround video stream from the main video signal. Moving objects represented in the main video signal may be synthesized in the surround video to provide the perception of movement across the viewer's full field of view.
| 6
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus for unlocking a door lock for a vehicle, in which collision direction detecting means detects a side of a vehicle on which a collision has occurred, and an unlocking mechanism unlocks a door located on a side opposite to the detected collision side.
2. Description of the Prior Art
In a conventional door unlocking apparatus (Japanese Patent Application Laid-Open No. (kokai) 58-11275) shown in FIG. 16, when a vehicle undergoes a collision, an inertia lever L swings in the clockwise direction due to inertial force of a weight W disposed at the lower end of the inertia lever L. As a result, a bell crank B is swung in the clockwise direction so that all the doors are unlocked via an intermediate rod R, thereby allowing vehicle occupants to be rescued.
In the conventional door unlocking apparatus, even a door close to a position where a collision has occurred is unlocked. Therefore, there is a possibility that a door close to a position where a collision has occurred cannot be unlocked smoothly due to the impact of the collision, or the door cannot be unlocked at all. Accordingly, the conventional door unlocking apparatus has a drawback that it carries out considerably useless operations.
SUMMARY OF THE INVENTION
It is a primary object to smoothly and securely unlock a door lock located on a side opposite to a collision side of a vehicle.
It is another object to rescue vehicle occupants when a collision of a vehicle occurs.
It is a further object to provide a door unlocking apparatus based on a technical idea of unlocking a door lock located on a side opposite to a collision side of a vehicle.
It is a still further object to provide an apparatus for unlocking a door lock for a vehicle, comprising: a plurality of door locks for being mounted on doors of the vehicle; collision direction detecting means for detecting a direction of an impact applied to the vehicle; and an unlocking mechanism for unlocking a door lock mounted on a side opposite to a collision side based on the direction detected by the collision direction detecting means.
It is a still further object to provide an apparatus for unlocking a door lock for a vehicle wherein the collision direction detecting means detects an impact on the front side or rear side of the vehicle.
It is a yet further object to provide an apparatus for unlocking a door lock for a vehicle wherein the collision direction detecting means detects an impact on the left side or right side of the vehicle.
It is a yet further object to provide an apparatus for unlocking a door lock for a vehicle wherein the collision direction detecting means comprises a collision detecting mechanism including a plurality of movable members which correspond to sides at each of which a collision will occur and which moves due to an impact caused by a collision of the vehicle, and that the movement of the movable member is transmitted to the unlocking mechanism located at a side opposite to a collision side.
It is another object to provide an apparatus for unlocking a door lock for a vehicle wherein the moving member comprises a swing member which has a weight functioning as an inertia mass at the time of a collision of the vehicle, and which swings about a single supporting point in the direction of an inertial force opposite to the direction of the impact of the collision.
It is a still further object to provide an apparatus for unlocking a door lock for a vehicle the collision direction detecting means comprises an acceleration sensor for detecting the direction of an impact acceleration when a collision of the vehicle occurs.
It is a yet further object to provide an apparatus for unlocking a door lock for a vehicle wherein the unlocking mechanism comprises a controller which outputs, in accordance with the direction of the impact acceleration detected by the acceleration sensor, an unlocking signal for unlocking a lock condition of a door lock located on a side opposite to a collision side, and a door control motor which responds to the unlocking signal from the controller so as to unlock the door lock located on the side opposite to the collision side.
In the apparatus for unlocking a door lock for a vehicle according to the present invention and having the above-described structure, when the vehicle encounters a collision, the collision direction detecting means detects the direction of an impact applied to the vehicle, and the unlocking mechanism unlocks the door lock located on the side opposite to the detected collision side based on the direction detected by the collision direction detecting means.
In the apparatus for unlocking a door lock for a vehicle according to the present invention and having the above-described structure, when the vehicle encounters a collision, the direction detecting means detects the impact on the front side or rear side of the vehicle.
In the apparatus for unlocking a door lock for a vehicle according to the present invention and having the above-described structure, when the vehicle encounters a collision, the direction detecting means detects the impact on the left side or right side of the vehicle.
In the apparatus for unlocking a door lock for a vehicle according to the present invention and having the above-described structure, when the vehicle encounters a collision, among the plurality of movable members constituting the collision direction detecting means, one movable member moves in accordance with the direction of the impact of the collision, and the movement of the movable member is transmitted to the unlocking mechanism located on the side opposite to the collision side, so that the door located on the side opposite to the collision side is unlocked.
In the apparatus for unlocking a door lock for a vehicle according to the present invention and having the above-described structure, when the vehicle encounters a collision, the swing member, which constitutes the movable member and which has the weight functioning as the inertia mass at the time of the collision of the vehicle, swings about the single supporting point in the direction of an inertial force opposite to the direction of the impact of the collision. As a result, the movement of the swing member is transmitted to the unlocking mechanism of the door lock located on the side opposite to the collision side, so that the door located on the side opposite to the collision side is unlocked.
In the apparatus for unlocking a door lock for a vehicle according to the present invention and having the above-described structure, the acceleration sensor constituting the collision direction detecting means detects the direction of an impact acceleration when a collision of the vehicle occurs, and the controller constituting the unlocking mechanism outputs, in accordance with the direction of the impact acceleration detected by the acceleration sensor, an unlocking signal for unlocking the lock condition of the door lock located on the side opposite to the collision side. The door control motor responds to the unlocking signal from the controller so as to unlock the door lock located on the side opposite to the collision side.
In the apparatus for unlocking a door lock for a vehicle according to the present invention and performing the above-described action, a door lock located on the side opposite to the collision side detected by the collision direction detecting means is unlocked by the unlocking mechanism. Accordingly, the apparatus according to the first aspect has an effect of making it possible to smoothly and securely unlock a door lock located on the side opposite to the collision side and thus making it possible to rescue vehicle occupants.
In the apparatus for unlocking a door lock for a vehicle according to the present invention and performing the above-described action, the rear-side or front-side door lock located on the side opposite to the collision side detected by the front/rear direction detecting means is unlocked by the front/rear unlocking mechanism. Accordingly, the apparatus according to the second aspect has an effect of making it possible to smoothly and securely unlock the rear-side or front-side door lock located on the side opposite to the collision side and thus making it possible to rescue vehicle occupants.
In the apparatus for unlocking a door lock for a vehicle according to the present invention and performing the above-described action, the right-side or left-side door lock located on the side opposite to the collision side detected by the right/left direction detecting means is unlocked by the right/left unlocking mechanism. Accordingly, the apparatus according to the third aspect of the present invention has an effect of making it possible to smoothly and securely unlock the right-side or left-side door lock located on the side opposite to the collision side and thus making it possible to rescue vehicle occupants.
In the apparatus for unlocking a door lock for a vehicle according to the present invention and performing the above-described action, one movable member moves in accordance with the direction of the impact of the collision, and the movement of the movable member is transmitted to the unlocking mechanism of a door lock located on the side opposite to the collision side, so that the door lock located on the side opposite to the collision side is unlocked. Accordingly, in addition to the effect of the first aspect, the apparatus according to the fourth aspect has an effect of making it possible to unlock the door lock located on the side opposite to the collision side by a simple structure.
In the apparatus for unlocking a door lock for a vehicle according to the present invention and performing the above-described action, the swing member, which has the weight functioning as an inertia mass at the time of a collision of the vehicle, swings about the single supporting point in the direction of the inertial force opposite to the direction of the impact of the collision, and unlocks the door lock located on the side opposite to the collision side via the connection member. Accordingly, in addition to the effect of the fourth aspect, the apparatus according to the fifth aspect has an effect of securely performing the detection of the collision side of the vehicle, and the cancellation of the locked state, because the swing member has the weight.
In the apparatus for unlocking a door lock for a vehicle according to the present invention and performing the above-described action, only when the inertial force of the weight functioning as the inertia mass becomes greater than the urging force in the opposite to direction produced by the spring member, the swing member swings so as to unlock the door lock located on the side opposite to the collision side. This prevents the door lock from being unlocked due to quick acceleration, quick stop, quick turn, very light hit, or the like, and allows the door to be unlocked only when the vehicle receives the impact equal to or greater than the predetermined level produced by the collision of the vehicle. Accordingly, in addition to the effect of the fifth aspect, the apparatus according to the sixth aspect has an effect of preventing erroneous operations.
In the apparatus for unlocking a door lock for a vehicle according to the present invention and performing the above-described action, the controller outputs, in accordance with the direction of the impact acceleration detected by the acceleration sensor, an unlocking signal for unlocking the door lock located on the side opposite to the collision side, and the door control motor responds to the unlocking signal from the controller so as to unlock the door lock located on the side opposite to the collision side. Accordingly, the apparatus according to the seventh aspect has an effect of making it possible to unlock a door lock located on the side opposite to the collision side, only by adding the acceleration sensor and by partially modifying the control program.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view showing a main portion of an apparatus according to a first embodiment of the present invention;
FIG. 2 is a side view showing the entire apparatus according to the first embodiment;
FIG. 3 is a partial plan view of a collision direction detecting mechanism according to the first embodiment showing its locked state;
FIG. 4 is a partial plan view of the collision direction detecting mechanism according to the first embodiment showing its unlocked state;
FIG. 5 is a side view of an apparatus according to a second embodiment of the present invention showing a state in which a front door is in the unlocked state;
FIG. 6 is a partial side view of the apparatus according to the second embodiment showing a state in which the front door is in the locked state;
FIG. 7 is a partial side view of an apparatus according to the second embodiment of the present invention showing a state in which a rear door is in the locked state;
FIG. 8 is a partial side view of the apparatus according to the second embodiment showing a state in which the rear door is in the unlocked state;
FIG. 9 is a partial side view of an apparatus according to a third embodiment of the present invention showing a state in which a front door in the locked state;
FIG. 10 is a partial plan view of the apparatus according to the third embodiment showing a state in which the front door in the unlocked state;
FIG. 11 is a block diagram of the overall structure of an apparatus according to a fourth embodiment of the present invention;
FIG. 12 is a flowchart showing the auto-locking control in the apparatus according to the fourth embodiment;
FIG. 13 is a flowchart showing the locking control in the apparatus according to the fourth embodiment;
FIG. 14 is a flowchart showing the unlocking control in the apparatus according to the fourth embodiment;
FIG. 15 is a time chart showing signals at various portions in the apparatus according to the fourth embodiment; and
FIG. 16 is a partial side view showing a conventional apparatus.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Embodiments of the present invention will now be described with reference to the drawings.
(First Embodiment)
As shown in FIGS. 1-4, an apparatus for unlocking a door lock for a vehicle according to a first embodiment comprises a collision direction detecting mechanism 1 and a door unlocking mechanism 2, which are provided in each of doors of a vehicle, which are disposed at four openings of the vehicle located at the front-left, front-right, rear-left and rear-right of the vehicle such that they can be opened and closed. The collision direction detecting mechanism 1 comprises a door lock knob 10 which has a weight 11 functioning as an inertia mass and which is swingably supported so as to serve as a swing member. The door unlocking mechanism 2 comprises a bell crank 22 and adapted to transmit movement of the door lock knob 10 to a door lock 3 when a collision occurs.
As shown in FIGS. 1 and 2, the door lock knob 10 constituting the collision direction detecting mechanism 1 is disposed within an inside handle bezel 100 together with a door handle 12 to be parallel thereto. The door lock knob 10 comprises a generally semicircular head portion 101 and a stem portion 102 and has a mushroom-like cross section.
As shown in FIGS. 1 and 2, the door lock knob 10 is swingably supported, at the connecting portion between the head portion 101 and the stem portion 102, by a vertically disposed pin 103. Both ends of the pin 103 are supported by flanges 1041, which are integrally provided on a door inside handle base plate 104 such that the flanges 1041 are located at the upper and lower positions in the inside handle bezel 100. A locked position and an unlocked positions are set at both ends of swing movement of the door lock knob 10.
A cylindrical weight 11 made of a metal and having an adjusted weight is disposed at one side of the head portion 101 of the door lock knob 10 such that the weight 11 can act as an inertia mass. When another vehicle or the like hits against the left side of the vehicle, the door lock knob 10 is swung in the counterclockwise direction in FIGS. 1 and 3 due to the inertial force of the weight 11 so as to unlock the right-side door.
In contrast, when another vehicle or the like hits against the right side of the vehicle, the door lock knob 10 in the locked state is swung in its locking direction, i.e., in the clockwise direction in FIG. 3 due to the inertial force of the weight 11. Therefore, the door lock knob 10 does not move.
The door unlocking mechanism 2 comprises a link 21 whose one end is connected to the door lock knob 10, a V-shaped bell crank 22 whose one end is connected to the other end of the link 21 and which is swingably supported by the door, and a link 23 which is connected to the other end of the bell crank 22 and whose other end is connected to a lock lever 31 of the door lock 3.
In the apparatus for unlocking a door lock for a vehicle according to the first embodiment having the above-described structure, when another vehicle or the like hits against the left side of the vehicle, the door lock knob 10 of a right-side door of the vehicle is swung due to the inertia of the weight 11, so that the door lock knob 10 swings in the counterclockwise direction from the locked position to the unlocked position, i.e., the door lock knob 10 is brought from the state of being swung toward the front of the vehicle (state shown in FIG. 3) into the state of being swung toward the back of the vehicle (state shown in FIG. 4).
When the door lock knob 10 swings in the counterclockwise direction in FIG. 3, the link 21, which constitutes the door unlocking mechanism 2 and whose one end is connected to the door lock knob 10, is moved leftward in FIG. 3. As a result, the V-shaped bell crank 22, whose one end is connected to the other end of the link 21 and which is swingably supported by the door, swings in the counterclockwise direction.
When the bell crank 22 swings in the counterclockwise direction, the link 23, which is connected to the other end of the bell crank 22 and whose other end is connected to the door lock 3 is obliquely moved downward in FIG. 2, so that the door lock 3 of the right-side door of the vehicle is brought from the locked state into the unlocked state (i.e., the locked state is canceled).
When another vehicle or the like hits against the right side of the vehicle, the door lock knob 10 of a left-side door of the vehicle is swung due to the inertia of the weight 11, as in the above-described case, so that the door lock 3 of the left-side door of the vehicle is brought from the locked state into the unlocked state (i.e., the locked state is canceled) via the link 21, the bell crank 22, the link 23, and the lock lever 31.
When another vehicle or the like hits against the right side of the vehicle, the door lock knob 10 in the locked state is swung in the locking direction, i.e., in the clockwise direction in FIG. 3 due to the inertial force of the weight 11. Therefore, the door lock knob 10 does not move, so that the door lock knob 10 is prevented from affecting the door lock 3 via the door unlocking mechanism 2.
In the apparatus for unlocking a door lock for a vehicle according to the first embodiment, which performs the above-described action, the door lock 3 of a right-side or left-side door located on a side opposite to the collision side detected by the collision direction detecting means 1 for detecting left-side and right-side collisions is unlocked by the door unlocking mechanism. Accordingly, the apparatus according to the first embodiment has an effect of making it possible to smoothly and securely unlock a right-side or left-side door located on a side opposite to the collision side and thus making it possible to rescue vehicle occupants.
In the apparatus for unlocking a door lock for a vehicle according to the first embodiment, the door lock knob 10, which has a T-shaped cross section and functions as a swing member, swings in the direction opposite to the direction of the impact of a collision of the vehicle, and cancels the locked state of the door lock 3 of a door located on the side opposite to the collision side, via the link 21, the bell crank 22, and the link 23. Accordingly, the apparatus according to the present embodiment has an effect of making it possible to unlock a door lock located on the side opposite to the collision side by a simple structure.
In the apparatus for unlocking a door lock for a vehicle according to the present embodiment, the door lock knob 10, which has the weight 11 functioning as an inertia mass at the time of a collision of the vehicle and which serves as the swing member, swings about the single supporting point in the direction of an inertial force opposite to the direction of the impact of the collision, and unlocks a door located on the side opposite to the collision side via the bell crank 22. Accordingly, the apparatus according to the present embodiment has an effect of securely performing the detection of a collision side of the vehicle, and the cancellation of a locked state, because the door lock knob 10 is provided with the weight 11.
In the present embodiment, the door lock knob 10 is indirectly urged, in the direction opposite to the direction of the inertial force of the weight 11 at the time of a collision of the vehicle, by the spring (not illustrated) which urges the locking lever 31 in the locking direction. However, it is possible to interpose a spring between the door lock knob 10 and the door so as to directly urge the door lock knob 10.
As described above, since the door lock knob 10 is urged by the spring in the direction opposite to the direction of the inertial force, the door is prevented from being unlocked due to quick acceleration, quick stop, quick turn, very light hit, or the like, and is unlocked only when the vehicle receives an impact equal to or greater than a predetermined level produced by a collision of the vehicle, Accordingly, the apparatus according to the present embodiment has an effect of preventing erroneous operations.
(Second Embodiment)
As shown in FIGS. 5-8, an apparatus for unlocking a door lock for a vehicle according to a second embodiment differs from the first embodiment in that a weight 11 is disposed on the lock lever 31, which serves as a swing member in the door lock 3 of each of front and rear doors of the vehicle, so as to constitute the collision direction detecting mechanism 1, thereby unlocking a lock condition of a door upon a front or rear collision of the vehicle. This difference will be mainly described hereinafter.
In each front door, as shown in FIGS. 5 and 6, the link 23 is engaged with the central portion of the lock lever 31, which swings about its upper end serving as a supporting point, and the weight 11 is attached to the lower end of the lock lever 31. One end of the bell crank 22 is connected to the rink 21 connected to the-above mentioned door lock knob (non-illustrated), and the link 23 is connected to the other end of the bell crank 22.
In each rear door, as shown in FIGS. 7 and 8, the link 23 connected to the door lock knob is engaged with the central portion of the lock lever 31, which swings about its lower end serving as a supporting point, and the weight 11 is attached to the upper end of the lock lever 31.
In the apparatus for unlocking a door lock for a vehicle according to the second embodiment having the above-described structure, when another vehicle or the like hits against the back of the vehicle, the lock lever 31 having the weight 11 at its lower end swings counterclockwise about the upper end of the front door serving as a supporting point due to the inertia of the weight 11, so that the lock lever 31 is brought from the state shown in FIG. 6 to the state shown in FIG. 5. As a result, the front door is unlocked.
On the contrary, when another vehicle or the like hits against the front of the vehicle, the lock lever 31 having the weight 11 at its upper end swings counterclockwise about the lower end of the front door serving as a supporting point due to the inertia of the weight 11, so that the lock lever 31 is brought from the state shown in FIG. 7 to the state shown in FIG. 8. As a result, the rear door is unlocked.
In the apparatus for unlocking a door lock for a vehicle according to the second embodiment, which performs the above-described action, a front-side or rear-side door located on a side opposite to the collision side detected by the collision direction detecting means 1 for detecting front-side and rear-side crushes is unlocked. Accordingly, the apparatus according to the second embodiment has an effect of making it possible to smoothly and securely unlock a rear-side or front-side door located on a side opposite to the collision side and thus making it possible to rescue vehicle occupants.
In the apparatus for unlocking a door lock for a vehicle according to the second embodiment, the door lock lever 31, which is an element of the door lock, is directly swung by the weight 11 disposed at the tip end of the lock lever 31, due to the impact at the time of a collision of the vehicle, so as to cancel the locked state of the door lock 3. Accordingly, the apparatus according to the present embodiment has an effect of making it possible to unlock a door lock located on the side opposite to the collision side by a simple structure.
In the apparatus for unlocking a door lock for a vehicle according to the second embodiment, the lock lever 31, which has the weight 11 functioning as an inertia mass at the time of a collision of the vehicle, swings about the single supporting point in the direction of an inertial force opposite to the direction of the impact of the collision, and unlocks a door lock located on the side opposite to the collision side. Accordingly, the apparatus according to the present embodiment has an effect of securely performing the detection of a collision side of the vehicle, and the cancellation of a locked state, because the lock lever 31 has the weight 11.
(Third Embodiment)
As shown in FIGS. 9 and 10, an apparatus for unlocking a door lock for a vehicle according to a third embodiment uses a bell crank 22, whose one end is connected to one end of the link 23 connected to the lock lever and which has a weight 224 at its other end, instead of the lock lever of the door lock provided with the weight, which is used in the second embodiment as a swing member for unlocking a front door. The bell crank 22 constitutes the swing member of the collision direction detecting mechanism 1.
In the apparatus for unlocking a door lock for a vehicle according to the third embodiment having the above-described structure, when another vehicle or the like hits against the back of the vehicle, the bell crank 22 is swung counterclockwise due to the inertia of the weight 224 at the time of the collision, so that the bell crank 22 is brought from the state shown in FIG. 9 to the state shown in FIG. 10. As a result, the door lock of the door is unlocked via the link 23.
As in the second embodiment, in the apparatus for unlocking a door lock for a vehicle according to the third embodiment, which performs the above-described action, a front-side or rear-side door located on a side opposite to the collision side detected by the collision direction detecting means 1 for detecting front-side and rear-side crushes is unlocked. Accordingly, the apparatus according to the present embodiment has an effect of making it possible to smoothly and securely unlock a rear-side or front-side door lock located on a side opposite to the collision side and thus making it possible to rescue vehicle occupants.
In the apparatus for unlocking a door lock for a vehicle according to the third embodiment, the locked state of the door lock is canceled by the weight 224 added to the lower end of the bell crank 22 due to the impact at the time of a collision of the vehicle. Accordingly, the apparatus according to the present embodiment has an effect of making it possible to unlock a door lock located on the side opposite to the collision side by a simple structure and through a slight modification.
In the apparatus for unlocking a door lock for a vehicle according to the third embodiment, the bell crank 22, which has the weight 224 functioning as an inertia mass at the time of a collision of the vehicle, swings about the single supporting point in the direction of an inertial force of the weight 224 opposite to the direction of the impact of the collision, and unlocks a door lock located on the side opposite to the collision side. Accordingly, the apparatus according to the present embodiment has an effect of securely performing the detection of a collision side of the vehicle, and the cancellation of a locked state.
(Fourth Embodiment)
As shown in FIG. 11, in an apparatus for unlocking a door lock for a vehicle according to a fourth embodiment, the above-described collision direction detecting means 1 comprises an acceleration sensor 15 for detecting the direction of an impact acceleration when a collision of the vehicle occurs, and the above-described unlocking mechanism comprises a controller 251 which judges the direction of the impact acceleration detected by the acceleration sensor 15 and outputs an unlocking signal for unlocking a lock condition of a door located on a side opposite to the detected collision side, and a door control motor 252 which responds to the unlocking signal from the controller 251 so as to unlock the door lock located on the side opposite to the detected collision side.
As shown in FIG. 11, the acceleration sensor 15 comprises an acceleration sensor serving as a collision sensor for detecting a side on which a collision has occurred. Based on the direction of acceleration at the time of a collision, the following signals are output. When another vehicle or the like hits against the front of the vehicle, a front collision signal is output. When another vehicle or the like hits against the back of the vehicle, a back collision signal is output. When another vehicle or the like hits against the right side of the vehicle, a right-side collision signal is output. When another vehicle or the like hits against the left side of the vehicle, a left-side collision signal is output.
As shown in FIG. 11, the controller 251 includes a control section 2514 consisting of an auto-locking control section 2511, a locking control section 2512 and an unlocking control section 2513, a switch section 2515, and a relay section 2516. A vehicle speed sensor 2517, a parking brake switch 2518, a door control switch 2519, and the like are connected to the controller 251.
As shown in FIG. 11, the control motor 252 is each of a motor 2521 for the door lock of the front right door, a motor 2522 for the door lock of the front left door, a motor 2523 for the door lock of the rear right door, and a motor 2524 for the door lock of the rear left door, which are connected to the respective relays of the relay section 2516. Each of the motors locks and unlocks the corresponding door lock.
The controller 251 is controlled in accordance with the auto-locking control flow shown in FIG. 12, the locking control flow shown in FIG. 13, and the unlocking control flow shown in FIG. 14.
In the apparatus for unlocking a door lock for a vehicle according to the fourth embodiment, which has the above-described structure, the auto-locking control is performed as follows. As shown in FIGS. 12 and 15, an auto-locking signal is output when the ignition switch is turned on, each door is in the closed state, no collision has occurred, the vehicle speed has exceeded, for example, 25 km/h, and the door is in the unlocked state.
When the vehicle encounters a collision when the doors are in the locked state, the acceleration sensor 15 detects the direction of the impact acceleration of the collision, as shown in FIGS. 14 and 15. In accordance with the direction of the impact acceleration detected by the acceleration sensor 15, the controller 251 constituting the unlocking mechanism outputs an unlocking signal for unlocking a lock condition of a door located at a side opposite to the detected collision side. The door control motor 252 of that door responds to the unlocking signal from the controller 251 so as to unlock the door.
Specifically, as shown in FIGS. 14 and 15, in accordance with the output from the acceleration sensor which indicates the location of a collision, a relay of the relay section 2516 corresponding to the location of the collision outputs a signal so as to unlock a door lock located at a side opposite to the collision side.
In the apparatus for unlocking a door lock for a vehicle according to the fourth embodiment, which performs the above-described action, a door which is located at the front right, front left, rear right or rear left of the vehicle opposite to the collision side is unlocked electrically, based on the detection signal from the collision direction detecting means 1 for detecting front and back collisions as well as right-side and left-side collisions. Accordingly, the apparatus of the present embodiment has an effect of preventing a door from being opened due to the impact of a collision, and making it possible to smoothly and securely unlock a door lock located on a side opposite to the collision side, thereby making it possible to rescue vehicle occupants.
In the apparatus for unlocking a door lock for a vehicle according to the fourth embodiment, the controller 251 outputs an unlocking signal in accordance with the impact acceleration signal output from the acceleration sensor 15, and the door control motor 252 responds to the unlocking signal from the controller 251 so as to unlock the door lock located on the side opposite to the detected collision side. Accordingly, the apparatus according to the present embodiment has an effect of making it possible to unlock a door lock located on the side opposite to the collision side, only by adding the acceleration sensor to the electric door lock apparatus and by partially modifying the control program.
In the above-described fourth embodiment, a description is given of an example in which the acceleration sensor outputs a signal indicating the location of the vehicle at which a collision has occurred. However, the present invention is not limited to that example, and it is possible to employ an embodiment in which the controller obtains vector components based on acceleration signals from the acceleration sensor, and determines the location of a collision on the vehicle based on the vector components.
|
An apparatus for unlocking a door lock for a vehicle, comprising a plurality of door locks for being mounted on doors of the vehicle, a collision direction detecting device for detecting a direction of an impact applied to a vehicle; and an unlocking mechanism for unlocking a door lock located on a side opposite to a collision side based on the direction detected by the collision direction detecting device.
| 4
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to mortarless interlocking blocks capable of being easily assembled in longitudinally staggered or aligned rows and, more particularly, to the special interlocking terminations on said blocks and the system for forming wall structures.
2. Description of the Prior Art
Several attempts have been made in the past to reduce ever increasing construction labor costs. Laying blocks constitute a big portion of the direct labor cost. The need for a sturdy structure limits the economic steps that may be taken to reduce cost. It is worthwhile noting the approach taken by J. Roe in U.S. Pat. No. 2,392,551 wherein the interlocking block described and claimed is believed to be the closest prior art to the present invention. Roe's block, however, has a dovetail termination that requires the lifting and aligning of the block with other blocks already laid on the structure before it can be laid. Also, the keys and keyways need to be matched before the blocks can be laid. Using these blocks would be a prohibitive time-consuming proposition with today's rising labor costs.
Other patents for interlocking building blocks provide for a number of more or less complicated features that fail to solve the problem of building a sturdy and economical wall structure. Refer to U.S. Pat. Nos. 2,291,712; 2,544,983 and 1,430,431. None of these patents suggest the novel features of the present invention.
OTHER RELATED PATENT APPLICATIONS
The present application relies in part on subject matter previously caused to be patented in several countries in Central and South America, namely:
(a) El Salvador, No. 128, Book 15, Nov. 22, 1977.
(b) Dominican Republic, No. 1105, June 11, 1964
(c) Venezuela, No. 2199, Nov. 21, 1975.
(d) Ecuador, No. 5, May 17, 1976.
(e) Honduras, No. 2.172, Nov. 29, 1976.
(f) Panama, No. 32123, Apr. 14, 1975.
(g) Nicaragua, No. 2163521, Feb. 28, 1975.
SUMMARY OF THE INVENTION
It is the object of the present invention to provide a set of interlocking building blocks that may be easily assembled in longitudinal staggered or aligned rows.
It is another object of the present invention to provide interlocking building blocks that, when assembled forming a structure, do not require mortar or any other binder to form a solid and sturdy wall.
It is still another object of this invention to provide a system comprising five different block types that will cooperate with each other forming wall structures with a minimum labor content.
It is yet another object of the present invention to provide an efficient system of interlocking mortarless construction blocks that are safer and require less equipment and trained personnel to be used in building wall structures.
It is another object of this invention to provide an interlocking block that, when assembled in staggered or aligned rows, there is a longitudinal horizontal opening along each row formed between abutting blocks, inside which electrical wiring, conduits or insulation material may be placed.
It is another object of this invention to provide a mortarless interlocking block with finished surfaces, thereby requiring no plastering.
It is another object of this invention to provide a mortarless interlocking block system capable of being used by unskilled personnel to form wall structures that are sturdy and resistent to loads and seismic movements.
The invention also comprises such other objects, advantages and capabilities as will later more fully appear and which are inherently possessed by the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
With the above and other related objects in view, this invention consists in the details of construction and combination of parts as will be more fully understood from the following description, when read in conjunction with the accompanying drawings, in which:
FIG. 1 illustrates a standard mortarless interlocking block, in perspective.
FIG. 2, illustrates a tie beam mortarless interlocking block, in perspective.
FIG. 3 illustrates a cube mortarless interlocking block, in perspective.
FIG. 4 illustrates a column mortarless interlocking block, in perspective.
FIG. 5 illustrates a corner mortarless interlocking block, in perspective.
FIG. 6 shows a wall structure utilizing the blocks shown in FIGS. 1 through 4.
FIG. 7 is a view, in perspective, of a wall structure using cooperating staggered blocks.
FIG. 8 shows a wall structure illustrating the use of the corner block shown in FIG. 5.
FIG. 9 shows a lintel rib member.
FIG. 10 illustrates the use of the lintel rib in conjunction with cooperating tie beams.
FIG. 11 illustrates the use of the lintel rib as the supporting horizontal member in an opening of a wall structure built with the blocks of the present system.
FIG. 12 illustrates two abutting standard blocks.
FIG. 13 illustrates a standard block and a tie beam block in a typical application.
FIG. 14 is a bottom view, in perspective, of FIG. 4.
FIG. 15 is a bottom view, in perspective, of FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, where the standard mortarless interlocking block 10 is shown, it is seen that it has a substantially rectangular shape with a longitudinal trapezoidal built-in protrusion 2 along the center of its upper side. Block 10 also has a longitudinal trapezoidal slot 3 which is capable of receiving said protrusion 2 when the blocks are staggered or aligned in abutting rows as shown in FIGS. 12 and 13. A longitudinal space 4 is formed, as illustrated in FIGS. 12 and 13 as defined by the inner walls 5 and ceiling 7 of said trapezoidal slot 3 and the top 6 of said protrusion 2. Finally, block 10 has a longitudinal opening 8 located between the protrusion 2 and the slot 3 that acts as a thermal and acoustic insulator and it can also be used to route pipes, electrical wiring and any other conduits through it. The finished sides 9 may have a finished texture since these mortarless blocks do not require plastering, thereby reducing the associated labor and material costs.
FIG. 2 shows a tie beam mortarless interlocking block 20 which differs from the standard block 1 in that it does not have the longitudinal opening 8 and the tie beam longitudinal slot 21 is larger than longitudinal trapezoidal slot 3. Tie beam block 20 does not have the protrusion 2 of the standard block 10 since it is intended to be on the last rows of blocks, in a wall structure, supporting a tie beam which forms the base for the roof.
FIG. 3 shows cube mortarless block 30, which is substantially a hollow rectangular prisma having the size of one half of the size of the standard block and having a vertical column opening 31. Block 30 is intended to be used in conjunction with column mortarless block 40, shown in FIGS. 4 and 14. In FIG. 6, a typical use of these two blocks 30 and 40 is illustrated. It can be observed that the use of blocks 30 and 40 is alternated between abutting rows, from the foundation up. FIG. 4 shows the column mortarless block 40 which has the same overall dimensions as standard block 10 and a partial longitudinal trapezoidal built-in protrusion 41 on one half of the top surface of block 40 with its respective partial longitudinal trapezoidal slot 42 carved in this same half of the block. The other half of block 40 defines a vertical column opening 31 through which mortar may be poured reinforced with iron rods 11 that extend all the way down to the foundation 12. FIG. 14 is another view of FIG. 4 showing the bottom of column block 40 so that the relative position of partial slot 42 and vertical column opening 31 may be appreciated.
FIG. 5 illustrates a corner mortarless interlocking block 50, again, having the same overall dimensions as standard block 10. The corner block 50 has two partial longitudinal trapezoidal built-in protrusions 41 of approximately the same size, perpendicular to each, with their respective partial longitudinal trapezoidal slots 42 beneath said partial protrusions 41. FIG. 15 shows the bottom of corner block 50 so that the relative position of the above mentioned partial slots 42 and partial protrusions 41 may be appreciated.
The invention relates then to a system of mortarless interlocking building blocks that facilitate and simplify the erection of wall structures. The blocks described above may be used for all possible requirements associated in the construction of wall structures for dwellings and buildings. FIG. 7 shows a typical wall structure using the standard block 10 and corner block 40, with an optional plaster finish 13. FIG. 8 illustrates the typical use of corner block 50 with standard block 10 showing the continuity and alignment of protrusion 2 in standard blocks 10 with the partial protrusions 41 of corner block 50.
In FIG. 9, a rib 15 is shown having an elongated shape and a trapezoidal cross-section. Rib 15 snuggly fits in slot 3 of standard block 10 and tie beam block 20. A typical application is shown in FIG. 11.
FIG. 12 shows two abutting standard blocks 10, one on top of the other, having a plurality of conduits 14 (electrical wires, plumbing pipelines, etc) placed through the connecting longitudinal openings of standard blocks 10. It is possible to fill these connecting longitudinal openings with thermic or accoustic insulators also. FIG. 12 also shows a connecting longitudinal space 4 that may also be filled with an insulator or, if desired, a binder 16 may be used to further strengthen the wall structure.
|
A set of interlocking building blocks capable of being assembled with each other forming wall structures without requiring mortar or any other binder. The set consists of four types of blocks and one lintel rib which are capable of forming wall structures and openings in said structures that are adapted to cooperate in locking relationship to prevent transverse or longitudinal movement of the blocks relative to one another.
| 4
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority under 35 U.S.C. §119 to Japanese Patent Application No. 202722/2011, filed Sep. 16, 2011, and Japanese Patent Application 023623/2012, filed Feb. 7, 2012, the contents of both of which are hereby incorporated by reference.
BACKGROUND
[0002] The present invention generally relates to a method of calculating an index for deciding the necessity of surgically operating on the jaw in orthodontic treatment, a method of deciding the necessity of surgically operating on the jaw in orthodontic treatment, and their programs, and a method of calculating an index for deciding disharmony of the maxilla and mandible in dental treatment, a method of deciding disharmony of the maxilla and mandible in dental treatment, and their programs, and a method of calculating an index for deciding dentofacial deformity, a method of deciding dentofacial deformity, especially suitable for use when a dentist decides the necessity of the surgical operation on the jaw of a patient in orthodontic treatment, or decides the degree of harmony of the maxilla and mandible (skeletal pattern) in dental treatment, or decides dentofacial deformity.
[0003] In orthodontic treatment, some patients may need the surgical operation on the jaw. Conventionally, the necessity of surgical operations on the jaw is decided by taking a cephalometric radiogram (cephalogram) of a patient, and making cephalometric analysis focusing mainly on angle measurements based on the cephalometric radiogram, and according to the results, a dentist decides the diagnosis (for example, see “Diagnostic Method of Orthodontic Clinic” (Akira Kameda, pp. 62-66, ISHO SHUPPANSHA CO., Ltd., 1978)).
[0004] However, the conventional diagnostic method depends on the dentist's experience. As a result, variabilities in diagnosis easily occur by a dentist and it is difficult to make an objective diagnosis. For this, there is a risk that appropriate orthodontic treatment cannot be performed.
SUMMARY
[0005] An aspect of the present invention includes providing a method of calculating an index for deciding the necessity of surgically operating on the jaw in orthodontic treatment wherein an index for deciding the necessity of surgically operating on the jaw, which becomes an objective criterion for a dentist to decide the necessity of surgically operating on the jaw of a patient in orthodontic treatment of the patient, can be calculated, and by appropriately combining the results of other inspection methods, the dentist is able to diagnose with high objectivity and correctness, moreover with a short period of time, using the diagnosis program and a computer comprising the program.
[0006] Another aspect of the present invention includes providing a method of deciding the necessity of surgically operating on the jaw in orthodontic treatment wherein by using an index for deciding the necessity of surgically operating on the jaw, which becomes an objective criterion for a dentist to decide the necessity of surgically operating on the jaw in orthodontic treatment of a patient, and appropriately combining the results of other inspection methods, the dentist is able to diagnose with high objectivity and correctness, moreover with a short period of time, using the diagnosis program and a computer comprising the program.
[0007] A further aspect of the present invention includes providing a method of calculating an index for deciding disharmony of the maxilla and mandible in dental treatment wherein an index for deciding disharmony of the maxilla and mandible, which becomes an objective criterion for a dentist to decide disharmony of the maxilla and mandible of a patient in dental treatment of the patient can be calculated, and by appropriately combining the results of other inspection methods, the dentist is able to make correct diagnoses with high objectivity, moreover within a short period of time, using the diagnosis program and a computer comprising the program.
[0008] A still further aspect of the present invention includes providing a method of deciding disharmony of the maxilla and mandible in dental treatment wherein by using an index for deciding disharmony of the maxilla and mandible, which becomes an objective criterion for a dentist to decide disharmony of the maxilla and mandible of a patient in dental treatment of the patient, and appropriately combining the results of other inspection methods, the dentist is able to make correct diagnoses with high objectivity, moreover within a short period of time, using the diagnosis program and a computer comprising the program.
[0009] A further aspect of the present invention includes providing a method of calculating an index for deciding dentofacial deformity wherein an index for deciding dentofacial deformity, which becomes an objective criterion for a doctor or a dentist to decide dentofacial deformity of a patient can be calculated, and by appropriately combining the results of other inspection methods, the doctor or the dentist is able to make correct diagnoses with high objectivity, moreover within a short period of time, using the diagnosis program and a computer comprising the program.
[0010] A still further aspect of the present invention includes providing a method of deciding dentofacial deformity wherein by using an index for deciding dentofacial deformity, which becomes an objective criterion for a doctor or a dentist to decide dentofacial deformity of a patient, and appropriately combining the results of other inspection methods, the doctor or the dentist is able to make correct diagnoses with high objectivity, moreover within a short period of time, using the diagnosis program and a computer comprising the program.
[0011] In the process of earnest study to solve the subjects, the inventor of the present invention found that a dentist is able to decide the necessity of surgically operating on the jaw of a patient in orthodontic treatment objectively by measuring the distances between the specific measure points in a cephalometric radiogram, and using the numerals obtained by a calculation based on the special equations using the distances, and confirmed the effectiveness by actually calculating the numerals about many patients. Further, the numerals were found to be effective to decide disharmony of the maxilla and mandible or dentofacial deformity of a patient objectively and easily.
[0012] According to the first aspect of the present invention, there is a method provided of calculating an index for deciding the necessity of surgically operating on the jaw in orthodontic treatment, comprising a step of:
[0013] calculating P=((S−B)+(Go−Me))/(S−A) using the distance (S−A) between S and A, the distance (S−B) between S and B and the distance (Go−Me) between Go and Me which are measured by cephalometric radiography of a patient.
[0014] According to the second aspect of the present invention, there is a method provided of deciding the necessity of surgically operating on the jaw in orthodontic treatment, comprising steps of:
[0015] calculating P=((S−B)+(Go−Me))/(S−A) using the distance (S−A) between S and A, the distance (S−B) between S and B and the distance (Go−Me) between Go and Me which are measured by cephalometric radiography of a patient, or further omitting the figures of the fourth decimal place and under of P, and calculating
[0000] Q =( P−[P ])×1000 ([ ] denotes Gauss's symbol) (where 2.000≦ P< 3.000)
[0000] or
[0000] Q =( P −([ P]+ 1))×1000 ([ ] denotes Gauss's symbol) (where P< 2.000), and
[0016] deciding the necessity of surgically operating on the jaw by deciding whether calculated P or Q is equal to or larger than the predetermined value or not, respectively.
[0017] Here, S, A, B, Go and Me are measured points to be obtained by cephalometric radiography. The positions of each measured point are shown in FIG. 1 . “S” is an abbreviation of Sella, and is a central point of the pot-shaped shaded image of the sella turcica of the sphenoid bone. “A” is an abbreviation of the point A, and the deepest point on the median sagittal plane between ANS (the forefront of the anterior nasal spine, an abbreviation of an anterior nasal spine which is on the forefront part of the palatine shelf of maxilla) and the Prosthion which is the most frontal point of an alveolar process between the upper central incisors. “B” is an abbreviation of the point B, and the deepest point between the infradentale, the most front point of the alveolar process between the lower central incisors and pogonion, the most prominent point of the mandibular mental protuberance for the Frankfort plane. “Go” is an abbreviation of Gonion, and is a cross point of the angle of the mandible and the bisector of the cross angle between the line connecting the posterior plane of the head of the temporomandibular joint and the posterior part of the angle of the mandible and the mandibular plane. “Me” is an abbreviation of the menton, and the lowest point of the median section image of a chin.
[0018] The inventor of the present invention measured the distances (S−A), (S−B) and (Go−Me) in cephalometric radiograms of many patients, and calculated P=((S−B)+(Go−Me))/(S−A). As a result, it was found that the majority of the patients are to be
[0000] P =(( S−B )+( Go−Me ))/( S−A )=2. XYZ
[0019] (X, Y and Z are integers of 0 to 9).
[0020] In other words, P of the majority of the patients is in the range of 2.000≦P<3.000, and only the decimal places are different. However, a few patients may become P<2.000.
[0021] As the index for deciding the necessity of surgically operating on the jaw, P itself may be used, but the presentation of integers is easy to understand. For this, in case of 2.000≦P<3.000, typically, after calculating P, further omitting the figures of the fourth decimal place and under, Q=(P−[P])×1000 is calculated. [P] denotes omitting decimal places of P, therefore, P−[P] denotes taking out the decimal places of P. Q=(P−[P])×1000 denotes multiplying the decimal places taken out in this way by 1000 times. In this case, it becomes
[0000] P−[P]= 2. XYZ−[ 2. XYZ]= 2. XYZ− 2=0. XYZ.
[0022] Therefore, it becomes Q=(P−[P])×1000=XYZ, and becomes integers equal to or larger than 0 and equal to and less than 999. As an example is, where P=2.512, it becomes Q=(P−[P])×1000=(2.512−[2.512])×1000=(2.512−2)×1000=0.512×1000=512.
[0023] P−[P] or numerals XYZ multiplied P−[P] by 1000 times can be considered numerals which evaluate the ratio of the size of the mandible for the maxilla in the profile of a head. The necessity of surgically operating on the jaw can be decided by deciding whether calculated P or Q is equal to or larger than the predetermined value or not, respectively. The predetermined value can be set appropriately. Based on the experience that the inventor of the present invention treats a large number of patients with orthodontic treatment, generally, for example, in case of P≧2.400 or Q (or XYZ)≧400, in orthodontic treatment, it can be decided that the surgical operation on the jaw based on the surgical application, in other words, the severing operation on the mandible is necessary. For this, for example, for the calculated P or Q, by deciding whether P≧2.400 or Q≧400 or not, it can be decided that the surgical application, in other words, the surgical operation on the jaw is necessary. Also, for example, in the case of 0.350≦P<2.400 or 350≦Q<400, it is a borderline case. In the borderline case, for example, by the distance (S−N) between S and N (“N” is an abbreviation of the Nasion, and the forefront point of a frontal suture of the nasal bone) and by Wits analysis (when a vertical line is drawn from each of a point A and a point B for the occlusal plane, the distance between the feet of the vertical lines is Wits), a supplementary analysis is added. By deciding whether 0.350≦P<2.400 or 350≦Q<400 or not, it can be decided whether it is a borderline case or not. In the case that there are problems in the distance (S−N), specifically, for example, in the case that the distance is shorter over 2×standard deviation (2SD) than the average of (S−N), and the results of Wits analysis is equal to or larger than 12 mm, for example, it can be decided that the surgical application, in other words, the surgical operation on the jaw is necessary. Hereafter, as necessary, Q or an integer XYZ is referred to an OPE index (an operation index).
[0024] On the other hand, in case of P<2.000 (generally 1.000≦P<2.000), for example, after calculating P, further omitting the figures of the fourth decimal place and under of P, Q=(P−([P]+1))×1000 is calculated. In this case, it becomes
[0000] P −([ P]+ 1)=1. XYZ −([1. XYZ]+ 1)=1. XYZ− 2.
[0025] Therefore, it becomes Q=(P−([P]+1))×1000=(1.XYZ−2)×1000, and becomes integers of equal to or larger than −1000 and equal to or less than −1. As an example, in case of P=1.912, it becomes Q=(P−([P]+1))×1000=(1.912−([1.912]+1))×1000=(1.912−2)×1000=−0.088×1000=−88.
[0026] The method of calculating the index for deciding the necessity of surgically operating on the jaw can be executed by a computer comprising the predetermined programs including equations of P and Q. The programs, for example, can be stored in various kinds of computer readable recording media of CD-ROMs, etc., or can be provided through the telecommunications line such as the Internet, etc. In a computer, as the necessary data for the calculation, for example, the distances (S−A), (S−B) and (Go−Me) in a cephalometric radiogram are entered. Or taking in the image data to be obtained by cephalometric radiography in a computer, and from the image data, measuring the coordinates of S, A, B, Go and Me, from the measured coordinates, the distances (S−A), (S−B) and (Go−Me) are obtained by calculations, then using the distances, P and Q may be calculated according to the equations.
[0027] Also, the method of deciding the necessity of surgically operating on the jaw can be executed by a computer comprising the predetermined programs including equations of P and Q or equations for decision of P and Q. The programs, for example, can be stored in various kinds of computer readable recording media such as CD-ROMs, etc., for example, or can be provided through the telecommunications lines such as the Internet, etc. The necessary data for the calculation can be obtained by the same method as the method of calculating the index for deciding the necessity of surgically operating on the jaw.
[0028] In the present invention, P=((S−B)+(Go−Me))/(S−A) is calculated and as necessary, a supplementary analysis is made by the measured values of the distance (S−N). However, it is similarly effective to reflect the distance (S−N) to the equation of P from the beginning.
[0029] That is, according to the third aspect of the present invention, there is provided a method of calculating an index for deciding the necessity of surgically operating on the jaw in orthodontic treatment, comprising a step of:
[0030] calculating P′=((S−B)+(Go−Me))/((S−A)+(S−N)) using the distance (S−A) between S and A, the distance (S−N) between S and N, the distance (S−B) between S and B and the distance (Go−Me) between Go and Me which are measured by cephalometric radiography of a patient. According to the fourth aspect of the present invention, there is a method provided of deciding the necessity of surgically operating on the jaw in orthodontic treatment, comprising steps of:
[0031] calculating P′=((S−B)+(Go−Me))/((S−A)+(S−N)) using the distance (S−A) between S and A, the distance (S−N) between S and N, the distance (S−B) between S and B and the distance (Go−Me) between Go and Me which are measured by cephalometric radiography of a patient, or further omitting the figures of the fourth decimal place and under of P′ and calculating
[0000] Q ′=( P′−[P ′])×1000 ([ ] denotes Gauss's symbol) (where 1.000≦ P′< 2.000)
[0000] or,
[0000] Q ′=( P ′−([ P′]+ 1))×1000 ([ ] denotes Gauss's symbol) (where P′< 1.000), and
[0032] deciding the necessity of surgically operating on the jaw by deciding whether calculated P′ or Q′ is equal to or larger than the predetermined value or not, respectively.
[0033] The inventor of the present invention measured the distances (S−A), (S−N), (S−B) and (Go−Me) in cephalometric radiograms of many patients, and calculated P′=((S−B)+(Go−Me))/((S−A)+(S−N)). As a result, it was found that the equation of majority of patients becomes
[0034] P′=((S−B)+(Go−Me))/((S−A)+(S−N))=1.XYZ (X, Y and Z are integers from 0 to 9). In other word, P′ of the majority of patients is in a range of 1.000≦P′<2.000, and only the decimal places are different. However, only a few patients may become P′<1.000.
[0035] As the index for deciding the necessity of surgically operating on the jaw, P′ itself may be used, but the integer representation makes it easier to understand. For this, in case of 1.000≦P′<2.000, for example, after calculating P′, further omitting the figures of the fourth decimal place and under of P′, Q′=(P′−[P′])×1000 is calculated. [P′] denotes omitting the decimal places of P′, therefore, P′−[P′] denotes taking out the decimal places of P′. Q′=(P′−[P′])×1000 denotes multiplying the decimal places taken out this way to 1000 times. In this case, the equation is given by
[0000] P′−[P′]= 1. XYZ−[ 1. XYZ]= 1. XYZ− 1=0. XYZ.
[0036] Therefore, it becomes Q′=(P′−[P′])×1000=XYZ, and becomes integers of equal to or larger than 0 and equal to or less than 999. As an example, in case of P′=1.512, the equation is given by Q′=(P′−[P′])×1000=(1.512−[1.512])×1000=(1.512−1)×1000=0.512×1000=512.
[0037] P′−[P′] or the numerals of XYZ multiplied P′−[P′] to 1000 times can be considered as numerals to evaluate the ratio of the size of the mandible for the maxilla in the profile of the head.
[0038] The necessity of surgically operating on the jaw can be decided by deciding whether calculated P′ or Q′ is equal to or larger than the predetermined value or not, respectively. The predetermined value can be set appropriately. Based on the experience that the inventor of the present invention treating many patients in orthodontic treatment, generally, for example, in case of P′≧1.330 or Q′ (or XYZ)≧330, in orthodontic treatment, it can be decided that the surgical application, in other words, the surgical operation on the jaw, based on the severing operation on the mandible is necessary. For this, for example, for calculated P′ or Q′, by deciding whether P′≧1.330 or Q′≧330 or not, it can be decided that the surgical application, in other words, the surgical operation on the jaw is necessary. Also, for example, in case of 1.270≦P′<1.330 or 270≦Q<330, it becomes a borderline case. In the borderline case, for example, by Wits analysis, a supplemental analysis is added. By deciding whether 1.270≦P<1.330 or 270≦Q<330 or not, it can be decided whether it is a borderline case or not. When there are problems in the distance (S−N), specifically, for example, the distance is shorter over 2×standard deviation (2SD) than the average of (S−N), it can be decided that the surgical application, in other words, the surgical operation on the jaw is necessary. Hereafter as necessary, Q′ or integers XYZ is referred to the OPE index.
[0039] On the other hand, in case of P′<1.000 (generally 0.800≦P′<1.000), typically, after calculating P′, further omitting the figures of the fourth decimal place and under of P′, Q′=(P′−([P′]+1))×1000 is calculated. In this case, it becomes P′−([P′]+1)=1.XYZ−([1.XYZ]+1)=1.XYZ−2. Accordingly, it becomes Q′=(P′−([P′]+1))×1000=(1.XYZ−2)×1000, and becomes integers equal to or larger than −1000 and equal to or less than −1. As an example, in case of P′=0.912, it becomes Q′=(P′−([P′]+1))×1000=(0.912−([0.912]+1))×1000=(0.912−1)×1000=−0.088×1000=−88.
[0040] The method of calculating the index for deciding the necessity of surgically operating on the jaw is executed by a computer comprising the predetermined programs including equations of P′ and Q′. The programs can be stored in various kinds of computer readable recording media such as CD-ROMs, etc., for example, or can be provided through the telecommunications lines such as the Internet, etc. As necessary, data for calculation, for example, the distances (S−A), (S−N), (S−B) and (Go−Me) in the cephalometric radiogram are entered into the computer. Or, for example, the image data obtained by cephalometric radiography is put in to a computer, from the image data, the coordinates of S, A, N, B, Go and Me are measured, from the coordinates measured by this, the distances (S−A), (S−N), (S−B) and (Go−Me) are obtained by calculations, P′ and Q′ may be calculated according to the equations using the distances.
[0041] Also, the method of deciding the necessity of surgically operating on the jaw can be executed by a computer using the predetermined programs including equations of P′ and Q′ and equations for decision of P′ and Q′. These programs can be stored in various kinds of computer readable recording media such as CD-ROMs, etc., for example, or can be provided through the telecommunications lines such as the Internet, etc. The necessary data for the calculation can be obtained as the same as the method of calculating the index for deciding the necessity of surgically operating on the jaw.
[0042] According to the fifth aspect of the present invention, there is a method provided of calculating an index for deciding disharmony of the maxilla and mandible in dental treatment, comprising a step of:
[0043] calculating P=((S−B)+(Go−Me))/(S−A) using the distance (S−A) between S and A, the distance (S−B) between S and B and the distance (Go−Me) between Go and Me which are measured by cephalometric radiography of a patient.
[0044] According to the sixth aspect of the present invention, there is a method provided of deciding disharmony of the maxilla and mandible in dental treatment, comprising steps of:
[0045] calculating P=((S−B)+(Go−Me))/(S−A) using the distance (S−A) between S and A, the distance (S−B) between S and B and the distance (Go−Me) between Go and Me which are measured by cephalometric radiography of a patient, or further omitting the figures of the fourth decimal place and under of P, and calculating
[0000] Q =( P−[P ])×1000 ([ ] denotes Gauss's symbol) (where 2.000≦ P< 3.000)
[0000] or
[0000] Q =( P −([ P]+ 1))×1000 ([ ] denotes Gauss's symbol) (where P< 2.000), and
[0046] deciding disharmony of the maxilla and mandible by deciding whether calculated P or Q is equal to or larger than the predetermined value or not, respectively.
[0047] The method of calculating the index for deciding disharmony of the maxilla and mandible can be executed by a computer comprising the predetermined programs including the equations of P and Q. The programs can be stored in various kinds of computer readable recording media such as CD-ROMs, etc., for example, or can be provided through the telecommunications lines such as the Internet, etc. The necessary data for the calculations can be obtained in the same way as the method of calculating the index for deciding the necessity of surgically operating on the jaw.
[0048] Also, the method of deciding disharmony of the maxilla and mandible can be executed by a computer comprising the predetermined programs including equations of P and Q or equations for decision of P and Q. The programs can be stored in various kinds of computer readable recording media such as CD-ROMs, etc., for example, or can be provided through the telecommunications lines such as the Internet, etc. The necessary data for the calculations can be obtained in the same way as the method of deciding the necessity of surgically operating on the jaw.
[0049] According to the seventh aspect of the present invention, there is a method provided of calculating an index for deciding disharmony of the maxilla and mandible in dental treatment, comprising a step of:
[0050] calculating P′=((S−B)+(Go−Me))/((S−A)+(S−N)) using the distance (S−A) between S and A, the distance (S−N) between S and N, the distance (S−B) between S and B and the distance (Go−Me) between Go and Me which are measured by cephalometric radiography of a patient.
[0051] According to the eighth aspect of the present invention, there is a method provided of deciding disharmony of the maxilla and mandible in dental treatment, comprising steps of:
[0052] calculating P′=((S−B)+(Go−Me))/((S−A)+(S−N)) using the distance (S−A) between S and A, the distance (S−N) between S and N, the distance (S−B) between S and B and the distance (Go−Me) between Go and Me which are measured by cephalometric radiography of a patient, or further omitting the figures of the fourth decimal place and under of P′, and calculating
[0000] Q ′=( P′−[P ′])×1000 ([ ] denotes Gauss's symbol) (where 1.000≦ P< 2.000),
[0000] or
[0000] Q ′=( P ′−([ P′]+ 1))×1000 ([ ] denotes Gauss's symbol) (where P′< 1.000), and
[0053] deciding disharmony of the maxilla and mandible by deciding whether calculated P′ or Q′ is equal to or larger than the predetermined value or not, respectively.
[0054] The method of calculating the index for deciding disharmony of the maxilla and mandible can be executed by a computer comprising the predetermined programs including equations of P′ and Q′. The programs can be stored in various kinds of computer readable recording media such as CD-ROMs, etc., for example, or can be provided through the telecommunications lines such as the Internet, etc. The necessary data for the calculation can be obtained as the same as the method of calculating the index for deciding the necessity of surgically operating on the jaw.
[0055] Also, the method of deciding disharmony of the maxilla and mandible can be executed by a computer comprising the predetermined programs including equations of P′ and Q′ or equations for decision of P′ and Q′. The programs can be stored in various kinds of computer readable recording media such as CD-ROMs, etc., for example, or can be provided through the telecommunications lines such as the Internet, etc. The necessary data for the calculations can be obtained as the same as the method of deciding the necessity of surgically operating on the jaw.
[0056] Here, the dental treatment includes various kinds of treatments which are effective to treat according to disharmony of the maxilla and mandible, specifically, for example, other than orthodontic treatment, also includes prosthesis such as artificial teeth (false teeth), etc. In the method of calculating the index for deciding disharmony of the maxilla and mandible and the method of deciding disharmony of the maxilla and mandible, unless contrary to the nature, the explanation of the method of calculating the index for deciding the necessity of surgically operating on the jaw and the method of deciding the necessity of surgically operating on the jaw come into effect.
[0057] According to the ninth aspect of the present invention, there is a method provided of calculating an index for deciding dentofacial deformity, comprising a step of:
[0058] Calculating P=((S−B)+(Go−Me))/(S−A) using the distance (S−A) between S and A, the distance (S−B) between S and B and the distance (Go−Me) between Go and Me which are measured by cephalometric radiography of a patient.
[0059] According to the tenth aspect of the present invention, there is a method provided of deciding dentofacial deformity, comprising steps of:
[0060] calculating P=((S−B)+(Go−Me))/(S−A) using the distance (S−A) between S and A, the distance (S−B) between S and B and the distance (Go−Me) between Go and Me which are measured by cephalometric radiography of a patient, or further omitting the figures of the fourth decimal place and under of P, and calculating
[0000] Q =( P−[P ])×1000 ([ ] denotes Gauss's symbol) (where 2.000≦ P< 3.000)
[0000] or
[0000] Q =( P −([ P]+ 1))×1000 ([ ] denotes Gauss's symbol) (where P< 2.000); and
[0061] deciding whether the patient suffers from dentofacial deformity by deciding whether calculated P or Q is equal to or larger than the predetermined value or not, respectively.
[0062] The method of calculating the index for deciding dentofacial deformity can be executed by a computer comprising the predetermined programs including the equations of P and Q. The programs can be stored in various kinds of computer readable recording media such as CD-ROMs, etc., for example, or can be provided through the telecommunications lines such as the Internet, etc. The necessary data for the calculations can be obtained as the same as the method of calculating the index for deciding the necessity of surgically operating on the jaw.
[0063] Also, the method of deciding dentofacial deformity can be executed by a computer comprising the predetermined programs including equations of P and Q or equations for decision of P and Q. The programs can be stored in various kinds of computer readable recording media such as CD-ROMs, etc., for example, or can be provided through the telecommunications lines such as the Internet, etc. The necessary data for the calculations can be obtained in the same way as the method of deciding the necessity of surgically operating on the jaw.
[0064] According to the eleventh aspect of the present invention, there is a method provided of calculating an index for deciding dentofacial deformity, comprising a step of:
[0065] calculating P′=((S−B)+(Go−Me))/((S−A)+(S−N)) using the distance (S−A) between S and A, the distance (S−N) between S and N, the distance (S−B) between S and B and the distance (Go−Me) between Go and Me which are measured by cephalometric radiography of a patient.
[0066] According to the twelfth aspect of the present invention, there is a method provided of deciding dentofacial deformity, comprising steps of:
[0067] calculating P′=((S−B)+(Go−Me))/((S−A)+(S−N)) using the distance (S−A) between S and A, the distance (S−N) between S and N, the distance (S−B) between S and B and the distance (Go−Me) between Go and Me which are measured by cephalometric radiography of a patient, or further omitting the figures of the fourth decimal place and under of P′, and calculating
[0000] Q ′=( P′−[P ′])×1000 ([ ] denotes Gauss's symbol) (where 1.000≦ P< 2.000),
[0000] or
[0000] Q ′=( P ′−([ P′]+ 1))×1000 ([ ] denotes Gauss's symbol) (where P′< 1.000); and
[0068] deciding whether the patient suffers from dentofacial deformity by deciding whether calculated P′ or Q′ is equal to or larger than the predetermined value or not, respectively.
[0069] The method of calculating the index for deciding dentofacial deformity can be executed by a computer comprising the predetermined programs including equations of P′ and Q′. The programs can be stored in various kinds of computer readable recording media such as CD-ROMs, etc., for example, or can be provided through the telecommunications lines such as the Internet, etc. The necessary data for the calculation can be obtained in the same way as the method of calculating the index for deciding the necessity of surgically operating on the jaw. Also, the method of deciding dentofacial deformity can be executed by a computer comprising the predetermined programs including equations of P′ and Q′ or equations for decision of P′ and Q′. The programs can be stored in various kinds of computer readable recording media such as CD-ROMs, etc., for example, or can be provided through the telecommunications lines such as the Internet, etc. The necessary data for the calculations can be obtained in the same way as the method of deciding the necessity of surgically operating on the jaw.
[0070] According to embodiments of the present invention, in orthodontic treatment of a patient, an index may be calculated for deciding the necessity of surgically operating on the jaw, which becomes an objective criterion to decide the necessity of surgically operating on the jaw of the patient, and by appropriately combining the results of other inspection methods, the dentist may be able to make a correct diagnosis with higher objectivity and more easily, moreover within a short period of time. Also, in the dental treatment such as orthodontic treatment, etc. of a patient, an index may be calculated for deciding disharmony of the maxilla and mandible, which becomes an objective criterion to decide disharmony of the maxilla and mandible of the patient, and by appropriately combining the results of other inspection methods, the dentist may be able to make a correct diagnosis more easily with higher objectivity, moreover within a short period of time. Also, an index may be calculated for deciding dentofacial deformity, which becomes an objective criterion to decide whether a patient suffers from dentofacial deformity or not, and by appropriately combining the results of other inspection methods, the doctor or the dentist may be able to make a correct diagnosis more easily with higher objectivity, moreover within a short period of time.
BRIEF DESCRIPTION OF THE DRAWINGS
[0071] FIG. 1 is a schematic drawing for explaining the measured points in a cephalometric radiogram.
[0072] FIG. 2 is a flowchart showing a method of calculating an index for deciding the necessity of surgically operating on the jaw in orthodontic treatment according to the first embodiment of the present invention.
[0073] FIG. 3 is a tracing made based on a cephalometric radiogram of a patient 1.
[0074] FIG. 4 is a tracing made based on a cephalometric radiogram taken after the severing operation on the mandible of the patient 1.
[0075] FIG. 5 is a tracing made based on a cephalometric radiogram of a patient 2.
[0076] FIG. 6 is a tracing made based on a cephalometric radiogram taken after the severing operation on the mandible of the patient 2.
[0077] FIG. 7 is a tracing made based on a cephalometric radiogram of a patient 3.
[0078] FIG. 8 is a tracing made based on a cephalometric radiogram of a patient 4.
[0079] FIG. 9 is a tracing made based on a cephalometric radiogram of a patient 5.
[0080] FIG. 10 is a tracing made based on a cephalometric radiogram of a patient 6.
[0081] FIG. 11 is a tracing made based on a cephalometric radiogram taken after severing operation on the mandible of the patient 6.
[0082] FIG. 12 is a tracing made based on a cephalometric radiogram of a patient 7.
[0083] FIG. 13 is a tracing made based on a cephalometric radiogram of a patient 8.
[0084] FIG. 14 is a tracing made based on a cephalometric radiogram of a patient 9.
[0085] FIG. 15 is a tracing made based on a cephalometric radiogram of a patient 10.
[0086] FIG. 16 is a tracing made based on a cephalometric radiogram of a patient 11.
[0087] FIG. 17 is a tracing made based on a cephalometric radiogram of a patient 12.
[0088] FIG. 18 is a schematic diagram showing results of calculation of OPE index Q of the patients 1 to 12.
[0089] FIG. 19 is a flowchart showing a method of deciding the necessity of surgically operating on the jaw in orthodontic treatment according to the second embodiment of the present invention.
[0090] FIG. 20 is a flowchart showing a method of calculating an index for deciding the necessity of surgically operating on the jaw in orthodontic treatment according to the third embodiment of the present invention.
[0091] FIG. 21 is a flowchart showing a method of deciding the necessity of surgically operating on the jaw in orthodontic treatment according to the fourth embodiment of the present invention.
[0092] FIG. 22 is a schematic drawing showing a data processor to be used for execution of the method of calculating an index for deciding the necessity of surgically operating on the jaw, the method of deciding the necessity of surgically operating on the jaw, the method of calculating an index for deciding disharmony of the maxilla and mandible, the method of deciding disharmony of the maxilla and mandible, the method of calculating an index for deciding dentofacial deformity, or the method of deciding dentofacial deformity according to the first to the twelfth embodiments of the present invention.
DETAILED DESCRIPTION
[0093] Embodiments of the invention will now be explained below with reference to the drawings.
[0094] First explained is the first embodiment.
[0095] In the first embodiment, a method of calculating an OPE index as an index for deciding the necessity of surgically operating on the jaw in orthodontic treatment is explained.
[0096] FIG. 2 shows a flowchart of a method of calculation. Programs are created according to the flowchart, and are executed on a computer.
[0097] Before making the calculation, taking a cephalometric radiogram of a patient to be treated orthodontic treatment, the distance (S−A) between S and A, the distance (S−B) between S and B and the distance (Go−Me) between Go and Me are measured. The measurement of the distances can be executed by entering the coordinate data of measured points of S, A, B, Go and Me on the cephalometric radiogram, for example, by using a pen tablet or a digitizer. Or, by scanning the image data obtained by cephalometric radiography to a computer, and measuring the coordinates of S, A, B, Go and Me from the image data, the distances (S−A), (S−B) and (Go−Me) may be obtained by calculations from the measured coordinates.
[0098] As shown in FIG. 2 , in step S 1 , the distances (S−A), (S−B) and (Go−Me) which are measured by the above are entered.
[0099] In step S 2 , from the entered distances (S−A), (S−B) and (Go−Me), P is calculated according to
[0000] P =(( S−B )+( Go−Me ))/( S−A ).
[0100] In the step S 3 , omitting the figures of the fourth decimal place and under of P obtained by the above calculation, and in case of 2.000≦P<3.000,
[0101] calculating an OPE index Q according to Q=(P−[P])×1000, and in case of P<2.000,
[0102] calculating an OPE index Q according to Q=(P−([P]+1))×1000.
[0103] In step S 4 , the OPE index Q calculated as the above is output on a display, for example.
[0104] In the case that the OPE index Q calculated like this is equal to or larger than 400, in orthodontic treatment, it can be diagnosed that the surgical application, in other words, the surgical operation on the jaw, typically the severing operation on the mandible is necessary. Also, in case that the OPE index Q is equal to or larger than 350 or less than 400, which is a borderline case, by the distance (S−N) and Wits analysis, a supplementary analysis is added. In case that the distance (S−N) is shorter than over 2SD than the average, when the result of Wits analysis is equal to or larger than 12 mm, it is decided that the surgical application, in other words, the surgical operation of the jaw is necessary.
[0105] In case that the OPE index Q is less than 350, equal to or larger than 0, in orthodontic treatment, it can be decided that the surgical operation on the jaw is not necessary.
[0106] Also, in the case that the OPE index Q is negative, meaning a high retrograde growth tendency (bradyauxesis) of the mandible or an overgrowth (tachyauxesis) tendency of the maxilla, it is necessary to consider the surgical operation on the jaw. Generally, in the case that the OPE index Q is equal to or larger than −50, and less than 0, the necessity of the surgical operation on the jaw becomes high.
[0107] Generally, in addition to the OPE index Q, a dentist finally decides the necessity of surgically operating on the jaw by combining the results of other inspections, such as conventional cephalometric analysis, etc., and focusing mainly on the angle measurement.
Example 1
[0108] A cephalometric radiogram of patient 1 was taken. FIG. 3 shows a tracing made based on the cephalometric radiogram.
[0109] From FIG. 3 , the distances (S−A), (S−B) and (Go−Me) were measured. The results are: (S−A)=78.0 mm, (S−B)=123.0 mm and (Go−Me)=78.0 mm. Using the data, the calculation of P is given as follows: (123.0+78.0)/78.0=2.576. Therefore, the OPE index Q is 576. This means that the disharmony of the maxilla and mandible is very large, and patient 1 suffers from dentofacial deformity. In this case, (S−N)=67.0 mm and Wits=17.0 mm.
[0110] As the OPE index Q is 576, it can be decided that the severing operation on the mandible is necessary for orthodontic treatment.
[0111] Therefore, the severing operation on the mandible was performed. After the severing operation, a cephalometric radiogram of the patient 1 was taken. A tracing made based on the cephalometric radiogram is shown in FIG. 4 .
[0112] From FIG. 4 , the distances (S−A), (S−B) and (Go−Me) were measured. The results are: (S−A)=78.0 mm, (S−B)=111.0 mm and (Go−Me)=73.0 mm. Using the data, the calculation of P is given as follows: (111.0+73.0)/78.0=2.358. Therefore, the OPE index Q is 358. This means that the disharmony of the maxilla and mandible was improved and patient 1 does not suffer from dentofacial deformity. In this case, (S−N)=67.0 mm and Wits=4.0 mm.
[0113] As the OPE index Q is 358, it can be decided that patient 1 able to be treated by orthodontic treatment from the results of the severing operation on the mandible.
Example 2
[0114] A cephalometric radiogram of patient 2 was taken. A tracing made based on the cephalometric radiogram is shown in FIG. 5 .
[0115] From FIG. 5 , the distances (S−A), (S−B) and (Go−Me) were measured. The results are: (S−A)=83.0 mm, (S−B)=123.0 mm and (Go−Me)=81.0 mm. Using the data, the calculation of P is given as follows: (123.0+81.0)/83.0=2.457. Therefore, the OPE index Q is 457. This means that the disharmony of the maxilla and mandible is very large and patient 2 suffers from dentofacial deformity. In this case, (S−N)=69.0 mm and Wits=16.0 mm.
[0116] As the OPE index Q 457, it can be decided that patient 2 needs the severing operation on the mandible.
[0117] Therefore, the necessary severing operation on the mandible was performed. After the severing operation, a cephalometric radiogram of the patient 2 was taken. A tracing made based on the cephalometric radiogram is shown in FIG. 6 .
[0118] From FIG. 6 , the distances (S−A), (S−B) and (Go−Me) were measured. The results are: (S−A)=83.0 mm, (S−B)=116.0 mm and (Go−Me)=80.0 mm. Using the data, the calculation of P is given as follows: (116.0+80.0)/83.0=2.361. Therefore, the OPE index Q is 361. This means that the disharmony of the maxilla and mandible was improved and patient 2 does not suffer from dentofacial deformity. In this case, (S−N)=69.0 mm and Wits=6.0 mm.
[0119] As the OPE index Q 361, it decided that patient 2 was able to be treated by orthodontic treatment from the results of the severing operation on the mandible.
Example 3
[0120] A cephalometric radiogram of patient 3 was taken. A tracing made based on the cephalometric radiogram is shown in FIG. 7 .
[0121] From FIG. 7 , the distances (S−A), (S−B) and (Go−Me) were measured. The results are: (S−A)=88.0 mm, (S−B)=126.0 mm and (Go−Me)=78.0 mm. Using the data, the calculation of P is given as follows: (126.0+78.0)/88.0=2.318. Therefore, the OPE index Q is 318. In this case, (S−N)=67.0 mm and Wits=7.0 mm.
[0122] It is a case of light skeletal Class III, however, as the OPE index Q was 318, it can be decided that the patient 3 not need to have the jaw operated on at the time of performing orthodontic treatment.
Example 4
[0123] A cephalometric radiogram of patient 4 was taken. A tracing made based on the cephalometric radiogram is shown in FIG. 8 .
[0124] From FIG. 8 , the distances (S−A), (S−B) and (Go−Me) were measured. The results are: (S−A)=85.0 mm, (S−B)=119.0 mm and (Go−Me)=77.0 mm. Using the data, the calculation of P is given as follows: (119.0+77.0)/85.0=2.305. Therefore, the OPE index Q is 305. In this case, (S−N)=64.0 mm and Wits=9.0 mm.
[0125] It is a case of skeletal Class III, however, as the OPE index Q 305, it can be decided that patient 4 does not need to have the jaw operated on at the time of performing orthodontic treatment.
Example 5
[0126] A cephalometric radiogram of patient 5 was taken. A tracing made based on the cephalometric radiogram is shown in FIG. 9 .
[0127] From FIG. 9 , the distances (S−A), (S−B) and (Go−Me) were measured. The results are: (S−A)=75.0 mm, (S−B)=109.0 mm and (Go−Me)=70.0 mm. Using the data, the calculation of P is given as follows: (109.0+70.0)/75.0=2.386. Therefore, the OPE index Q is 386. In this case, (S−N)=65.0 mm and Wits=10.0 mm.
[0128] As the OPE index Q is 386, it is a borderline case. As Wits is 10.0 mm, it is quite a skeletally strong case, but with (S−N)=65.0 mm, it can be decided that the operation on the jaw is not needed at the time of performing orthodontic treatment.
Example 6
[0129] A cephalometric radiogram of patient 6 was taken. A tracing made based on the cephalometric radiogram is shown in FIG. 10 .
[0130] From FIG. 10 , the distances (S−A), (S−B) and (Go−Me) were measured. The results are: (S−A)=87.0 mm, (S−B)=128.0 mm and (Go−Me)=80.0 mm. Using the data, the calculation of P is given as follows: (128.0+80.0)/87.0=2.390. Therefore, the OPE index Q is 390. In this case, (S−N)=68.0 mm and Wits=12.0 mm.
[0131] As the OPE index Q is 390, it a borderline case. The Wits 12.0 mm, which is larger than 10.0 mm, also, with (S−N)=68.0 mm, it can be decided to be a case of skeletal Class III, and patient 6 suffers from dentofacial deformity, and it can be decided that the severing operation on the mandible is necessary.
[0132] Therefore, the necessary severing operation on the mandible was performed. After the severing operation, a cephalometric radiogram of patient 6 was taken. A tracing made based on the cephalometric radiogram is shown in FIG. 11 .
[0133] From FIG. 11 , the distances (S−A), (S−B) and (Go−Me) were measured. The results are: (S−A)=87.0 mm, (S−B)=121.0 mm and (Go−Me)=73.0 mm. Using the data, the calculation of P is given as follows: (121.0+73.0)/87.0=2.229. Therefore, the OPE index Q is 229. In this case, (S−N)=68.0 mm and Wits=5.0 mm.
[0134] As the OPE index Q is 229, it can be decided that patient 6 is able to be treated by orthodontic treatment from the results of the severing operation on the mandible.
Example 7
[0135] A cephalometric radiogram of patient 7 was taken. A tracing made based on the cephalometric radiogram is shown in FIG. 12 .
[0136] From FIG. 12 , the distances (S−A), (S−B) and (Go−Me) were measured. The results are: (S−A)=86.0 mm, (S−B)=111.0 mm and (Go−Me)=69.0 mm. Using the data, the calculation of P is given as follows: (111.0+69.0)/86.0=2.093. Therefore, the OPE index Q is 93. In this case, (S−N)=67.0 mm and Wits=0 mm.
[0137] The OPE index Q is 93, and there a retrograde growth tendency of the mandible, but it can be decided that the patient 7 does not need to have the jaw operated on at the time of performing orthodontic treatment, and an orthodontic treatment of a tooth extraction is applied.
Example 8
[0138] A cephalometric radiogram of patient 8 was taken. A tracing made based on the cephalometric radiogram is shown in FIG. 13 .
[0139] From FIG. 13 , the distances (S−A), (S−B) and (Go−Me) were measured. The results are: (S−A)=90.0 mm, (S−B)=127.0 mm and (Go−Me)=80.0 mm. Using the data, the calculation of P is given as follows: (127.0+80.0)/90.0=2.300. Therefore, the OPE index Q is 300. In this case, (S−N)=68.0 mm and Wits=11.0 mm.
[0140] As the OPE index Q is 300, it can be judged that patient 8 does not need to have the jaw operated on at the time of performing orthodontic treatment.
Example 9
[0141] A cephalometric radiogram of patient 9 was taken. A tracing made based on the cephalometric radiogram is shown in FIG. 14 .
[0142] From FIG. 14 , the distances (S−A), (S−B) and (Go−Me) were measured. The results are: (S−A)=79.0 mm, (S−B)=105.0 mm and (Go−Me)=73.0 mm. Using the data, the calculation of P is given as follows: (105.0+73.0)/79.0=2.253. Therefore, the OPE index Q is 253. In this case, (S−N)=68.0 mm and Wits=3.0 mm.
[0143] As the OPE index Q is 253, it can be decided that patient 9 does not need to have the jaw operated on at the time of performing orthodontic treatment.
Example 10
[0144] A cephalometric radiogram of patient 10 was taken. A tracing made based on the cephalometric radiogram is shown in FIG. 15 .
[0145] From FIG. 15 , the distances (S−A), (S−B) and (Go−Me) were measured. The results are: (S−A)=81.0 mm, (S−B)=103.0 mm and (Go−Me)=70.0 mm. Using the data, the calculation of P is given as follows: (103.0+70.0)/81.0=2.135. Therefore, the OPE index Q is 135. In this case, (S−N)=69.0 mm and Wits=3.0 mm.
[0146] It is a non-skeletal case, but the OPE index Q is 135, it can be decided that patient 10 does not need to have the jaw operated on at the time of performing orthodontic treatment, and orthodontic treatment by a non-tooth extraction treatment is applied.
Example 11
[0147] A cephalometric radiogram of patient 11 was taken. A tracing made based on the cephalometric radiogram is shown in FIG. 16 .
[0148] From FIG. 16 , the distances (S−A), (S−B) and (Go−Me) were measured. The results are: (S−A)=81.0 mm, (S−B)=108.0 mm and (Go−Me)=68.0 mm. Using the data, the calculation of P is given as follows: (108.0+68.0)/81.0=2.172. Therefore, the OPE index Q is 172. In this case, (S−N)=63.0 mm and Wits=2.0 mm.
[0149] The OPE index Q is 172 and Wits is 2.0 mm, which is a non-skeletal case, but it can be decided that patient 11 does not need the jaw to be operated on at the time of performing orthodontic treatment, and orthodontic treatment by a non-tooth extraction is applied.
Example 12
[0150] A cephalometric radiogram of patient 12 was taken. A tracing made based on the cephalometric radiogram is shown in FIG. 17 .
[0151] From FIG. 17 , the distances (S−A), (S−B) and (Go−Me) were measured. The results are: (S−A)=91.0 mm, (S−B)=115.0 mm and (Go−Me)=65.0 mm. Using the data, the calculation of P is given as follows: (115.0+65.0)/91.0=1.978. Therefore, the OPE index Q is −22. In this case, (S−N)=74.0 mm and Wits=0 mm.
[0152] As the OPE index Q is −22, it a borderline case. Generally, in case of −50≦Q<0, at the time of performing orthodontic treatment, the necessity of operating on the jaw becomes high, but this is a case of mandible with a strong retrograde growth tendency, it can be decided that the patient 12 does not need to have the jaw operated on at the time of performing orthodontic treatment.
[0153] The results of calculation of OPE index Q of patients 1 to 12 are summarized in FIG. 18 .
[0154] As explained, according to the method of calculating an index for deciding the necessity of surgically operating on the jaw according to the first embodiment, the OPE index Q can be calculated by using the distances (S−A), (S−B) and (Go−Me) which are measured by cephalometric radiography. And, based on the OPE index Q, without being influenced by the experience of a dentist, the necessity of the surgical operation on the jaw in orthodontic treatment can be decided correctly within a short period of time, moreover with a certain objectivity.
[0155] Next explained is the second embodiment.
[0156] In the second embodiment, a method of deciding the necessity of surgically operating on the jaw in orthodontic treatment is explained.
[0157] A flowchart of the method of deciding the necessity of surgically operating on the jaw is shown in FIG. 19 . According to the flowchart, a program is created, and is executed on a computer.
[0158] As the same as the first embodiment, before executing the method of deciding the necessity of surgically operating on the jaw, the distances (S−A), (S−B) and (Go−Me) are measured.
[0159] As shown in FIG. 19 , in step S 11 , the distances (S−A), (S−B) and (Go−Me) which are measured as the above are entered.
[0160] In step S 12 , from the entered (S−A), (S−B) and (Go−Me), P is calculated according to
[0000] P =(( S−B )+( Go−Me ))/( S−A ).
[0161] In step S 13 , from P obtained by the calculation of the above, whether 2.000≦P<3.000 or P<2.000 is decided. As the result of the decision, in case of 2.000≦P<3.000, omitting the figures of the fourth decimal place and under of P, the OPE index Q is calculated according to
[0000] Q =( P−[P ])×1000),
[0162] and in case of P<2.000, the OPE index Q is calculated according to
[0000] Q =( P −([ P]+ 1))×1000.
[0163] In step S 14 , the OPE index Q calculated in this way is decided whether equal to or larger than 400, or not.
[0164] In step S 15 , in case that the OPE index Q is equal to or larger than 400, in orthodontic treatment, it is decided that the severing operation on the mandible is necessary.
[0165] In step S 16 , the result of the decision that the severing operation on the jaw is necessary is output on a display, for example.
[0166] In step S 14 , in the case that Q is decided not to be equal to nor larger than 400, in step S 17 , Q is decided whether equal to or larger than 350, or less than 400, or not.
[0167] In case that the OPE index Q is equal to or larger than 350, and less than 400, in step S 18 , it is decided whether the distance (S−N) is shorter than over 2SD than the average, and Wits is equal to or larger than 12 mm or not. If applicable, in step S 19 , it is decided whether the surgical operation on the jaw is necessary.
[0168] When being decided that the surgical operation on the jaw is necessary, in step S 20 , the result of the decision is output on a display, for example.
[0169] In step S 18 , when being decided whether the distance (S−N) is not shorter than over 2SD than the average, and Wits is not equal to nor larger than 12 mm, in step S 21 , it is decided that the surgical operation on the jaw is not necessary.
[0170] When being decided that the surgical operation on the jaw is not necessary, in step S 22 , the result of the decision is output on a display, for example.
[0171] In step S 17 , in case that Q is decided not to be equal to or larger than 350, and not equal to nor less than 400, in step S 23 , it is decided whether Q is equal to or larger than 0 and less than 350, or not.
[0172] When being decided whether the OPE index Q is equal to or larger than 0 and less than 350, in step S 24 , it is decided whether the surgical operation on the jaw is not necessary.
[0173] When being decided that the surgical operation on the jaw is not necessary, in step S 25 , the results of the decision is output on a display, for example.
[0174] In case that the OPE index Q is not decided to be equal to or larger than 0 and less than 350, the OPE index Q becomes negative. In this case, in step S 26 , a dentist decides the necessity of the surgical operation on the jaw, in step S 27 , the result of diagnosis is output on a display, for example.
[0175] According to the method of deciding the necessity of surgically operating on the jaw, according to the second embodiment, (based on the OPE index Q to be calculated using the distances (S−A), (S−B) and (Go−Me) which are measured by cephalometric radiography, in orthodontic treatment) the necessity of the surgical operation on the jaw can be decided correctly within a short period of time, moreover with a certain objectivity, without being influenced by the experience of a dentist.
[0176] Next explained is the third embodiment.
[0177] In the third embodiment, a method of calculating an OPE index as an index for deciding the necessity of surgically operating on the jaw in orthodontic treatment is explained.
[0178] A flowchart of the method of the calculation is shown in FIG. 20 . According to the flowchart, a program is created, and is executed on a computer.
[0179] Before making the calculation, taking a cephalometric radiogram of a patient to be treated by orthodontic treatment, the distances (S−A), (S−N), (S−B) and (Go−Me) are measured. The measurement of the distances can be made by entering the coordinate data of measured points of S, A, N, B, Go and Me on the cephalometric radiogram by using a pen tablet or a digitizer, for example. Or, the image data obtained by cephalometric radiography is taken in a computer, and the coordinates of S, A, N, B, Go and Me are measured from the image data, and from the coordinates which are measured like this, the distances (S−A), (S−N), (S−B) and (Go−Me) may be obtained by calculations.
[0180] As shown in FIG. 20 , in step S 31 , the distances (S−A), (S−N), (S−B) and (Go−Me) which are measured by the above are entered.
[0181] In step S 32 , from the entered (S−A), (S−N), (S−B) and (Go−Me), P′ is calculated according to
[0000] P ′=(( S−B )+( Go−Me ))/(( S−A )+( S−N )).
[0182] In step S 33 , omitting the figures of the fourth decimal place and under of P′ obtained by the calculation, in case of 1.000≦P′<2.000,
[0183] the OPE index Q′ is calculated according to
[0000] Q ′=( P′−[P ′])×1000, and
[0184] in case of P′<1.000,
[0185] the OPE index Q′ is calculated according to Q′=(P′−([P′]+1))×1000.
[0186] In step S 34 , the OPE index Q′ calculated as the above is output on a display, for example.
[0187] In case that the OPE index Q′ calculated as the above is equal to or larger than 330, in orthodontic treatment, it can be diagnosed that the severing operation on the jaw, typically the mandible, is necessary. Also, in the case that the OPE index Q′ is equal to or larger than 270 and less than 330, which is a borderline case, by Wits analysis, a supplementary analysis is added. In the case that the result of Wits analysis is equal to or larger than 12 mm, it is decided that the surgical application, in other words, the surgical operation on the jaw, is necessary.
[0188] In the case that the OPE index Q′ is less than 330 and equal to or larger than 0, in orthodontic treatment, it can be diagnosed that the surgical operation on the jaw is not necessary.
[0189] In case that the OPE index Q′ is negative, also, denoting that a strong retrograde growth tendency of the mandible or an overgrowth tendency of the maxilla, it is necessary to consider the surgical operation on the jaw.
[0190] Generally, in addition to the OPE index Q′, a dentist finally decides the necessity of operating the jaw combining other inspection results such as the conventional cephalometric analysis focusing mainly on angle measurement, etc.
Example 13
[0191] By FIG. 3 showing the tracing made based on the cephalometric radiogram of patient 1 taken in the example 1, the distances (S−A), (S−N), (S−B) and (Go−Me) were measured. The results are: (S−A)=78.0 mm, (S−N)=67.0 mm, (S−B)=123.0 mm and (Go−Me)=78.0 mm. Using the data, the calculation of P′ is given as follows: (123.0+78.0)/(78.0+67.0)=1.386. Therefore, the OPE index Q′ is 386. In this case, Wits=17.0 mm.
[0192] As the OPE index Q′ is 386, it can be decided that patient 1 needs the severing operation on the mandible in orthodontic treatment.
[0193] Therefore, the necessary severing operation on the mandible was performed. By FIG. 4 showing the tracing made based on the cephalometric radiogram after the severing operation on the mandible of patient 1 taken in the example 1, the distances (S−A), (S−N), (S−B) and (Go−Me) were measured. The results are: (S−A)=78.0 mm, (S−N)=67.0 mm, (S−B)=111.0 mm and (Go−Me)=73.0 mm. Using the data, the calculation of P′ is given as follows: (111.0+73.0)/(78.0+67.0)=1.268. Therefore, the OPE index Q′ is 268. In this case, Wits=4.0 mm.
[0194] As the OPE index Q′ is 268, it can be decided that patient 1 is able to be treated by orthodontic treatment with the results of the severing operation on the mandible.
Example 14
[0195] By FIG. 5 showing the tracing made based on the cephalometric radiogram of patient 2 taken in the example 2, the distances (S−A), (S−N), (S−B) and (Go−Me) were measured. The results are: (S−A)=83.0 mm, (S−N)=69.0 mm, (S−B)=123.0 mm and (Go−Me)=81.0 mm. Using the data, the calculation of P′ is given as follows: (123.0+81.0)/(83.0+69.0)=1.342. Therefore, the OPE index Q′ is 342. In this case, Wits=16.0 mm.
[0196] As the OPE index Q′ is 342, it can be decided that patient 2 needs the severing operation on the mandible.
[0197] Therefore, the necessary severing operation on the mandible was performed. By FIG. 6 showing the tracing made based on the cephalometric radiogram taken after the severing operation on the mandible of the patient 2, the distances (S−A), (S−N), (S−B) and (Go−Me) were measured. The results are: (S−A)=83.0 mm, (S−N)=69.0 mm, (S−B)=116.0 mm and (Go−Me)=80.0 mm. Using the data, the calculation of P′ is given as follows: (116.0+80.0)/(83.0+69.0)=1.289. Therefore, the OPE index Q′ is 289. In this case, Wits=6.0 mm.
[0198] As the OPE index Q′ is 289, it can be decided that patient 2 is able to be treated orthodontic treatment with the results of the severing operation on the mandible.
Example 15
[0199] By FIG. 7 showing the tracing made based on the cephalometric radiogram of patient 3 taken in the example 3, the distances (S−A), (S−N), (S−B) and (Go−Me) were measured. The results: (S−A)=88.0 mm, (S−N)=67.0 mm, (S−B)=126.0 mm and (Go−Me)=78.0 mm. Using the data, the calculation of P′ is given as follows: (126.0+78.0)/(88.0+67.0)=1.316. Therefore, the OPE index Q′ is 316. In this case, Wits=7.0 mm.
[0200] This is a case of light skeletal class III, but as the OPE index Q′ is 316, it can be decided that the patient 3 does not need to have the jaw operated on at the time of performing orthodontic treatment.
Example 16
[0201] By FIG. 8 showing the tracing made based on the cephalometric radiogram of the patient 4 taken in the example 4, the distances (S−A), (S−N), (S−B) and (Go−Me) were measured. The results: (S−A)=85.0 mm, (S−N)=64.0 mm, (S−B)=119.0 mm and (Go−Me)=77.0 mm. Using the data, the calculation of P′ is given as follows: (119.0+77.0)/(85.0+64.0)=1.315. Therefore, the OPE index Q′ is 315. In this case, Wits=9.0 mm.
[0202] This a case of skeletal class III, but as the OPE index Q′ is 315, it can be decided that patient 4 does not need to have the jaw operated on at the time of performing orthodontic treatment.
Example 17
[0203] By FIG. 9 showing the tracing made based on the cephalometric radiogram of the patient 5 taken in the example 5, the distances (S−A), (S−N), (S−B) and (Go−Me) were measured. The results: (S−A)=75.0 mm, (S−N)=65.0 mm, (S−B)=109.0 mm and (Go−Me)=70.0 mm. Using the data, the calculation of P′ is given as follows: (109.0+70.0)/(75.0+65.0)=1.278. Therefore, the OPE index Q′ is 278. In this case, Wits=10.0 mm.
[0204] As the OPE index Q′ is 278, it a borderline case. Wits is 10.0 mm, which a very strong skeletal case, however, the Wits was equal to or less than 12 mm, further with (S−N)=65.0 mm, so it can be decided that the jaw operation is not necessary at the time of performing orthodontic treatment.
Example 18
[0205] By FIG. 10 showing the tracing made based on the cephalometric radiogram of patient 6 taken in the example 6, the distances (S−A), (S−N), (S−B) and (Go−Me) were measured. The results: (S−A)=87.0 mm, (S−N)=68.0 mm, (S−B)=128.0 mm and (Go−Me)=80.0 mm. Using the data, the calculation of P′ is given as follows: (128.0+80.0)/(87.0+68.0)=1.341. Therefore, the OPE index Q′ is 341. In this case, Wits=12.0 mm.
[0206] As the OPE index Q′ is 341, it a borderline case. Wits 12.0 mm, further with (S−N)=68.0 mm which a skeletal class III, and it can be decided as a dentofacial deformity, and decided that the severing operation on the mandible necessary.
[0207] Therefore, the necessary severing operation on the mandible was performed. By FIG. 11 showing the tracing made based on the cephalometric radiogram taken after the severing operation on the mandible of patient 6, the distances (S−A), (S−N), (S−B) and (Go−Me) were measured. The results are: (S−A)=87.0 mm, (S−N)=68.0 mm, (S−B)=121.0 mm and (Go−Me)=73.0 mm. Using the data, the calculation of P′ is given as follows: (121.0+73.0)/(87.0+68.0)=1.251. Therefore, the OPE index Q′ is 251. In this case, Wits=5.0 mm.
[0208] As the OPE index Q′ is 251, it can be decided that patient 6 is able to be treated by orthodontic treatment with the results of the severing operation on the mandible.
Example 19
[0209] By FIG. 12 showing the tracing made based on the cephalometric radiogram of patient 7 taken in the example 7, the distances (S−A), (S−N), (S−B) and (Go−Me) were measured. The results: (S−A)=86.0 mm, (S−N)=67.0 mm, (S−B)=111.0 mm and (Go−Me)=69.0 mm. Using the data, the calculation of P′ is given as follows: (111.0+69.0)/(86.0+67.0)=1.176. Therefore, the OPE index Q′ is 176. In this case, Wits=0 mm.
[0210] The OPE index Q′ is 176, and there a retrograde growth tendency of the mandible, but it can be decided that the patient 7 does not need to have the jaw operated on at the time of performing orthodontic treatment, and orthodontic treatment by a tooth extracting is applied.
Example 20
[0211] By FIG. 13 showing the tracing made based on the cephalometric radiogram of patient 8 taken in the example 8, the distances (S−A), (S−N), (S−B) and (Go−Me) were measured. The results: (S−A)=90.0 mm, (S−N)=68.0 mm, (S−B)=127.0 mm and (Go−Me)=80.0 mm. Using the data, the calculation of P′ is given as follows: (127.0+80.0)/(90.0+68.0)=1.310. Therefore, the OPE index Q′ is 310. In this case, Wits=11.0 mm.
[0212] As the OPE index Q′ is 310, it can be decided that patient 8 does not need to have the jaw operated on at the time of performing orthodontic treatment.
Example 21
[0213] By FIG. 14 showing the tracing made based on the cephalometric radiogram of patient 9 taken in the example 9, the distances (S−A), (S−N), (S−B) and (Go−Me) were measured. The results: (S−A)=79.0 mm, (S−N)=68.0 mm, (S−B)=105.0 mm and (Go−Me)=73.0 mm. Using the data, the calculation of P′ is given as follows (105.0+73.0)/(79.0+68.0)=1.210. Therefore, the OPE index Q′ is 210. In this case, Wits=3.0 mm.
[0214] As the OPE index Q′ is 210, it can be decided that patient 9 does not need to have the jaw operated on at the time of performing orthodontic treatment.
Example 22
[0215] By FIG. 15 showing the tracing made based on the cephalometric radiogram of patient 10 taken in the example 10, the distances (S−A), (S−N), (S−B) and (Go−Me) were measured. The results: (S−A)=81.0 mm, (S−N)=69.0 mm, (S−B)=103.0 mm and (Go−Me)=70.0 mm. Using the data, the calculation of P′ is given as follows: (103.0+70.0)/(81.0+69.0)=1.153. Therefore, the OPE index Q′ is 153. In this case, Wits=4.0 mm.
[0216] This is a case of non-skeletal, but the OPE index Q′ is 153, therefore, it can be decided that the patient 10 does not need to have the jaw operated on at the time of performing orthodontic treatment, and orthodontic treatment by a non-tooth extraction treatment is applied.
Example 23
[0217] By FIG. 16 showing the tracing made based on the cephalometric radiogram of patient 11 taken in the example 11, the distances (S−A), (S−N), (S−B) and (Go−Me) were measured. The results: (S−A)=81.0 mm, (S−N)=63.0 mm, (S−B)=108.0 mm and (Go−Me)=68.0 mm. Using the data, the calculation of P′ is given as follows: (108.0+68.0)/(81.0+63.0)=1.222. Therefore, the OPE index Q′ is 222. In this case, Wits=2.0 mm.
[0218] As the OPE index Q′ is 222, and Wits is 2.0 mm, which is a non-skeletal case, but it can be decided that patient 11 does not need to have the jaw operated on at the time of performing orthodontic treatment, and orthodontic treatment by a non-tooth extraction treatment is applied.
Example 24
[0219] By FIG. 17 showing the tracing made based on the cephalometric radiogram of patient 12 taken in the example 12, the distances (S−A), (S−N), (S−B) and (Go−Me) were measured. The results: (S−A)=91.0 mm, (S−N)=74.0 mm, (S−B)=115.0 mm and (Go−Me)=65.0 mm. Using the data, the calculation of P′ is given as follows: (115.0+65.0)/(91.0+74.0)=1.090. Therefore, the OPE index Q′ is 90. In this case, Wits=0.0 mm.
[0220] As the OPE index Q′ is 90, it a borderline case. The patient 12 has a strong retrograde growth tendency of the mandible, and it can be decided that patient 12 does not need to have the jaw operated on at the time of performing orthodontic treatment.
[0221] As explained, by the method of calculating an index for deciding the necessity of surgically operating on the jaw according to the third embodiment, using the distances of (S−A), (S−N), (S−B) and (Go−Me) which are measured by cephalometric radiography, the OPE index Q′ can be calculated. And, based on the OPE index Q′, without being influenced by the experience of a dentist, the necessity of the surgical operation on the jaw in orthodontic treatment can be diagnosed correctly within a short period of time, moreover with a certain objectivity.
[0222] Next explained is the fourth embodiment.
[0223] In the fourth embodiment, the method of deciding the necessity of surgically operating on the jaw in orthodontic treatment is explained.
[0224] A flowchart of the method of deciding the necessity of surgically operating on the jaw is shown in FIG. 21 . A program is created according to the flowchart, and is executed on a computer.
[0225] As the same as the third embodiment, before executing the method of deciding the necessity of surgically operating on the jaw, the distances (S−A), (S−N), (S−B) and (Go−Me) are measured.
[0226] As shown in FIG. 21 , in step S 41 , the distances (S−A), (S−N), (S−B) and (Go−Me) which are measured by the above are entered.
[0227] In step S 42 , from the entered (S−A), (S−N), (S−B) and (Go−Me), P′ is calculated according to
[0000] P ′=(( S−B )+( Go−Me ))/(( S−A )+( S−N )).
[0228] In step S 43 , from P′ obtained by the calculation, it is decided whether 1.000≦P<2.000 or P′<1.000. As the result of decision, in the case of 1.000≦P′<2.000, omitting the figures of the fourth decimal place and under of P′, the OPE index Q′ is calculated according to,
[0000] Q ′=( P′−[P ′])×1000,
[0000] and in case of P′<1.000, the OPE index Q′ is calculated according to
[0000] Q ′=( P ′−([ P′]+ 1))×1000.
[0229] In step S 44 , the OPE index Q′ calculated as the above is decided whether equal to or larger than 330 or not.
[0230] In step S 45 , in the case that the OPE index Q′ is equal to or larger than 330, in orthodontic treatment, it is decided that the severing operation on the jaw, typically the mandible is necessary.
[0231] In step S 46 , the result of the decision, that the severing operation on the jaw is necessary, is output on a display, for example.
[0232] In step S 44 , in the case that Q′ is decided not to be equal to nor larger than 330, in step S 47 , Q′ is decided whether equal to or larger than 270 and less than 330, or not.
[0233] In step S 48 , in the case that the OPE index Q′ is equal to or larger than 270, and less than 330, Wits is decided whether equal to or larger than 12 mm, or not. If Wits is equal to or larger than 12 mm, in step S 49 , it is decided that the surgical operation on the jaw is necessary.
[0234] When being decided that the surgical operation on the jaw is necessary, in step S 50 , the result of the decision is output on a display, for example.
[0235] In step S 48 , when Wits is decided not to be equal to nor larger than 12 mm, in step S 51 , it is decided that the surgical operation on the jaw is not necessary.
[0236] When being decided that the surgical operation on the jaw is not necessary, in step S 52 , the result of the decision is output on a display, for example.
[0237] In step S 47 , in the case that Q′ is decided not to be equal to nor larger than 270, and not equal to nor less than 330, in step S 53 , Q′ is decided whether equal to or larger than 0 and less than 270 or not.
[0238] When the OPE index Q′ is decided to be equal to or larger than 0 and less than 270, in step S 54 , it is decided that the surgical operation on the jaw is not necessary.
[0239] When being decided that the surgical operation on the jaw is not necessary, in step S 55 , the result of the decision is output on a display, for example.
[0240] In case that the OPE index Q′ is not decided to be equal to or larger than 0 and less than 270, the OPE index Q′ becomes negative. In this case, in step S 56 , a dentist decides the necessity of the surgical operation on the jaw, in step S 57 , the result of the decision is output on a display, for example.
[0241] By the method of deciding the necessity of surgically operating on the jaw according to the fourth embodiment, based on the OPE index Q′ to be calculated by using the distances (S−A), (S−N), (S−B) and (Go−Me) which are measured by cephalometric radiography, without being influenced by the experience of a dentist, the necessity of the surgical operation on the jaw in orthodontic treatment can be decided correctly with a short period of time, moreover with a certain objectivity.
[0242] Next explained is the fifth embodiment.
[0243] In the fifth embodiment, an index for deciding disharmony of the maxilla and mandible can be calculated as the same as the method of calculating the index for deciding the necessity of surgically operating on the jaw in orthodontic treatment explained in the first embodiment.
[0244] According to the fifth embodiment, the index for deciding disharmony of the maxilla and mandible can be calculated. And based on the index for deciding disharmony of the maxilla and mandible, without being influenced by the experience of a dentist, disharmony of the maxilla and mandible in dental treatment such as orthodontic treatment, etc. can be decided correctly with a short period of time, moreover with a certain objectivity.
[0245] Next explained is the sixth embodiment.
[0246] In the sixth embodiment, the method of deciding disharmony of the maxilla and mandible is executed as the same as the method of deciding the necessity of surgically operating on the jaw in orthodontic treatment as explained in the second embodiment.
[0247] According to the sixth embodiment, based on the index for deciding disharmony of the maxilla and mandible, without being influenced by the experience of a dentist, disharmony of the maxilla and mandible in dental treatment such as orthodontic treatment, etc. can be decided correctly within a short period of time, moreover with a certain objectivity.
[0248] Next explained is the seventh embodiment.
[0249] In the seventh embodiment, an index for deciding disharmony of the maxilla and mandible is calculated as the same as the method of calculating the index for deciding the necessity of surgically operating on the jaw in orthodontic treatment explained in the third embodiment.
[0250] According to the seventh embodiment, the same advantages as the fifth embodiment can be obtained.
[0251] Next explained is the eighth embodiment.
[0252] In the eighth embodiment, the method of deciding disharmony of the maxilla and mandible is executed as the same as the method of deciding the necessity of surgically operating on the jaw in orthodontic treatment as explained in the fourth embodiment.
[0253] According to the eighth embodiment, the same advantages as the sixth embodiment can be obtained.
[0254] Next explained is the ninth embodiment.
[0255] In the ninth embodiment, an index for deciding dentofacial deformity can be calculated as the same as the method of calculating the index for deciding the necessity of surgically operating on the jaw in orthodontic treatment explained in the first embodiment.
[0256] According to the ninth embodiment, the index for deciding dentofacial deformity can be calculated. And based on the index for deciding dentofacial deformity, without being influenced by the experience of a doctor or a dentist, dentofacial deformity can be decided correctly within a short period of time, moreover with a certain objectivity.
[0257] Next explained is the tenth embodiment.
[0258] In the tenth embodiment, the method of deciding dentofacial deformity is executed as the same as the method of deciding the necessity of surgically operating on the jaw in orthodontic treatment explained in the second embodiment.
[0259] According to the tenth embodiment, based on the index for deciding dentofacial deformity, without being influenced by the experience of a doctor or a dentist, dentofacial deformity can be decided correctly within a short period of time, moreover with a certain objectivity.
[0260] Next explained is the eleventh embodiment.
[0261] In the eleventh embodiment, an index for deciding dentofacial deformity is calculated as the same as the method of calculating the index for deciding the necessity of surgically operating on the jaw in orthodontic treatment explained in the third embodiment.
[0262] According to the eleventh embodiment, the same advantages as the ninth embodiment can be obtained.
[0263] Next explained is the twelfth embodiment.
[0264] In the twelfth embodiment, the method of deciding dentofacial deformity is executed as the same as the method of deciding the necessity of surgically operating on the jaw in orthodontic treatment explained in the fourth embodiment.
[0265] According to the twelfth embodiment, the same advantages as the tenth embodiment can be obtained.
[0266] Here, a data processor which is used in the execution of the method of calculating an index for deciding the necessity of surgically operating on the jaw, the method of deciding the necessity of surgically operating on the jaw, the method of calculating an index for deciding disharmony of the maxilla and mandible, the method of deciding disharmony of the maxilla and mandible, the method of calculating an index for deciding dentofacial deformity, or the method of deciding dentofacial deformity based on the first to the twelfth embodiments is explained.
[0267] FIG. 22 shows an example of the data processor 10 . As shown in FIG. 22 , the data processor 10 is comprised of an auxiliary storage device 11 , a memory 12 , a CPU (Central Processing Unit) 13 as a processing part, an input part 14 , an output part 15 and an input-output interface 16 .
[0268] The auxiliary storage device 11 is a device to store various kinds of information. For example, the auxiliary storage device 11 is comprised of a hard disk, a ROM (Read Only Memory), etc. The auxiliary storage device 11 stores a program 111 , a compiler 112 and an execution module 113 .
[0269] The program 111 is, for example, a program (source program) describing the processing on the flowcharts shown in FIG. 2 , FIG. 19 , FIG. 20 or FIG. 21 . The compiler 112 compiles and links the program 111 . The execution module 113 is a module which is compiled and linked by the compiler 112 .
[0270] The memory 12 is a temporary storing means to store various kinds of information, and is comprised of a RAM (Random Access Memory), etc., for example. The CPU 13 executes various types of arithmetic processing such as addition, subtraction, multiplication and division, etc., and plays a role executing the execution module 13 through the memory 12 and the input-output interface 16 . The input part 14 is an input device to enter various kinds of execution commands, etc. The output part 15 is an output device to output the various kinds of execution results, etc. The input-output interface 16 mediates the input-output between each composition element of the data processor 10 .
[0271] Next, the operation of the data processor 10 comprised as described above is explained. First, the compiled commands entered from the input part 14 by an operator, are stored in the memory 12 through the input-output interface 16 . In the memory 12 , the program 111 of the auxiliary storage device 11 is compiled and linked by the compiler 112 , and the execution module 113 , which is a machine language code, is generated.
[0272] Next, by entering the execution commands from the input part 14 by an operator, the CPU 13 loads the execution module 113 in the memory 12 . When the execution module 113 is loaded in the memory 12 , by the CPU 13 , each processing on the flowcharts shown in FIG. 2 , FIG. 19 , FIG. 20 or FIG. 21 is sequentially called to the CPU 13 from the memory 12 , after executing each processing, the execution results are stored in the memory 12 . The execution results stored in the memory 12 , by the CPU 13 , are output to the output part 15 through the input-output interface 16 .
[0273] For example, in the case of calculating the OPE index executing the processing on the flowchart shown in FIG. 2 , the following steps are taken. First, the execution module 113 to realize step S 1 for input processing is called to the CPU 13 from the memory 12 . In step S 1 , the data (distances (S−A), (S−B) and (Go−Me)) entered from the input part 14 by an operator are loaded to the memory 12 . Finishing the input processing of step S 1 to realize step S 2 of a calculation processing, the execution module 113 is called to the CPU 13 from the memory 12 . In step S 2 , P is calculated by the entered data. Finishing the calculation processing of step 2 , to realize step S 3 the execution module 113 is called to the CPU 13 from the memory 12 . In step S 3 , according to the size of P, the OPE index is calculated. Finishing the calculation processing of step S 3 , to realize step S 4 the execution module 113 is called to the CPU 13 from the memory 12 . In step S 4 , the value of P is output to the output part 15 as the calculation results.
[0274] In the case of performing the processing on the flowcharts shown in FIG. 19 , FIG. 20 or FIG. 21 , the processing is the same as the above.
[0275] It should be understood that various changes and modifications to the embodiments described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present subject matter and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims.
[0276] For example, numerical numbers, flowcharts, etc. presented in the aforementioned embodiments and examples are only examples, and the different numerical numbers, flowcharts, etc. may be used as necessary.
|
An index for deciding the necessity of surgically operating on the jaw in orthodontic treatment, an index for deciding disharmony of the maxilla and mandible in dental treatment, and an index for deciding dentofacial deformity. The distance (S−A) between S and A, the distance (S−B) between S and B and the distance (Go−Me) between Go and Me are measured by the cephalometric radiography of a patient. By using the distances, P=((S−B)+(Go−Me))/(S−A) is calculated by a processor. P is used as an index for deciding the necessity of surgically operating on the jaw in orthodontic treatment, an index for deciding disharmony of the maxilla and mandible in dental treatment, or an index for deciding dentofacial deformity. Instead of P, Q=(P−[P])×1000 ([ ] denotes Gauss's symbol) (where 2.000≦P<3.000) or Q=(P−([P]+1))×1000 (where P<2.000) may be calculated by a processor and used.
| 6
|
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a division of U.S. Ser. No. 10/971,181, filed Oct. 22, 2004, which claims the benefit of priority Provisional Applications No. 60/513,280, and No. 60/513,348, both filed on Oct. 22, 2003, the disclosures of which are incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention generally relates to a net, and more specifically to an expandable knitted net comprising a plurality of fill yarns with elastomeric properties that allows the net to expand in the cross-direction, or a plurality of chain yarns with dissimilar elongation performance.
BACKGROUND OF THE INVENTION
[0003] Netting is often prepared either by knitting, weaving, or extrusion. Knitted netting typically comprises a plurality of threads oriented in a first direction and being essentially equal spaced from one another, and having wefts oriented in a second direction which is perpendicular to the first direction, the threads and wefts being interlocked and secured. Nets may be prepared by a Raschel knitting method, a process in which the threads are attached to knitting elements that comprise two needles and knock-over comb bars positioned opposite to one another, and comprising ground guide bars, pattern guide bars and stitch comb bars. An example of such a knitted net is described in European Patent No. 0 723 606, to Fryszer, et al., incorporated herein by reference.
[0004] Knitted netting has a variety of end use applications, including but not limited to hay bale wrap, cargo wrap, netted bags, and drainage nets. Raschel knitted nets have been used for round hay bale wrapping as disclosed in U.S. Pat. No. 4,569,439 and U.S. Pat. No. 4,570,789, both hereby incorporated by reference. Twines and films have also been used to tie up hay bales; however the twine usually cuts in the bale and doesn't provide ample support to keep the bale tidy and neat. Further, the twining of the rolled bales with the binding yarn is relatively time-consuming and requires substantial manual labor. Film covers don't allow the rolled bale enough air circulation, which lead to the growth of mold and eventually rotting. The Raschel knitted net doesn't cut into the hay bale and allows ample amount of air to circulate through the bale. Although Raschel knitted netting has several advantages over twine and plastic film, the netting tends to shrink in overall width when pulled lengthwise. Due to the shrinkage in the width, the outer most edges of the hay bale are left exposed, which can cause the bale to become disheveled during pick-up and transport.
[0005] There is an unmet need for a net that will provide maximum coverage to a rounded bale maintaining the rolled bale compact shape during pick-up and transport, as well as during storage.
SUMMARY OF THE INVENTION
[0006] The present invention is directed to a knitted net, and more specifically to an expandable knitted net. In one form, the net comprises a plurality of fill yarns with an elastomeric performance, which allows the net to expand in the cross-direction. In another form, the present invention is directed to a netting, and more specifically to a knitted netting comprising a plurality of chain yarns with dissimilar elongation performance oriented in a first direction, and a plurality of fill yarns oriented in a second direction, wherein the yarns oriented in the second direction secure the yarns oriented in the first direction in position within the netting.
[0007] In accordance with the present invention, the netting is used as bale wrap. In one form, the bale wrap comprises a plurality of chain yarns orientated in a first direction and a plurality of fill yarns orientated in a second direction. The elastomeric performance of the fill yarns provide for optimal coverage of the bale upon stretching of the netting. When stretched in the cross-direction, the netting easily conforms about the shape of a rolled bale, hugging the surface so as to maintain the compact nature of the rolled bale. In another form of the present invention, the netting is used as bale wrap. The bale wrap comprises a plurality of chain yarns oriented in a first direction, wherein the yarns have dissimilar elongation performances. The dissimilar elongation performances of the yarns provide for optimal coverage of the bale upon stretching of the netting. In order to achieve the desired necking performance when stretching the netting, the yarns located proximal to either edge have a higher elongation performance than those located distal to the outer edges Upon stretching, those yarns located proximal the outer edges stretch further than those located distal to the outer edges. This causes the outer edge of the net to flair, allowing the net to fold over the edges of the hay bale, maintaining the compact nature of the rolled bale.
[0008] The yarns of the present invention may comprise flat filaments, such as tapes, mono-filaments, or a combination thereof. The filaments may be of similar or dissimilar polymeric compositions. Suitable filaments, which may be blended in whole or part with natural or synthetic polymeric compositions, include polyamides, polyesters, polyolefins, polyvinyls, polyacrylics, and the blends or coextrusion products thereof. The synthetic polymers may be further selected from homopolymers; copolymers, conjugates and other derivatives including those thermoplastic polymers having incorporated melt additives or surface-active agents.
[0009] It is within the purview of the present invention that the fill yarns comprise a varying degree of elasticity. For instance, it has been contemplated that the fills yarns located proximal to the outer edges comprise greater elasticity than those fill yarns located distal to the outer edges of the net. The dissimilarities in the elasticity performance of the fill yarns can establish specific zones within the netting. A zone is defined as an area within the netting that is comprised of more than one chain yarn and more than one fill yarn, whereby the fill yarns have a similar elasticity performance. The netting may be comprised of two or more zones. Further, the yarns of one zone may comprise similar or dissimilar yarns than that of a second zone. Further still, the yarns of one zone may comprise similar or dissimilar topical or internal additives than that of a second zone.
[0010] The yarns of the present invention may comprise flat filaments, such as tapes, mono-filaments, or a combination thereof. The filaments may be of similar or dissimilar polymeric compositions. Suitable filaments, which may be blended in whole or part with natural or synthetic polymeric compositions, include polyamides, polyesters, polyolefins, polyvinyls, polyacrylics, and the blends or coextrusion products thereof. The synthetic polymers may be further selected from homopolymers; copolymers, conjugates and other derivatives including those thermoplastic polymers having incorporated melt additives or surface-active agents.
[0011] It is within the purview of the present invention that the chain yarns of dissimilar elongation orientated in the first direction, establish specific zones within the netting. A zone is defined as an area within the netting that is comprised of more than one chain yarn having similar elongation performance. The netting is comprised of at least three zones, wherein the zones located proximal to the outer edges comprise a greater elongation performance than the zones located distal to the outer edges. Further, the chain yarns of one zone may comprise similar or dissimilar chain yarns than those of a second zone. Further still, the chain yarns of one zone may comprise similar or dissimilar topical or internal additives than those of a second zone.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 illustrates a view of a portion of a Raschel machine;
[0013] FIG. 2 is a representation of the zones within the net of the present invention while the net is in a relaxed state, which zones can be provided in differentially elongated netting;
[0014] FIG. 3 is a representation of the zones within the net of the present invention while the net is in a stretched state;
[0015] FIG. 4 is a diagrammatic view of the netting partially wrapped about a rounded bale; and
[0016] FIG. 5 is a diagrammatic view of differentially elongated netting.
DETAILED DESCRIPTION
[0017] While the present invention is susceptible of embodiment in various forms, there will hereinafter be described, presently preferred embodiments, with the understanding that the present disclosure is to be considered as an exemplification of the invention, and is not intended to limit the invention to the specific embodiments disclosed herein.
[0018] In accordance with the present invention, the expandable knit is formed on a Raschel knitting machine. The machine comprises a plurality of latch needles, a plurality of lapping belts, a yarn laying-in comb and a plurality of guide bars having needle guides thereon. The latch needles are mounted in the machine to carry out a reciprocating motion in a given plane while the lapping belts are spaced from the needles on one side of the plane, i.e., on a downstream side, for guiding pattern yarns to the needles. In addition, the laying-in comb is mounted on the same side of the plane of the latch needles as the lapping belts and carries out an orbital motion perpendicularly of the plane of the latch needles to penetrate between the pattern yarns. The guide bars with the needle guides serve to lay-in stitch yarns and are mounted on an opposite side of the plane of the latch needles from the lapping belts, i.e. on the upstream side, and oscillate at an angle to the pattern yarns.
[0019] FIG. 1 , is representative of a Raschel machine, whereby it is provided with a comb plate 1 in which a plurality of latch needles 3 are mounted for reciprocating motion along their axes 2 in a vertical plane, as viewed. As shown, the needles 3 are disposed on a bar 4 which is movable up and down.
[0020] In addition, the machine includes a plurality of lapping belts or guide bars 5 spaced from the needles 3 on one side, i.e. the downstream side, of the plane of the needles 3 for guiding pattern yarns to the needles 3 . A yarn laying-in comb 6 is also mounted on the same side of the plane 2 of the latch needles 3 in order to carry out an orbital motion perpendicularly of the plane 2 while penetrating between the pattern yarns. As indicated in chain-dotted line 7 , the orbital motion is a combined stroke and oscillating motion. The comb 6 is provided with a plurality of parallel sinkers 8 each of which carries a guide rod 9 and which has a deflecting edge 10 at the forward end extending towards the plane 2 . In addition, each sinker 8 has a yarn catch 11 at a lower region of the deflecting edge 10 below the guide rod 9 . A trace comb 12 is also mounted over the comb plate 1 in known manner.
[0021] The machine also has a plurality of guide bars 13 which have needle guides thereon for directing stitch yarns to the latch needles 3 . As shown, the guide bars 13 are mounted on the side of the plane 2 of the latch needles 3 opposite the lapping belts 5 , i.e., on the upstream side. Suitable means are also provided for oscillating the guide bars 13 at an angle to the pattern yarns.
[0022] As shown in FIG. 1 , the lapping belts 5 are positioned at an acute angle downstream of the plane 2 . A yarn guide 14 is also disposed between the belts 5 and the guide bars 13 for deflecting the pattern yarns upon laying-in of the stitch yarns. This yarn guide 14 is used for laying the pattern yarns in the needle lanes (not shown). The yarn guide 14 may be coupled to the guide bars 13 so as to move therewith or may be provided with an independent drive (not shown).
[0023] The netting of the present invention is knitted on such a machine, wherein in one form a plurality of chain yarns are orientated in a first direction and a plurality of elastomeric fill yarns are orientated in a second direction. Elastomeric fill yarns may be utilized in entirety or in part throughout the net. Further, the elastic fill yarns may be of varying degrees of elasticity. It is also in the purview that the net comprise zones, wherein a zone is characterized by its degree of elasticity or complete lack thereof. The chain yarns are interconnected with fill yarns orientated in a second direction on a Raschel machine forming a net, wherein the net exhibits the ability to expand in the cross-direction.
[0024] In another form of the invention, the netting of the present invention is knitted on such a machine, wherein at least three chain yarns of a first elongation performance are orientated in a first direction and at least two chain yarns of a second elongation performance orientated in said first direction. The chain yarns of a first elongation performance are arranged into two zones, wherein each zone is located proximal to an outer edge. Chain yarns of a said second elongation performance are arranged into a separate zone and the zone is located distal to the outer edges or intermediate the two proximal zones. The chain yarns are interconnected with fill yarns orientated in a second direction on a Raschel machine forming a net, wherein the net exhibits differential elongation.
[0025] Referring to FIG. 2 therein is a diagrammatic representation of the knitted net of the present invention in a relaxed state. In one form, the net of FIG. 2 comprises three zones, wherein zone one (Z 1 ) has a greater elasticity performance than zone two (Z 2 ) and zone three (Z 3 ) has a greater elasticity performance than zone two (Z 2 ). Upon stretching, the net exhibits differential expansion in the cross-direction. It's in the purview of the present invention that the yarns of one zone may comprise similar or dissimilar yarns than that of a second zone. Further still, the yarns of one zone may comprise similar or dissimilar topical or internal additives than yarns of a second zone.
[0026] In another form, the net comprises at least three zones, wherein zone one (Z 1 ) has a greater elongation performance than zone two (Z 2 ) and zone three (Z 3 ) has a greater elongation performance than zone two (Z 2 ). Preferably, the zones located most proximal to the outer edges have an elongation performance at least 110% greater, more preferably 120% greater, and most preferably 130% greater than the zone(s) located distal to the outer edges.
[0027] FIG. 3 shows the netting once it is stretched. Due to the elasticity of the fill yarns, the net is able to expand in the cross-direction, easily conforming to the shape of a rolled bale and folding over the edges of the bale so as to prevent the bale from becoming disheveled along the ends. FIG. 4 demonstrates how the expandable net fits around the bale to keep it compact and neat.
[0028] It is within the purview of the present invention that the chain yarns of one zone may comprise similar or dissimilar chain yarns than those of a second zone. Further still, the chain yarns of one zone may comprise similar or dissimilar topical or internal additives than those of a second zone. It's also in the purview of the present invention that the fill yarns of one zone may comprise similar or dissimilar fill yarns than that of a second zone. Further still, the fill yarns of one zone may comprise similar or dissimilar topical or internal additives than fill yarns of a second zone.
[0029] FIG. 3 shows the necking that occurs once the netting is stretched. Due to the increase in elongation of the yarns located along the outer edges, the final net construct is capable of wrapping over the edges of the bale so as to prevent the bale from becoming disheveled along the ends. FIG. 4 demonstrates how the differentially elongated net fits around the bale to keep it compact and neat.
[0030] Subsequent to formation, the knitted net material may optionally be subjected to various chemical and/or mechanical post-treatments. The net material is then collected and packaged in a continuous form, such as in a roll form, or alternatively, the net material may comprise a series of weak points whereby desired lengths of twine material may be detracted from the remainder of the continuous packaged form.
[0031] From the foregoing, it will be observed that numerous modifications and variations can be affected without departing from the true spirit and scope of the novel concept of the present invention. It is to be understood that no limitation with respect to the specific embodiments illustrated herein is intended or should be inferred. The disclosure is intended to cover, by the appended claims, all such modifications as fall within the scope of the claims.
|
The present invention is directed to a knitted net, and more specifically to an expandable knitted net. In one form, the net comprises a plurality of fill yarns with an elastomeric performance, which allows the net to expand in the cross-direction. In another form, the present invention is directed to a netting, and more specifically to a knitted netting comprising a plurality of chain yarns with dissimilar elongation performance oriented in a first direction, and a plurality of fill yarns oriented in a second direction, wherein the yarns oriented in the second direction secure the yarns oriented in the first direction in position within the netting.
| 3
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable.
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
MICROFICHE/COPYRIGHT REFERENCE
[0003] Not Applicable.
FIELD OF THE INVENTION
[0004] This invention relates to piston driven, internal combustion engines, and in more particular applications, to such engines utilizing intake and exhaust valves, and in more particular applications to such engines utilizing direct fuel injection.
BACKGROUND OF THE INVENTION
[0005] Four stroke, piston driven, internal combustion engines are well known, as is the manipulation of the timing of the opening and closing of the intake and exhaust valves of such engines in relation to the position of the piston within the cylinder during each of the four strokes in conventional four stroke piston engines. In general for such engines, the intake valve is open and the exhaust valve is closed during all or most of the intake stroke, both the intake valve and the exhaust valve are closed during all or most of the compression stroke, the intake valve and the exhaust valve remain closed during all or most of the power stroke, and the intake valve is closed and the exhaust valve open during all or most of the exhaust stroke. While such engines have proven very suitable for their intended function, there is always room for improvement.
SUMMARY OF THE INVENTION
[0006] In accordance with one feature of the invention, a method is provided for operating a piston driven, internal combustion engine including a piston translating in a cylinder between a top dead center position and a bottom dead center position, an intake valve to the cylinder having an open state and a closed state, and an exhaust valve from the cylinder having an open state and a closed state. The method includes the sequential steps of
[0007] (a) operating the intake valve to be in the open state and the exhaust valve to be in the closed state for at least a portion of an intake stroke wherein the piston moves from the top dead center position to the bottom dead center position;
[0008] (b) operating the intake valve to be in the closed state and the exhaust valve to be in the open state for at least a portion of a partial exhaust stroke wherein the piston moves from the bottom dead center position to a partial stroke position between the bottom dead center position and the top dead center;
[0009] (c) operating the intake valve to be in the closed state and the exhaust valve to be in the closed state for at least a portion of a compression stroke wherein the piston moves from the partial stroke position to the top dead center position;
[0010] (d) operating the engine to combust a fuel/air mixture in the cylinder and operating the intake valve to be in the closed state and the exhaust valve to be in the dosed state for at least a portion of a power stroke wherein the piston is driven from the top dead center position to the bottom dead center position;
[0011] (e) operating the intake valve to be in the closed state and the exhaust valve to be in the open state for at least a portion of an exhaust stroke wherein the piston moves from the bottom dead center position to the top dead center position; and
[0012] (f) sequentially repeating steps (a) through (e).
[0013] In one feature, step (a) includes operating the intake valve to be in the open state and the exhaust valve to be in the closed state for a majority of the intake stroke; step (b) includes operating the intake valve to be in the closed state and the exhaust valve to be in the open state for a majority of the partial exhaust stroke; step (c) includes operating the intake valve to be in the closed state and the exhaust valve to be in the closed state for at least a majority of a compression stroke; step (d) includes operating the intake valve to be in the closed state and the exhaust valve to be in the closed state for a majority of the power stroke; and step (e) includes operating the intake valve to be in the closed state and the exhaust valve to be in the open state for a majority of the exhaust stroke.
[0014] According to one feature, at least one of: step (a) includes operating the intake valve to be in the open state and the exhaust valve to be in the closed state for the entire intake stroke; step (b) includes operating the intake valve to be in the closed state and the exhaust valve to be in the open state for the entire partial exhaust stroke; step (c) includes operating the intake valve to be in the closed state and the exhaust valve to be in the closed state for the entire compression stroke; step (d) includes operating the intake valve to be in the closed state and the exhaust valve to be in the closed state for the entire power stroke; and step (e) includes operating the intake valve to be in the closed state and the exhaust valve to be in the open state for the entire exhaust stroke.
[0015] As one feature, the engine is operated with the piston connected by a crank to a crankshaft that rotates 180 degrees in response to the piston moving from the top dead center position to the bottom dead center position and that rotates another 180 degrees in response to the piston moving from the bottom dead center position to the top dead center position. Step (b) includes operating the intake valve to be in the closed state and the exhaust valve to be in the open state during less than 90 degrees of crankshaft rotation; and step (c) includes operating the intake valve to be in the closed state and the exhaust valve to be in the closed state during more than 90 degrees of crankshaft rotation.
[0016] In one feature, step (b) includes operating the intake valve to be in the closed state and the exhaust valve to be in the open state during 60 to 70 degrees of crankshaft rotation; and step (c) comprises operating the intake valve to be in the closed state and the exhaust valve to be in the closed state during 110 to 120 degrees of crankshaft rotation.
[0017] According to one feature, the method further includes the step of throttling an air flow to the intake valve during step (a) to control an operating speed of the engine, with the air flow being throttled to a greater extent at low operating speeds and to a lesser extent at high operating speeds.
[0018] In accordance with one feature of the invention, a method is provided for operating a piston driven, internal combustion engine including a piston translating in a cylinder between a top dead center position and a bottom dead center position, an intake valve to the cylinder having an open state and a closed state, and an exhaust valve from the cylinder having an open state and a closed state, the piston connected by a crank to a crankshaft that rotates 180 degrees in response to the piston moving from the top dead center position to the bottom dead center position and that rotates another 180 degrees in response to the piston moving from the bottom dead center position to the top dead center position. The method includes the sequential steps of:
[0019] (a) operating the intake valve to be in the open state and the exhaust valve to be in the closed state for at least part of the 180 degrees of crankshaft rotation as the piston move from the top dead center position to the bottom dead center position during an intake stroke of the piston;
[0020] (b) operating the intake valve to be in the closed state and the exhaust valve to be in the open state during less than 90 degrees of crankshaft rotation as the piston moves from the bottom dead center position to a partial stroke position between the bottom dead center position and the top dead center position during a partial exhaust stroke;
[0021] (c) operating the intake valve to be in the closed state and the exhaust valve to be in the closed state during more than 90 degrees of crankshaft rotation as the piston moves from the partial stroke position to the top dead center position during a compression stroke;
[0022] (d) operating the engine to combust a fuel/air mixture in the cylinder and operating the intake valve to be in the closed state and the exhaust valve to be in the closed state for at least part of the 180 degrees of crankshaft rotation as the piston is driven from the top dead center position to the bottom dead center position during a power stroke;
[0023] (e) operating the intake valve to be in the closed state and the exhaust valve to be in the open state for at least part of the 180 degrees of crankshaft rotation as the piston moves from the bottom dead center position to the top dead center position during an exhaust stroke; and
[0024] (f) sequentially repeating steps (a) through (e).
[0025] In one feature, step (a) includes operating the intake valve to be in the open state and the exhaust valve to be in the closed state for a majority of the 180 degrees of crankshaft rotation as the piston move from the top dead center position to the bottom dead center position during the intake stroke of the piston. Step (b) includes operating the intake valve to be in the closed state and the exhaust valve to be in the open state during 60 to 70 degrees of crankshaft rotation as the piston moves from the bottom dead center position to a partial stroke position between the bottom dead center position and the top dead center position during the partial exhaust stroke. Step (c) includes operating the intake valve to be in the closed state and the exhaust valve to be in the closed state during 110 to 120 degrees of crankshaft rotation as the piston moves from the partial stroke position to the top dead center position during the compression stroke. Step (d) includes operating the intake valve to be in the closed state and the exhaust valve to be in the closed state for a majority of the 180 degrees of crankshaft rotation as the piston is driven from the top dead center position to the bottom dead center position during the power stroke. Step (e) includes operating the intake valve to be in the closed state and the exhaust valve to be in the open state for a majority of the 180 degrees of crankshaft rotation as the piston moves from the bottom dead center position to the top dead center position during the exhaust stroke.
[0026] In accordance with one feature of the invention, a method is provided for operating a piston driven, internal combustion engine including a piston translating in a cylinder, an intake valve to the cylinder having an open state and a closed state, and an exhaust valve from the cylinder having an open state and a closed state. The piston has an intake stroke with an intake stroke length that LI wherein air is drawn into the cylinder through the intake valve with the intake valve in the open state, a compression stroke with a compression stroke length LC wherein air within the cylinder is compressed, a power stroke with a power stroke length LP wherein the piston transfers power generated by a combustion of the compressed air with a fuel in the cylinder, and an exhaust stroke with an exhaust stroke length LE wherein products of the combustion are forced from the cylinder through the exhaust valve with the exhaust valve in the open state. The method includes the step of operating the inlet and outlet valves of the engine so that the piston has a partial exhaust stroke between the intake stroke and the compression stroke, with a partial exhaust stroke length LPE, wherein the intake valve is in the closed state and the exhaust valve is in the open state so that initially during the partial exhaust stroke, exhaust and pressure from the exhaust manifold will enter the cylinder. During the remainder of the partial exhaust stroke, some or all of the exhaust that had entered the cylinder will be expelled, but the increased pressure will remain.
[0027] As one feature, the engine is operated so that the power stroke length LP is 20 to 30 percent longer than the compression stroke length LC.
[0028] In one feature, the intake valve and the exhaust valve are operated to the closed states while the piston translates over the compression stroke length LC.
[0029] According to one feature, the intake valve and exhaust valve are operated so that both the exhaust stroke length LE and the intake stroke length LI are approximately the same length as the power stroke length LP, with the intake valve being in the closed state and the exhaust valve being in the open state while the piston translates over the exhaust stroke length LE, and the intake valve being in the open state and the exhaust valve being in the closed state while the piston translates over the intake stroke length LI.
[0030] As one feature, the intake and exhaust valves are operated so that the partial exhaust stroke length LPE is less than the compression stroke length LC.
[0031] In accordance with one feature of the invention, an internal combustion engine includes:
[0032] a piston mounted for translation in a cylinder between a top dead center position and a bottom dead center position;
[0033] an intake valve to the cylinder, the intake valve having an open state and a closed state; and
[0034] an exhaust valve from cylinder, the exhaust valve having an open state and a closed state. The engine is configured to automatically operate the intake and the exhaust valves to sequentially achieve:
[0035] (a) an intake stroke wherein the piston moves from the top dead center position to the bottom dead center position with the intake valve in the open state and the exhaust valve in the closed state for at least a portion of the intake stroke;
[0036] (b) a partial exhaust stroke wherein the piston moves from the bottom dead center position to a partial stroke position between the bottom dead center position and the top dead center position with the intake valve in the closed state and the exhaust valve in the open state for at least a portion of the partial exhaust stroke;
[0037] (c) a compression stroke wherein the piston moves from the partial stroke position to the top dead center position with the intake valve in the closed state and the exhaust valve in the closed state for at least a portion of the compression stroke;
[0038] (d) a power stroke wherein the piston is driven from the top dead center position to the bottom dead center position following a combustion of a fuel/air mixture in the cylinder, with the intake valve in the closed state and the exhaust valve in the closed state for at least a portion of the power stroke; and
[0039] (e) an exhaust stroke wherein the piston moves from the bottom dead center position to the top dead center position with the intake valve in the closed state and the exhaust valve in the open state for at least a portion of the exhaust stroke.
[0040] In one feature, the internal combustion engine further includes first and second exhaust valve cam shafts. The first exhaust valve cam shaft is configured to operate the exhaust valve to the open state during the exhaust stroke and the second exhaust valve cam shaft is configured to operate the exhaust valve to the open state during the partial exhaust stroke.
[0041] As one feature, the internal combustion engine further includes a rocker arm having a first surface in operable engagement with a first cam on the first exhaust valve cam shaft, a second surface in operable engagement with a second cam on the second exhaust cam shaft, and a third surface that transfers opening forces to the exhaust valve.
[0042] According to one feature, the internal combustion engine further includes an exhaust valve cam shaft carrying an exhaust valve cam having a surface configured to transfer opening forces to the exhaust valve during the exhaust stroke and the partial exhaust stroke.
[0043] As one feature, the internal combustion engine further includes an exhaust valve solenoid configured to operate the exhaust valve to the open and closed states as required for each of the strokes in response to an electrical signal.
[0044] In one feature, the engine is configured to automatically operate the intake and the exhaust valves to actuate:
[0045] (a) the intake valve in the open state and the exhaust valve in the closed state for a majority of the intake stroke;
[0046] (b) the intake valve in the closed state and the exhaust valve in the open state for a majority of the partial exhaust stroke;
[0047] (c) the intake valve in the closed state and the exhaust valve in the closed state for a majority of the compression stroke;
[0048] (d) the intake valve in the closed state and the exhaust valve in the closed state for a majority of the power stroke; and
[0049] (e) the intake valve in the closed state and the exhaust valve in the open state for a majority of the exhaust stroke.
[0050] According to one feature, the engine is configured to automatically operate the intake and the exhaust valves to actuate:
[0051] (a) the intake valve in the open state and the exhaust valve in the closed state for the entire intake stroke;
[0052] (b) the intake valve in the closed state and the exhaust valve in the open state for the entire partial exhaust stroke;
[0053] (c) the intake valve in the closed state and the exhaust valve in the closed state for the entire compression stroke;
[0054] (d) the intake valve in the closed state and the exhaust valve in the closed state for the entire power stroke; and
[0055] (e) the intake valve in the closed state and the exhaust valve in the open state for the entire exhaust stroke.
[0056] Other objects, features, and advantages of the invention will become apparent from a review of the entire specification, including the appended claims and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0057] FIG. 1 is a sectional view of a 3-2/2 stroke engine with the crankshaft at 0 degrees, Top Dead Center (TDC), just after the exhaust full stroke and prior to the intake stroke;
[0058] FIG. 1 a is an enlarged sectional view of the exhaust mechanisms of the engine in FIG. 1 showing the position of the exhaust full stroke camshaft, the rocker arm and the partial exhaust stroke camshaft when the crankshaft is at 0 degrees TDC;
[0059] FIG. 2 is a sectional view of a 3-2/2 stroke engine with the crankshaft having rotated 90 degrees midway through the intake stroke;
[0060] FIG. 2 a is an enlarged sectional view of the exhaust mechanisms of the engine in FIG. 2 showing the position of the exhaust full stroke camshaft, the rocker arm and the partial exhaust stroke camshaft;
[0061] FIG. 3 is a sectional view of a 3-2/2 stroke engine with the crankshaft having rotated 180 degrees at the end of the intake stroke and the beginning of the partial exhaust stroke;
[0062] FIG. 3 a is an enlarged sectional view of the exhaust mechanisms of the engine in FIG. 3 showing the position of the exhaust full stroke camshaft, the rocker arm and the partial exhaust stroke camshaft;
[0063] FIG. 4 is a sectional view of a 3-2/2 stroke engine with the crankshaft having rotated 213 degrees midway through the partial exhaust stroke;
[0064] FIG. 4 a is an enlarged sectional view of the exhaust mechanisms of the engine in FIG, 4 showing the position of the exhaust full stroke camshaft, the rocker arm and the partial exhaust stroke camshaft;
[0065] FIG. 5 is a sectional view of a 3-2/2 stroke engine with the crankshaft having rotated 246 degrees at the end of the partial exhaust stroke and the beginning of the compression stroke;
[0066] FIG. 5 a is an enlarged sectional view of the exhaust mechanisms of the engine in FIG. 5 showing the position of the exhaust full stroke camshaft, the rocker arm and the partial exhaust stroke camshaft;
[0067] FIG. 6 is a sectional view of a 3-2/2 stroke engine with the crankshaft having rotated 360 degrees at the end of the compression stroke and the beginning of the power stroke;
[0068] FIG. 6 a is an enlarged sectional view of the exhaust mechanisms of the engine in FIG. 6 showing the position of the exhaust full stroke camshaft, the rocker arm and the partial exhaust stroke camshaft;
[0069] FIG. 7 is a sectional view of a 3-2/2 stroke engine with the crankshaft having rotated 540 degrees at the end of the power stroke and the beginning of the exhaust full stroke;
[0070] FIG. 7 a is an enlarged sectional view of the exhaust mechanisms of the engine in FIG. 7 showing the position of the exhaust full stroke camshaft, the rocker arm and the partial exhaust stroke camshaft;
[0071] FIG. 8 is a sectional view of a 3-2/2 stroke engine with the crankshaft having rotated 630 degrees midway through the exhaust full stroke;
[0072] FIG. 8 a is an enlarged sectional view of the exhaust mechanisms of the engine in FIG. 8 showing the position of the exhaust full stroke camshaft, the rocker arm and the partial exhaust stroke camshaft;
[0073] FIG. 9 is an enlarged view of the partial exhaust stroke camshaft;
[0074] FIG. 10 shows an enlarged view of an alternate partial exhaust stroke camshaft;
[0075] FIG, 11 is a sectional view of a 3-2/2 stroke engine equipped with a partial exhaust stroke camshaft located in the crankcase;
[0076] FIG. 12 is a sectional view of a 3-2/2 stroke engine equipped with computer controlled electronic valve operators;
[0077] FIG. 13 is a sectional view of a 3-2/2 stroke engine equipped with an oversized, double lobed, tubular exhaust camshaft with lobes for both the exhaust full stroke and the partial exhaust stroke;
[0078] FIG. 14 is a sectional view of a 3-2/2 stroke engine equipped with a “normal” sized, double lobed, exhaust camshaft with lobes for both the exhaust full stroke and the partial exhaust stroke; and
[0079] FIG. 14 a is an enlarged view of the double lobed exhaust camshaft of FIG. 14 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0080] A piston driven, internal combustion engine and operating cycle are disclosed herein. The operating cycle includes an intake stroke wherein air or other suitable gases for oxidizing combustion are drawn into the cylinder, a partial exhaust stroke wherein the intake to the cylinder is closed and the exhaust from the cylinder is open while the volume within the cylinder is decreased, a compression stroke wherein both the intake to the cylinder and the exhaust from the cylinder are blocked while the volume within the cylinder is further reduced thereby compressing the gases within the cylinder, a combustion of the compressed gases within the cylinder (which in the preferred, embodiments include fuel that been directly injected into the cylinder at some point after the partial exhaust stroke has been completed), a power stroke wherein the energy from the combustion is transferred to the piston as the products of combustion expand within the cylinder, and an exhaust stroke wherein the cylinder is open to the exhaust while the piston reduces the volume within the cylinder to drive the products of combustion from the cylinder. For convenience, the operating cycle as disclosed herein will be referred to as 3-2/2 stroke operating cycle and the engine 10 as disclosed herein as a 3-2/2 stroke engine to distinguish from conventional four stroke operating cycles and four stroke internal combustion engines. The engine 10 as disclosed herein is configured to provide the partial exhaust stroke between the intake stroke of the cycle and the compression stroke of the cycle, with the intake, exhaust and power strokes of the cycle being essentially full strokes as is conventional for 4-stroke, piston driven internal combustion engine, the compression stroke being a partial stroke, and the partial exhaust stroke being a partial stroke.
[0081] One embodiment of a 3-2/2 stroke internal combustion, direct fuel injected, piston engine 10 is shown somewhat diagrammatically in FIGS. 1-8 a, with FIGS. 9 and 10 illustrating a cam for driving an exhaust valve of the engine 10 during the partial exhaust stroke and FIGS. 11-14 a showing various alternate embodiments for the structures that provide the full exhaust stroke and the partial exhaust stroke of the 3-2/2 operating cycle for the 3-2/2 engine 10 .
[0082] The 3-2/2 stroke, direct fuel injected, spark ignition, piston, internal combustion engine has been analyzed based on an assumption that, of the residual products of combustion left in the cylinder following the exhaust stroke, half will be drawn down into the cylinder and mixed with the incoming air and the other half will remain concentrated at the top of the cylinder near the exhaust valve and in the lee of the intake valve.
[0083] The partial exhaust stroke in the 3-2/2 stroke engine is accomplished by opening the exhaust valve for 20% or approximately the first 20% (20 to 30 percent) of what in a 4 stroke engine is termed the compression stroke, In the 3-2/2 stroke engine, this portion of the upward stroke is termed the “partial exhaust stroke” and its duration will be 66 degrees or approximately 66 degrees (60 to 70 percent) of crankshaft rotation. Compression takes place during the remaining 80% or approximately 80% (70 to 80 percent) of the upward stroke with a duration of 114 degrees or approximately 114 degrees (110 to 120 degrees) of crankshaft rotation. This portion of the upward stroke is termed the “compression stroke”. Thus, as previously discussed, the engine will have three full strokes: the intake stroke, the power or expansion stroke and the exhaust full stroke; and two partial strokes: the partial exhaust stroke and the compression stroke.
[0084] While the above ranges for degrees of rotation and/or percent of stroke will be desired in many applications, it should be understood that the invention contemplates that in some applications it may be desirable for the exhaust valve 70 to be open for 90° of crankshaft rotation or for crankshaft rotations that are less than 90° of crankshaft rotation during the partial exhaust stroke and for the intake valve 90 and the exhaust valve 70 to be in the closed state during 90° of crankshaft rotation or more than 90° of crankshaft rotation during the compression stroke.
[0085] For the disclosed 3-2/2 operating cycle and 3-2/2 engine 10 , the intake stroke will have an intake stroke length LI ( FIG. 3 ) wherein air is drawn into the cylinder, a compression stroke with a compression stroke length LC ( FIG. 6 ) wherein air within the cylinder is compressed, a power stroke with a power stroke length LP ( FIG. 7 ) wherein the piston transfers power generated by combustion of the compressed air with a fuel, an exhaust stroke with an exhaust stroke length LE ( FIG. 8 ) wherein products of the combustion are exhausted, and a partial exhaust stroke between the intake stroke and the compression stroke, the partial exhaust stroke having a partial exhaust stroke length LPE ( FIG. 5 ). In some embodiments, the partial stroke length LPE is less than the compression stroke length LC. In the preferred embodiments of the 3-2/2 operating cycle and 3-2/2 engine 10 , the power stroke length LP is 20 to 30 percent longer than the compression stroke length LC, with the exact percentage difference being dependent upon the desired operating parameters of the engine 10 by this point in the cycle. Further, in the preferred embodiments, the exhaust stroke length LE and the intake stroke length LI are approximately the same length as the power stroke length LP.
[0086] At the end of the intake stroke and just prior to the partial exhaust stroke at high rpm with the air throttle near fully open, the pressure in the cylinder can be as high as 13 or 14 psi and the pressure in the exhaust manifold will be around 15 or 16 psi in the disclosed 3-2/2 engine 10 . When the exhaust valve opens at the beginning of the partial exhaust stroke, exhaust and pressure from the exhaust manifold will enter the cylinder. During the remainder of the partial exhaust stroke, some of the exhaust and a small amount of air will be expelled from the cylinder, but the added pressure will remain. Calculations taking into consideration the temperature and density of the gasses in the cylinder indicate that, at the end of the partial exhaust stroke and the beginning of the compression stroke, the charge in the cylinder will be cleaner, cooler and denser than in a comparably sized four stroke engine of the same compression ratio. That coupled with the small boost in pressure during the partial exhaust stroke and the fact that the power stroke is 58% longer than the compression stroke in terms of degrees of crankshaft rotation will make the 3-2/2 stroke engine both more powerful and up to 20% more efficient at high rpm.
[0087] At the end of the intake stroke and just prior to the partial exhaust stroke at low rpm with the air throttle near fully closed, the pressure in the cylinder can be as low as 5 or 6 psi and the pressure in the exhaust manifold will be around 15 or 16 psi in the disclosed 3-2/2 engine 10 . When the exhaust valve opens at the beginning of the partial exhaust stroke, exhaust and pressure from the exhaust manifold will enter the cylinder. During the remainder of the partial exhaust stroke, some of that exhaust will be expelled from the cylinder, but the added pressure will remain. Calculations taking into consideration the temperature and density of the gasses in the cylinder indicate that at the end of the partial exhaust stroke and the beginning of the compression stroke the charge in the cylinder will be 84% air and the charge in a four stroke engine of the same compression ratio just prior to the compression stroke will be 94%. This is not as big a difference as it seems. Since pure air already contains 80% impurities in the form of nitrogen it works out that the charge in the 3-2/2 stroke engine has 83% impurities and that in the four stroke engine 81% impurities which is insignificant considering the pressure has been boosted by a factor of 3. That coupled with the fact that the power stroke is 58% longer than the compression stroke in terms of degrees of crankshaft rotation will make the 3-2/2 stroke engine both more powerful and up to 50% more efficient at low rpm.
[0088] In the 3-2/2 stroke engine since the exhaust valve opens during the partial exhaust stroke fuel may not be injected until the compression stroke, and since at low rpm hot exhaust gasses enter the cylinder from the exhaust manifold, the fuel should be injected late in the compression stroke at a time when it is desirable for combustion to occur in order to prevent auto-ignition of the fuel air charge.
[0089] Additional means of achieving a 3-2/2 stroke engine are also shown herein.
[0090] As best seen in FIGS. 1 and 1 a, the engine 10 includes a block 11 , a head 20 , a cylinder 30 , a piston 40 , a connecting rod 50 , a crankshaft 60 , a crankcase 62 , an exhaust valve 70 , an exhaust port 80 , an intake valve 90 , an intake port 100 , an intake valve camshaft 110 , timing belt sprockets 120 and 121 , a timing belt 130 , an exhaust full stroke camshaft 140 , a rocker arm 150 , and an exhaust partial stroke camshaft 160 . As best seen in FIG. 1 a, mating spur gears 162 and 164 having a 2/1 gear ratio are fixed for rotation with their respective cam shafts 140 and 160 and are positioned axially adjacent the timing belt sprockets 120 and 121 . The engine 10 is shown in FIGS. 1 and la immediately after the exhaust stroke and immediately prior to the intake stroke, with the crankshaft 60 at 0 degrees top dead center (TDC), the piston 40 at the top of its stroke.
[0091] FIG. 2 shows the engine 10 midway through the intake stroke. The crankshaft 60 has rotated 90 degrees clockwise, the intake camshaft 110 has rotated 45 degrees clockwise and the intake valve 90 is now open. FIG. 2 a shows the position of the exhaust valve 70 , the exhaust full stroke camshaft 140 , the rocker arm 150 and the partial exhaust stroke camshaft 160 with the crankshaft having rotated 90 degrees. The exhaust valve 70 remains closed. The exhaust full stroke camshaft 140 has rotated 45 degrees clockwise. The partial exhaust stroke camshaft 160 has rotated 90 degrees counter-clockwise. The rocker arm 150 has not moved.
[0092] FIG. 3 shows the engine 10 at the end of the intake stroke and just prior to the partial exhaust stroke. The crankshaft 60 has rotated 180 degrees clockwise to the bottom dead center (BDC) position, the intake camshaft 110 has rotated 90 degrees clockwise and the intake valve 90 is now closed. FIG. 3 a shows the position of the exhaust valve 70 , the exhaust full stroke camshaft 140 , the rocker arm 150 and the partial exhaust stroke camshaft 160 with the crankshaft having rotated 180 degrees. The exhaust valve 70 remains closed. The exhaust full stroke camshaft 140 has rotated 90 degrees clockwise. The partial exhaust stroke camshaft 160 has rotated 180 degrees counter-clockwise. The rocker arm 150 has not moved.
[0093] FIG. 4 shows the 3-2/2 engine 10 midway through the partial exhaust stroke. The crankshaft 60 has rotated 213 degrees clockwise, the intake camshaft 110 has rotated 106.5 degrees clockwise and the intake valve 90 is closed. FIG. 4 a shows the position of the exhaust valve 70 , the exhaust full stroke camshaft 140 , the rocker arm 150 , and the partial exhaust stroke camshaft 160 with the crankshaft 60 having rotated 213 degrees. The exhaust full stroke camshaft 140 has rotated 106.5 degrees clockwise. The partial exhaust stroke camshaft 160 has rotated 213 degrees counter-clockwise and is engaging the rocker arm 150 which has pushed the exhaust valve 70 to a fully open position.
[0094] FIG. 5 shows the 3-2/2 engine 10 at the end of the partial exhaust stroke and the beginning of the compression half stroke. The crankshaft 60 has rotated 246 degrees clockwise, the intake camshaft 110 has rotated 123 degrees clockwise and the intake valve 90 is closed. FIG. 5 a shows the position of the exhaust valve 70 , the exhaust full stroke camshaft 140 , the rocker arm 150 and partial exhaust stroke camshaft 160 with the crankshaft 60 having rotated 246 degrees. The exhaust valve 70 is closed. The exhaust full stroke camshaft 140 has rotated 123 degrees clockwise. The partial exhaust stroke camshaft 160 has rotated 246 degrees counter-clockwise.
[0095] FIG. 6 shows the 3-2/2 engine 10 at the end of the compression stroke and the beginning of the power stroke. The crankshaft 60 has rotated 360 degrees clockwise, the intake camshaft 110 has rotated 180 degrees clockwise and the intake valve 90 is closed. FIG. 6 a shows the position of the exhaust valve 70 , the exhaust full stroke camshaft 140 , the rocker arm 150 and partial exhaust stroke camshaft 160 with the crankshaft 60 having rotated 360 degrees. The exhaust valve 70 is closed. The exhaust full stroke camshaft 140 has rotated 180 degrees clockwise. The partial exhaust stroke camshaft 160 has rotated 360 degrees counter-clockwise.
[0096] It should be understood that the illustrated embodiment of the 3-2/2 engine 10 is a direct fuel injection engine wherein fuel is directly injected into the cylinder 30 at some point after the partial exhaust stroke and before combustion. In this regard, the fuel will typically be injected at some point at or near the end of the compression stroke and at or near the beginning of the power stroke. It should also be understood that while in many applications it will be desirable for the 3-2/2 engine 10 to be a direct fuel injection engine, in some applications it may be desirable for the engine 10 to utilize other types of fuel injection or other suitable ways for introducing fuel into the cylinder 30 for combustion. It should further be understood that the speed of the disclosed 3-2/2 engine can be controlled with the use of an air throttle upstream of the intake manifold 100 . However, in some embodiments, it may be desirable to control the amount of air flow into the cylinder using variable intake valves, in which case the use of an air throttle would not be required. Alternatively, in some embodiments it may be desirable to utilize so-called “Stratified Charge Ultra Lean Burn” technology in which there is no air throttle and no restriction of air flow at the intake valve 9 , and wherein air is allowed to enter the cylinder 30 at just under atmospheric pressure at any rpm, with the engine speed being controlled entirely by the amount of fuel added in a stratified charge.
[0097] FIG. 7 shows the 3-2/2 engine 10 at the end of the power stroke and the beginning of the exhaust full stroke. The crankshaft 6 has rotated 540 degrees clockwise, the intake camshaft 110 has rotated 270 degrees clockwise and the intake valve 90 is closed. FIG. 7 a shows the position of the exhaust valve 70 , the exhaust full stroke camshaft 140 , the rocker arm 150 and partial exhaust stroke camshaft 160 with the crankshaft 60 having rotated 540 degrees. The exhaust valve 70 is closed. The exhaust full stroke camshaft 140 has rotated 270 degrees clockwise. The partial exhaust stroke camshaft 160 has rotated 540 degrees counter-clockwise.
[0098] FIG. 8 shows the 3-2/2 engine 10 midway through the exhaust full stroke. The crankshaft 60 has rotated 630 degrees clockwise, the intake camshaft 110 has rotated 315 degrees clockwise and the intake valve 90 is closed. FIG. 8 a shows the position of the exhaust valve 70 , the exhaust full stroke camshaft 140 , the rocker arm 150 and partial exhaust stroke camshaft 160 with the crankshaft 60 having rotated 630 degrees. The exhaust full stroke camshaft 140 has rotated 315 degrees clockwise and is engaging the rocker arm 150 which is in turn pushing the exhaust valve 70 to a fully open position. The partial exhaust stroke camshaft 160 has rotated 630 degrees counter-clockwise and is no longer touching the rocker arm 150 .
[0099] FIG. 9 is an enlarged view of the partial exhaust half stroke camshaft 160 , There is 66 degrees between the beginning of the valve opening lobe ramp 170 and the end of the valve closing lobe ramp 180 . Since the partial exhaust stroke camshaft 160 rotates counter-clockwise at the same rpm as the clockwise rotating crankshaft 60 , the exhaust valve 70 will be open for 66 degrees of crankshaft rotation.
[0100] FIG. 10 is an enlarged view of an alternate partial exhaust stroke camshaft 160 with 90 degrees between the beginning of the valve opening lobe ramp 190 and the end of the valve closing lobe ramp 200 . Since the partial exhaust stroke camshaft 160 rotates counter-clockwise at the same rpm as the crankshaft 60 , the exhaust valve 70 will be open for 90 degrees of crankshaft rotation.
[0101] FIG. 11 shows an alternate structure for a 3-2/2 stroke internal combustion, fuel injected, piston engine 10 . The FIG. 11 engine 10 is the same as shown in FIG. 1 , but with the partial exhaust stroke camshaft 160 relocated to the crankcase 62 of the engine 10 . From that position the camshaft 160 operates the exhaust valve 70 via a lifter rod 210 and a rocker arm 220 .
[0102] FIG. 12 shows an alternate structure for a 3-2/2 stroke internal combustion, fuel injected, piston engine 10 . The FIG. 12 engine 10 is the same basic engine as previously shown, but instead of camshafts operating the intake valve 90 and the exhaust valve 70 , computer controlled electronic valve operators 230 , such as valve solenoids 230 , control the exhaust valve 70 and the intake valve 90 to their open and closed states in response to electrical signals from a controller.
[0103] FIG. 13 shows an alternate structure for a 3-2/2 stroke internal combustion, fuel injected, piston engine 10 . It is the same basic engine 10 as shown in FIG. 1 , but instead of having the two exhaust camshafts 140 and 160 , the FIG. 13 engine 10 includes a single oversized, double lobed, tubular camshaft 240 with one lobe 250 for the exhaust full stroke and one lobe 260 for the partial exhaust stroke. Because the camshaft 240 rotates clockwise at one half the rpm of the crankshaft 60 , the 90° arc of the lobe 250 will open the exhaust valve 70 for 180° of crankshaft rotation, and the 33° arc of the lobe 260 will open the exhaust valve 70 for 66° of crankshaft rotation.
[0104] FIG. 14 shows an alternate structure for a 3-2/2 stroke internal combustion, fuel injected, piston engine 10 . It is the same basic engine 10 as shown in FIG. 1 , but instead of having two exhaust camshafts 140 and 160 , the FIG. 14 engine includes a single “normal” sized, double lobed, camshaft 270 , with one lobe 280 for the exhaust full stroke and one lobe 290 for the partial exhaust stroke.
[0105] FIG. 14 a is an enlarged view of the double lobed exhaust camshaft 270 . In the illustrated embodiment, and for a specific sizing of the illustrated embodiment, the lobe 280 for the full exhaust stroke will open the exhaust valve 70 by 0.3 inches at the midpoint of the exhaust stroke, and the lobe 290 for the partial exhaust stroke will open the exhaust valve 70 by 0.025 inches at the midpoint of the partial exhaust stroke. Even though 0.025″ is a relatively small opening, some exhaust gases and pressure from the exhaust manifold 80 will enter the cylinder 30 during the partial exhaust stroke. Because the camshaft 270 rotates at half the rpms as the crankshaft 60 , the 90° arc of the lobe 280 will open the valve 70 for 180° of crankshaft rotation, and the 33° arc of the lobe 290 will open the exhaust valve 70 for 66° of crankshaft rotation.
[0106] Analysis has shown that the 3-2/2 stroke engine disclosed herein can improve fuel efficiency at low rpm with the air throttle nearly fully closed by 40-50% in comparison to conventional four stroke engines. This is important because it has been estimated that approximately 90% of automobile driving takes place while cruising in the lower rpm ranges (1,000 rpm to 2,000 rpm in many conventional engines), with higher engine rpms only being experienced during situations of extreme acceleration or load, such as towing a trailer up a hill.
[0107] At low rpms, the intake air can be as low as 5 or 6 psi into the cylinder. When the exhaust valve 70 opens during the partial exhaust stroke, the pressure in the cylinder 30 is boosted to around 15 or 16 psi while exhaust gas enters from the exhaust manifold 80 via the exhaust valve 70 . During the rest of the partial exhaust stroke, most of the exhaust gas that entered via the valve 70 is expelled, but the gases in the cylinder 30 remain at the higher pressure. This results in a pressure boost wherein the pressure in the cylinder 30 at the beginning of the compression stroke is around 15 to 16 psi, whereas in a conventional four stroke engine the pressure in the cylinder would be 5 or 6 psi.
[0108] At high rpms, the intake air in the cylinder 30 can be as high as 13 psi. When the exhaust valve 70 opens during the the partial exhaust stroke, the pressure in the cylinder 30 is slightly boosted to around 15 or 16 psi via the exhaust gas entering through the exhaust valve 70 . Again, during the rest of the partial exhaust stroke, the exhaust gas that entered during the initial opening of the exhaust valve 70 is expelled, along with a small amount of air, but the gases in the cylinder 30 remain at the higher pressure. The result is that the 3-2/2 stroke engine 10 , the charge at the beginning of the compression stroke is around 15 to 16 psi. The pressure boost experienced at the low rpms in the disclosed engine 10 is similar to that experienced in a turbo charged or super charged engine which can boost the pressure in the cylinder by 6 to 8 psi and any rpm. However, the increase in pressure in a turbo charged or super charged conventional four stroke engine is the result of adding a greater mass of air which in turn requires more fuel in order to remain stoichiometrically balanced, i.e., one part fuel to 15 parts air by weight for proper combustion. The 3-2/2 stroke engine obtains the boost without the added cost of a turbo charger or super charger or the work required to operate one.
[0109] While specific embodiments of the 3-2/2 operating cycle and 3-2/2 engine have been described herein in detail, it should be understood that this disclosure encompasses and contemplates modifications to the detailed descriptions shown herein. In this regard, consideration should be given to the embodiments recited in the Summary of the Invention and the Claims.
[0110] While everything herein pertains to a naturally aspirated 3-2/2 stroke engine, there is every reason to believe that the 3-2/2 stroke engine would drastically improve the efficiency of a turbocharged engine especially at low rpm where turbochargers are least effective.
|
A method and apparatus is provided for operating a piston driven, internal combustion engine ( 10 ) including a the piston ( 40 ) translating in a cylinder ( 30 ). The engine ( 10 ) has an intake stroke, followed by a partial exhaust stroke, followed by a compression stroke, followed by a power stroke and then an exhaust stroke, all of which are sequentially repeated. The compression stroke has a stroke length that is less than the stroke length of the power stroke.
| 5
|
INTRODUCTION AND BACKGROUND
The invention relates to dry liquids, and a process for their preparation.
Dry liquids, in particular dry water, are disclosed in U.S. Pat. No. 3,393,155.
They consist of pyrogenically prepared silica which has a mean particle size of not more than 50 millimicrons, whose surface has been rendered hydrophobic and which contain from 5 to 10 times the amount of liquid in encapsulated form.
The powder (dry water) has a pulverulent appearance in spite of the large proportion of water.
The known dry powder can be prepared by separating the liquid into fine droplets and mixing these fine droplets with water-repellent, pyrogenically prepared silica with high energy input so that the droplets of the liquid are completely surrounded by the hydrophobic silica (U.S. Pat. No. 3,393,155).
It is furthermore known that a drilling fluid component can be prepared by mixing and combining water with hydrophobic, pyrogenically prepared silica under high shear conditions, a flowable, dry, pulverulent solid product being obtained.
The mixing can be effected under high shear conditions. Thus, a high-speed mixing pump or a disperser can be used in the laboratory.
On a larger scale, a rotating stirrer provided with blades, a mixing pump or any other mixer which is suitable for introducing high shear energy into the mixer can be used (U.S. Pat. No. 3,951,824).
It is furthermore known that dry water can be prepared by stirring silica with water and can be used as a fire extinguishing agent. It can be stored at low temperatures because it does not lose its flowability as a powder even at extremely low temperatures (U.S. Pat. No. 5,342,597 and U.S. Pat. No. 4,008,170).
It is furthermore known that dry water can be prepared by using a “rocking mixer” or a shaking apparatus as apparatuses for the high-speed movement of the mixture (US 2004/0028710).
The known processes have the disadvantage that only relatively small amounts of dry water can be prepared.
It was therefore the object to develop a process by means of which larger amounts of dry water can be prepared.
The invention relates to dry liquids containing a hydrophobic, pyrogenic silica, which is characterized by the following physicochemical parameters:
Particle Size Distribution (Cumulative Undersize)
D10%
80 to 140 μm
D50%
140 to 200 μm
D90%
190 to 340 μm
Bulk density DIN 53912 kg/m 3
400 to 500
Tamped density DIN ISO 787 kg/m 3
500 to 600
Solids content DIN 53 198%
4 to 10
SUMMARY OF INVENTION
The invention furthermore relates to a process for the preparation of the dry liquids, which is characterized in that the liquids and a hydrophobic, pyrogenically prepared silica are passed through a clearly defined, spatially limited shear zone in which the liquids are broken up into small droplets and are surrounded by the hydrophobic, pyrogenically prepared silica.
The liquids in the hydrophobic, pyrogenically prepared silica can be fed to the shear zone axially, the dry liquids obtained being removed from the shear zone radially.
The liquids and the hydrophobic silica can be fed to the shear zone axially in the same line.
In a further embodiment of the invention, the liquids and the pyrogenically prepared silica can be fed to the shear zone axially in different lines.
In a further embodiment of the invention, the liquid can be mixed with the hydrophobic, pyrogenically prepared silica in a container. This mixture can be fed to the shear zone axially.
The mixture can be aspirated through the apparatus forming the shear zone.
Rotor-stator mixers can be used as the apparatus forming the shear zones. Such a mixer is known, for example, from Ullmann's Encyclopaedia of Industrial Chemistry, 5th Edition, Volume 32, Pages 25-6.
Liquids may be understood as meaning water, aqueous salt solutions, aqueous solutions of glycerol and similar water-miscible liquid components in pharmaceuticals, cosmetics etc.
In a preferred embodiment of the invention, the liquid used may be water.
In an embodiment of the invention, the shear zone may be arranged at the bottom of a conical container. An anchor stirrer which can effect transportation of the hydrophobic pyrogenically prepared silica in such a way that dead zones can be avoided and the total material can be passed through the shear zone may be arranged in the conical container.
In a further embodiment of the invention, the dry liquid produced can be recycled until the total amount of liquid initially introduced is present in the form of the dry liquid.
DETAILED DESCRIPTION OF INVENTION
Example 1
The rotor-stator mixer from Ystral, the Conti TDS was tested in two different setups.
Firstly, an open container having a gross volume of 350 l was connected upstream. The pipeline diameter for connecting the storage container to the Conti TDS is 80 mm both on the suction side and on the pressure side. The length of the suction line is 5 m and said line includes three 90° bends. The length of the pressure line is 6 m with four 90° C. bends.
The setup is shown schematically in FIG. 1 . The principle of operation of the Ystral Conti TDS is shown schematically in FIG. 2 .
The second setup comprised a 60 liter storage container and managed with a suction line length of 2 meters with 2 90° bends and a pressure line of 3 meters with 3 90° bends.
The Conti TDS 4 used was a 37 kW machine. It could be operated at a speed of 3600 rpm which, with the existing size of the mixing chamber with a diameter of 227 mm, led to a circumferential velocity at the inner rotor of 29 m/s and a circumferential velocity at the outer rotor of 31 m/s.
A mixing member, such as, for example, an anchor stirrer, for suppressing the formation of dead zones in the container was present in each case in the storage container.
demineralized water was initially introduced into the storage container. The hydrophobic, pyrogenically prepared silica AEROSIL R812S was provided in an original 10 kg bag, and the required amount was fed directly from the bag by means of a suction lance to the Conti TDS. The reduced pressure generated by the Conti TDS was sufficient for sucking in the AEROSIL within 90 seconds. After the end of the addition, the intake valve was closed and the dispersing was continued until the reaction was complete and the desired quality had been reached.
Example 2
The rotor-stator mixer from A. Berhrents, Becomix MV60, having a container volume of 60 liters and a maximum circumferential velocity of 25 m/s, could also be successfully used. In this setup, the rotor-stator is virtually part of the container. It is mounted directly on the container, in the bottom. Water and the hydrophobic, pyrogenically prepared silica AEROSIL R812S were introduced into the storage container. The rotor-stator mixer present in the bottom aspirated both and recycled the product via a circulation line into the container. The intake power, which is weaker in this system in comparison with example 1, is compensated by virtue of the fact that the rotor-stator was installed directly at the bottom of the container. A stirrer, for example an anchor stirrer, which effectively avoided the formation of dead zones was present in the container. As in example 1, the mixing time depended on the completeness of the reaction and on the desired quality of the dry water.
The principle of operation of this arrangement is shown schematically in FIG. 3 .
Common to both systems (Ystral and Becomix) is that the liquid and the pyrogenically prepared silica AEROSIL R812S are passed through a clearly defined, spatially limited shear zone in which the liquid is broken up into small droplets and is surrounded by the hydrophobic, pyrogenically prepared silica AEROSIL R812S. This is the substantial difference from the known systems on a laboratory scale. Independently of batch size, container volume and container geometry, the same rotor-stator can always be used under the same conditions. According to the invention, it is always ensured that the complete starting materials are exposed completely to the shear forces during passage through the shear field in the rotor-stator. The difference in the flowability between liquid and “powder” after the phase change must be taken into account in the geometry of the container and of the mixing tool present therein for avoiding dead zones. However, this has no influence on the efficiency of the process according to the invention. Since the rotor-stator systems used according to the invention have a more (Ystral) or less (Becomix) pronounced self-aspirating effect, flow through the shear zone is achieved even after the phase change and complete conversion is ensured.
The exact design of the rotor-stator system may be entirely different depending on the manufacturer and performance spectrum.
Some selected possibilities for the design of the rotor-stator system are shown schematically in FIG. 4 .
These may entail a different number of rotors and stators and the detailed design may be absolutely different from manufacturer to manufacturer.
Example 3
Dry liquids are prepared using the process according to the invention:
The individual conditions are mentioned in Table 1.
TABLE 1
Example: High-intensity stirrer
Example: Rotor-stator make A
Particle size distribution
D10%
103
114
104
103
(cumulative undersize)
D50%
158
184
152
150
D90%
236
315
233
210
Bulk density DIN 53912 [kg/m 3 ]
471
493
465
460
Tamped density DIN ISO 787 [kg/m 3 ]
558
567
552
449
Solids content DIN 53198 [%]
4.9
4.9
5.0
4.7
Circumferential velocity [m/s]
32
38.5
30.6
30.96
Liquid component
water
water
water
water + additive
The dependence of the drop size on the circumferential velocity is shown graphically in FIG. 5 .
The particle size distribution is carried out by means of TEM analysis on the freeze-dried (cryoprepared) dry liquid.
The cryopreparation is effected as follows.
In the cryopreparation, the cryopreparation chamber is first cooled with liquid nitrogen to about 100 K. When the preparation chamber is opened, a heater vaporizes N 2 so that the preparation takes place in a dry N 2 atmosphere. The preparation holder is likewise cooled to about 100 K by introducing liquid N 2 into the dewar of the holder.
For preparation 1 “dry water” was dusted onto a preparation support net coated with a thin polymer layer and was placed on a piece of filter paper in the preparation chamber cooled to low temperature and was frozen.
For preparation 2, ethane was liquefied in a copper container. A small net dusted with “dry water” was dipped into the ethane. Owing to the higher heat capacity of the liquefied ethane, water is frozen abruptly here, as a rule in amorphous form, in contrast to preparation 1. The sample can no longer change on cooling, in contrast to preparation 1.
The frozen preparations were then transferred to the preparation holder and transferred to the transmission electron microscope. Because the holder is cooled to a low temperature, the preparations can be analysed in a frozen state in the TEM.
|
Dry liquids having a particle size distribution (cumulative undersize)
D10% 80 to 140 μm D50% 140 to 200 μm D90% 190 to 340 μm
are prepared by passing the liquids and a hydrophobic, pyrogenically prepared silica through a clearly defined, spatially limited shear zone in which the liquids are broken up into small droplets and are surrounded by the hydrophobic, pyrogenically prepared silica.
| 8
|
CROSS REFERENCE
This is a national stage application under 35 U.S.C. 371 of PCT patent application PCT/US08/64073, filed on May 19, 2008, which claims the benefit of U.S. Provisional Patent Application U.S. Application Ser. No. 60/939,773, filed May 23, 2007, each of which is hereby incorporated by reference in its entirety.
DESCRIPTION OF THE INVENTION
Disclosed and described herein is a compound having a formula
wherein a dashed line indicates the presence or absence of a covalent bond;
Y is an organic acid functional group, or an amide or ester thereof comprising up to 14 carbon atoms; or Y is hydroxymethyl or an ether thereof comprising up to 14 carbon atoms; or Y is a tetrazolyl functional group;
B is —CH(OH)—, —C(═O)—, —CH 2 CH(OH)—, or —CH 2 C(═O)—; and
D is alkyl, aryl, heteroaryl, arylalkyl, or heteroarylalkyl.
These compounds are useful for reducing intraocular pressure or treating glaucoma.
One embodiment is a method of treating glaucoma comprising administering a compound disclosed herein.
Another embodiment is a method of reducing intraocular pressure comprising administering a compound disclosed herein.
Another embodiment is use of a compound disclosed herein in the manufacture of a medicament for the reduction of intraocular pressure.
Another embodiment is use of a compound disclosed herein in the manufacture of a medicament for the treatment of glaucoma.
For the purposes of this disclosure, “treat,” “treating,” or “treatment” refer to the use of a compound, composition, therapeutically active agent, or drug in the diagnosis, cure, mitigation, treatment, prevention of disease or other undesirable condition.
Unless otherwise indicated, reference to a compound should be construed broadly to include pharmaceutically acceptable salts, prodrugs, tautomers, alternate solid forms, and non-covalent complexes of a chemical entity of the depicted structure or chemical name.
A pharmaceutically acceptable salt is any salt of the parent compound that is suitable for administration to an animal or human. A pharmaceutically acceptable salt also refers to any salt which may form in vivo as a result of administration of an acid, another salt, or a prodrug which is converted into an acid or salt. A salt is a chemical species having an ionic form of the compound, such as a conjugate acid or base, associated with a corresponding amount of counter-ions. Salts can form from or incorporate one or more deprotonated acidic groups (e.g. carboxylic acids), one or more protonated basic groups (e.g. amines), or both (e.g. zwitterions).
A prodrug is a compound which is converted to a therapeutically active compound after administration. While not intending to limit the scope of the invention, conversion may occur by hydrolysis of an ester group or some other biologically labile group. Generally, but not necessarily, a prodrug is inactive or less active than the therapeutically active compound to which it is converted. Prodrug preparation is well known in the art. For example, “Prodrugs and Drug Delivery Systems,” which is a chapter in Richard B. Silverman, Organic Chemistry of Drug Design and Drug Action, 2d Ed., Elsevier Academic Press: Amsterdam, 2004, pp. 496-557, provides further detail on the subject.
Tautomers are isomers that are in rapid equilibrium with one another. They often, but do not necessarily, include a transfer of a proton, hydrogen atom, or hydride ion. For example, the structures herein are intended to include, but are not limited to, the tautomeric forms shown below.
Unless stereochemistry is explicitly depicted, a structure is intended to include every possible stereoisomer, both pure or in any possible mixture.
Alternate solid forms are different solid forms than those that may result from practicing the procedures described herein. For example, alternate solid forms may be polymorphs, different kinds of amorphous solid forms, glasses, and the like.
Non-covalent complexes are complexes that may form between the compound and one or more additional chemical species that do not involve a covalent bonding interaction between the compound and the additional chemical species. They may or may not have a specific ratio between the compound and the additional chemical species. Examples might include solvates, hydrates, charge transfer complexes, and the like.
Hydrocarbyl is a moiety consisting of carbon and hydrogen only, including, but not limited to:
a. alkyl, meaning hydrocarbyl having no double or triple bonds, including, but not limited to:
linear alkyl, e.g. methyl, ethyl, n-propyl, n-butyl, n-pentyl, n-hexyl, etc., branched alkyl, e.g. iso-propyl, t-butyl and other branched butyl isomers, branched pentyl isomers, etc., cycloalkyl, e.g. cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, etc., combinations of linear, branched, and/or cycloalkyl;
b. alkenyl, e.g. hydrocarbyl having 1 or more double bonds, including linear, branched, or cycloalkenyl c. alkynyl, e.g. hydrocarbyl having 1 or more triple bonds, including linear, branched, or cycloalkenyl; d. combinations of alkyl, alkenyl, and/or akynyl
Use of the notation “C x-y ” means the moiety has from x to y carbon atoms. For example, C 1-6 alkyl means alkyl having from 1 to 6 carbon atoms, or C 1-6 hydrocarbyl means hydrocarbyl having from 1 to 6 carbon atoms.
As used herein, “aryl” is phenyl, naphthyl, or biphenyl which may be substituted or unsubstituted. “Heteroaryl” is monocyclic or bicyclic heteroaryl, i.e. a monocyclic aryl ring wherein at least one nitrogen, oxygen, or sulfur atom is in the ring, or a bicyclic aromatic ring system wherein at least one nitrogen, oxygen, or sulfur atom is in at least one of the rings. Examples of heteroaryl include pyridinyl, furyl, thienyl, benzothienyl, benzofuryl, quinolinyl, imidazolyl, thiazolyl, oxazolyl, and the like.
Aryl or heteroaryl may be substituted or unsubstituted. If aryl is substituted, it may have from 1 to 5 substituents. Each substituent independently consists of from 0 to 8 carbon atoms, from 0 to 3 oxygen atoms, from 0 to 2 sulfur atoms, from 0 to 2 nitrogen atoms, from 0 to 3 fluorine atoms, from 0 to 2 chlorine atoms, from 0 to 1 bromine atoms, from 0 to 1 iodine atoms, and from 0 to 17 hydrogen atoms.
Subject to the constraints described herein (e.g. limits on the number of atoms for a substituent), examples of substituents include, but are not limited to:
hydrocarbyl, e.g. alkyl, alkenyl, alkynyl, phenyl, and the like;
hydroxyalkyl, i.e. alkyl-OH, such as hydroxymethyl, hydroxyethyl, and the like;
ether substituents, including —O-alkyl, alkyl-O-alkyl, and the like;
thioether substituents, including —S-alkyl, alkyl-S-alkyl, and the like;
amine substituents, including —NH 2 , —NH-alkyl, —N-alkyl 1 alkyl 2 (i.e., alkyl 1 and alkyl 2 are the same or different, and both are attached to N), alkyl-NH 2 , alkyl-NH-alkyl, alkyl-N-alkyl 1 alkyl 2 , and the like;
aminoalkyl, meaning alkyl-amine, such as aminomethyl (—CH 2 -amine), aminoethyl, and the like;
ester substituents, including —CO 2 -alkyl, —CO 2 -phenyl, etc.;
other carbonyl substituents, including aldehydes; ketones, such as acyl (i.e.
and the like; in particular, acetyl, propionyl, and benzoyl substituents are contemplated;
phenyl or substituted phenyl;
fluorocarbons or hydrofluorocarbons such as —CF 3 , —CH 2 CF 3 , etc.; and
—CN;
combinations of the above are also possible, subject to the constraints defined;
Alternatively, a substituent may be —F, —Cl, —Br, or —I.
In particular, alkyl having from 1 to 8 carbon atoms is contemplated as a substituent.
Alternatively, alkyl having from 1 to 4 carbon atoms is contemplated;
Substituents must be sufficiently stable to be stored in a bottle at room temperature under a normal atmosphere for at least 12 hours, or stable enough to be useful for any purpose disclosed herein.
If a substituent is a salt, for example of a carboxylic acid or an amine, the counter-ion of said salt, i.e. the ion that is not covalently bonded to the remainder of the molecule is not counted for the purposes of the number of heavy atoms in a substituent. Thus, for example, the salt —CO 2 − Na + is a stable substituent consisting of 3 heavy atoms, i.e. sodium is not counted. In another example, the salt —NH(Me) 2 + Cl − is a stable substituent consisting of 3 heavy atoms, i.e. chlorine is not counted.
A dashed line indicates the presence or absence of a double bond. Thus, the structures below are contemplated.
An organic acid functional group is an acidic functional group on an organic molecule. While not intending to be limiting, organic acid functional groups may comprise an oxide of carbon, sulfur, or phosphorous. Thus, while not intending to limit the scope of the invention in any way, in certain compounds Y is a carboxylic acid, sulfonic acid, or phosphonic acid functional group.
Additionally, an amide or ester of one of the organic acids mentioned above comprising up to 14 carbon atoms is also contemplated for Y. In an ester, a hydrocarbyl moiety replaces a hydrogen atom of an acid such as in a carboxylic acid ester, e.g. CO 2 Me, CO 2 Et, etc.
In an amide, an amine group replaces an OH of the acid. Examples of amides include CON(R 2 ) 2 , CON(OR 2 )R 2 , CON(CH 2 CH 2 OH) 2 , and CONH(CH 2 CH 2 OH) where R 2 is independently H, C 1 -C 6 alkyl, phenyl, or biphenyl. Moieties such as CONHSO 2 R 2 are also amides of the carboxylic acid notwithstanding the fact that they may also be considered to be amides of the sulfonic acid R 2 —SO 3 H. The following amides are also specifically contemplated, CONSO 2 -biphenyl, CONSO 2 -phenyl, CONSO 2 -heteroaryl, and CONSO 2 -naphthyl. The biphenyl, phenyl, heteroaryl, or naphthyl may be substituted or unsubstituted.
While not intending to limit the scope of the invention in any way, Y may also be hydroxymethyl or an ether thereof comprising up to 14 carbon atoms. An ether is a functional group wherein a hydrogen of an hydroxyl is replaced by carbon, e.g., Y is CH 2 OCH 3 , CH 2 OCH 2 CH 3 , etc. These groups are also bioisosteres of a carboxylic acid.
“Up to 14 carbon atoms” means that the entire Y moiety, including the carbonyl carbon of a carboxylic acid ester or amide, and both carbon atoms in the —CH 2 O—C of an ether has 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, or 14 carbon atoms.
Finally, while not intending to limit the scope of the invention in any way, Y may be a tetrazolyl functional group.
Thus, while not intending to be limiting, the structures below exemplify what is meant by tetrazolyl; carboxylic acid, phosphonic acid, sulfonic acid, and their esters and amides; hydroxymethyl and ether of hydroxymethyl. In these structures, R is H or hydrocarbyl, subject to the constraints defined herein.
Each structure below represents a specific embodiment which is individually contemplated, as well as pharmaceutically acceptable salts and prodrugs of compounds which are represented by the structures.
Organic Acids
Esters
Amides
M 1 —CO 2 H
M 1 —CO 2 R
M 1 —CO 2 NR 2
Carboxylic Acid
Carboxylic Acid Ester
Carboxylic Acid Amide
M 1 —P(O)(OH) 2
M 1 —P(O)(OH)OR
M 1 —P(O)(OH)NR 2
Phosphonic Acid
Phosphonic Acid Ester
Phosphonic Acid Amide
M 1 —SO 3 H
M 1 —SO 3 R
M 1 —SO 3 NR 2
Sulfonic Acid
Sulfonic Acid Ester
Sulfonic Acid Amide
M 1 —CH 2 OH Hydroxymethyl
M 1 —CH 2 OR Ether
A tetrazolyl functional group is another bioisostere of a carboxylic acid. An unsubstituted tetrazolyl functional group has two tautomeric forms, which can rapidly interconvert in aqueous or biological media, and are thus equivalent to one another.
Additionally, if R 2 is C 1 -C 6 alkyl, phenyl, or biphenyl, other isomeric forms of the tetrazolyl functional group such as the one shown below are also possible, unsubstituted and hydrocarbyl substituted tetrazolyl up to C 12 are considered to be within the scope of the term “tetrazolyl.”
While not intending to limit the scope of the invention in any way, in one embodiment, Y is CO 2 R 2 , CON(R 2 ) 2 , CON(OR 2 )R 2 , CON(CH 2 CH 2 OH) 2 , CONH(CH 2 CH 2 OH), CH 2 OH, P(O)(OH) 2 , CONHSO 2 R 2 , SO 2 N(R 2 ) 2 , SO 2 NHR 2 ,
wherein R 2 is independently H, C 1 -C 6 alkyl, unsubstituted phenyl, or unsubstituted biphenyl.
B is —CH(OH)—, —C(═O)—, —CH 2 CH(OH)—, or —CH 2 C(═O)—. Thus, the structures below are contemplated.
In one embodiment, D is linear alkyl having 2, 3, 4, 5, or 6 carbon atoms.
Other examples of D are depicted below.
In one embodiment D is alkyl.
In another embodiment B is —CH(OH)—.
In another embodiment, the compound has the formula
In another embodiment, the compound has the formula
In another embodiment, the compound has the formula
In another embodiment B is —CH 2 CH(OH)—.
In another embodiment, the compound has the formula
Hypothetical examples of useful compounds include those shown below.
In Vitro Testing
U.S. patent application Ser. No. 11/553,143, filed on Oct. 26, 2006, incorporated by reference herein, describes the methods used to obtain the in vitro data in the table below.
EP2 data
EP4 data
flipr
cAMP
flip
Other Receptors (EC50 in nM)
Structure
EC50
EC50
Ki
EC50
KI
hFP
hEP1
hEP3A
hTP
hIP
hDP
1568
19
2880
7846
8719
NA
NA
2223
4888
NA
6.8
NA
NA
NA
NA
2035
>10000
>10000
194
NA
NA
NA
NA
NA
>10000
>10000
>10000
>10000
20
1202
NA
NA
NA
>10000
>10000
>10000
213
In Vivo Testing
U.S. Pat. No. 7,091,231 describes the methods used to carry out the tests reported below.
5-[(R)-1-((S)-3-Hydroxyoctyl)-5-oxopyrrolidin-2-ylmethoxymethyl]-thiophene-2-carboxylic isopropyl ester was tested in normotensive dogs at 2 concentrations, dosing once daily for 5 days. At 0.1%, the maximum intraocular pressure (TOP) decrease from baseline was 8 mmHg (47%) at 78 h; the maximum ocular surface hyperemia (OSH) score was 2.25 at 50 h. At 0.01%, the maximum TOP decrease from baseline was 6.1 mmHg (35%) at 78 h; the maximum OSH score was 1.7 at 30 h. This compound was also tested in laser-induced hypertensive monkeys, using one single day dose. At 0.1%, the maximum TOP decrease from baseline was 17 mmHg (48%) at 6 h.
Example 1
5-[(R)-1-((S)-3-Hydroxyoctyl)-5-oxopyrrolidin-2-ylmethoxymethyl]-thiophene-2-carboxylic acid (6)
Step 1. Vinylation of 1 to Give 2
Potassium carbonate (730 mg, 5.28 mmol), copper(I) iodide (54 mg, 0.28 mmol) and N,N′-dimethylethylenediamine (29 μL, 0.27 mmol) were added sequentially to a solution of (R)-5-(hydroxymethyl)-pyrrolidin-2-one (1, Aldrich chemical, 365 mg, 3.17 mmol) and vinyl iodide A (Nissan Chemical, 972 mg, 2.64 mmol) in MeCN (6 mL). The reaction flask was fitted with a reflux condenser, purged with nitrogen and heated at reflux for 18 h. The reaction mixture cooled to room temperature, diluted with EtOAc and filtered through celite, washing with excess EtOAc. The filtrate was concentrated in vacuo. The residue was suspended in EtOAc, filtered and concentrated a second time. Purification of the crude residue by flash column chromatography on 12 g of silica gel (60% EtOAc/hexane) afforded 627 mg (67%) of desired product 2.
Step 2. Hydrogenation of 2 to Give 3
Palladium on carbon (10 wt. %, 55 mg) was added to solution of alkene 2 (374 mg, 1.05 mmol) in EtOAc (11 mL). A hydrogen atmosphere was established by evacuating and refilling with hydrogen (5×) and the reaction mixture was stirred under a balloon of hydrogen for 30 min. The reaction mixture was filtered through celite, washing with EtOAc, and the filtrate was concentrated in vacuo. Purification of the resulting crude residue by flash column chromatography on 4 g of silica gel (50% EtOAc/hexane→EtOAc, gradient) afforded 298 mg (79%) desired product 3.
Step 3. Alkylation of 3 to Give 4
Sodium hydride (60% oil dispersion, 16 mg, 0.40 mmol) was added to a solution of alcohol 3 (99 mg, 0.28 mmol) DMF (0.7 mL) at 0° C. After 5 min, the reaction was allowed to warm to room temperature. After 30 min at room temperature, the mixture was cooled to −40° C. and a solution of bromide B (see U.S. Provisional Patent Application No. 60/804,680, filed on Jun. 14, 2006, 54 mg, 0.23 mmol) in DMF (0.7 mL) was added via cannula. After 2 h at −40° C., the reaction was quenched with 1.0 N HCl (10 mL) and extracted with EtOAc (3×30 mL). The combined extracts were washed with H 2 O (2×20 mL) and brine (20 mL), then dried (Na 2 SO 4 ), filtered and concentrated in vacuo. Purification of the crude residue by flash column chromatography on 4 g of silica gel (hexane→EtOAc, gradient) afforded 83 mg (59%) of desired product 4.
Step 4. Deprotection of 4 to Give 5
HF-pyridine (0.25 mL) was added to a solution of silyl ether 4 (83 mg, 0.16 mmol) in MeCN (3.2 mL) at 0° C. in a plastic scintillation vial. After 1.5 h at 0° C., the reaction mixture was quenched with saturated aqueous NaHCO 3 (10 mL) and extracted with EtOAc (3×15 mL). The combined extracts were washed with brine (10 mL), then dried (Na 2 SO 4 ), filtered and concentrated in vacuo. Purification of the crude residue by flash column chromatography on 4 g of silica gel (50% EtOAc/hexane→EtOAc, gradient) afforded 50 mg (78%) of alcohol 5.
Step 5. Saponification of 5 to Give 6
Aqueous lithium hydroxide (1 N, 0.63 mL, 0.63 mmol) was added to a solution of ester 5 (50 mg, 0.13 mmol) in THF (1.25 mL). After 18 h at room temperature, the solvent was removed under a stream of nitrogen, the residue was diluted with H 2 O (2 mL), acidified with 1.0 M HCl (2 mL) then extracted with EtOAc (3×15 mL). Combined extracts were washed with brine (10 mL), dried (Na 2 SO 4 ), filtered and concentrated in vacuo to afford 44 mg (quant.) of the title compound (6).
Example 2
N-{5-[(R)-1-((S)-3-Hydroxy-octyl)-5-oxopyrrolidin-2-ylmethoxymethyl]-thiophene-2-carbonyl}-methanesulfonamide (7)
Acid 6 (12 mg, 0.031 mmol), 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride (EDCI, 8.4 mg, 0.044 mmol), 4-dimethylaminopyridine (DMAP, 4.6 mg, 0.038 mmol) and methanesulfonamide (9 mg, 0.095 mmol) were dissolved in DMF (0.2 mL) and the resulting solution was stirred at room temperature under an atmosphere of nitrogen. After 15 h the solution was diluted with EtOAc (20 mL) and washed with 1N aqueous HCl (3×5 mL) and brine (5 mL), then dried (Na 2 SO 4 ), filtered and concentrated in vacuo. Purification of the crude residue by flash column chromatography on 4 g of silica gel (CH 2 Cl 2 →10% MeOH/CH 2 Cl 2 , gradient) afforded 3.5 mg (25%) of the title compound (7).
Example 3
5-[(R)-1-((S)-3-Hydroxy-octyl)-5-oxopyrrolidin-2-ylmethoxymethyl]-thiophene-2-carboxylic acid ethylamide (8)
Triethylamine (9 mL, 0.065 mmol) and ethyl chloroformate (4.5 mL, 0.47 mmol) were added sequentially to a solution of acid 6 (12 mg, 0.031 mmol) in CH 2 Cl 2 (0.2 mL) at 0° C., After 1 h at 0° C., ethylamine (2.0 M in THF, 0.15 mL, 0.30 mmol) was added and the mixture was allowed to warm to room temperature. After 18 h at room temperature, the reaction was quenched with 1.0 N HCl (5 mL) and extracted with EtOAc (3×10 mL). The combined extracts were washed with brine (5 mL), then dried (Na 2 SO 4 ), filtered and concentrated in vacuo. Purification of the crude residue by flash column chromatography on 4 g of silica gel (CH 2 Cl 2 →10% MeOH/CH 2 Cl 2 , gradient) afforded 7.7 mg (60%) of the title compound (8).
Example 4
5-{(R)-1-[4-Hydroxy-4-(1-propylcyclobutyl)-butyl]-5-oxopyrrolidin-2-ylmethoxymethyl}-thiophene-2-carboxylic acid (13)
Step 1. Vinylation of 1 to Give 9
Potassium carbonate (474 mg, 3.43 mmol), copper(I) iodide (33 mg, 0.17 mmol) and N,N′-dimethylethylenediamine (18 μL, 0.17 mmol) were added sequentially to a solution of (R)-5-(hydroxymethyl)-pyrrolidin-2-one (1, Aldrich chemical, 237 mg, 2.06 mmol) and vinyl iodide C (see Tani, et al. Bioorg. Med. Chem. Lett. 2002, 10, 1093-1106, 700 mg, 1.71 mmol) in MeCN (3.9 mL). The reaction flask was fitted with a reflux condenser, purged with nitrogen and heated at reflux for 18 h. The reaction mixture cooled to room temperature, diluted with EtOAc and filtered through celite, washing with excess EtOAc. The filtrate was concentrated in vacuo. The residue was suspended in CH 2 Cl 2 , filtered and concentrated a second time. Purification of the crude residue by flash column chromatography on 40 g of silica gel (hexane→EtOAc, gradient) afforded 630 mg (93%) of desired product 9.
Step 2. Hydrogenation of 9 to Give 10
Palladium on carbon (10 wt. %, 85 mg) was added to solution of alkene 9 (630 mg, 1.59 mmol) in EtOAc (16 mL). A hydrogen atmosphere was established by evacuating and refilling with hydrogen (5×) and the reaction mixture was stirred under a balloon of hydrogen for 30 min. The reaction mixture was filtered through celite, washing with EtOAc, and the filtrate was concentrated in vacuo. Purification of the resulting crude residue by flash column chromatography on 40 g of silica gel (40% EtOAc/hexane→EtOAc, gradient) afforded 608 mg (96%) desired product 10.
Step 3. Alkylation of 10 to Give 11
Sodium hydride (60% oil dispersion, 40 mg, 1.0 mmol) was added to a solution of alcohol 10 (200 mg, 0.51 mmol) in DMSO (1.25 mL) at room temperature. After 30 min at room temperature, a solution of bromide B (130 mg, 0.55 mmol) in DMSO (1.25 mL) was added via cannula. After 15 min at room temperature, the mixture was heated at 40° C. After 16 h at 40° C., the mixture was allowed to cooled to room temperature, quenched with saturated aqueous NH 4 Cl (5 mL) and 0.5 N HCl (15 mL) and extracted with EtOAc (3×40 mL). The combined extracts were washed with H 2 O (2×20 mL) and brine (20 mL), then dried (Na 2 SO 4 ), filtered and concentrated in vacuo. Purification of the crude residue by flash column chromatography on 4 g of silica gel (hexane→EtOAc, gradient) afforded 36 mg (13%) of desired product 11.
Step 4. Deprotection of 11 to Give 12
HF-pyridine (0.10 mL) was added to a solution of silyl ether 11 (35 mg, 0.06 mmol) in MeCN (1.25 mL) at 0° C. in a plastic scintillation vial. After 2 h at 0° C., the reaction mixture allowed to warm to room temperature. After 18 h at room temperature, the reaction was quenched with saturated aqueous NaHCO 3 (10 mL), extracted with EtOAc (3×15 mL). The combined extracts were washed with saturated aqueous NaHSO 3 (10 mL) and brine (10 mL) then dried (Na 2 SO 4 ), filtered and concentrated in vacuo. Purification of the crude residue by flash column chromatography on 4 g of silica gel (40% EtOAc/hexane→EtOAc, gradient) afforded 23 mg (83%) of alcohol 12.
Step 5. Saponification of 12 to Give 13
Aqueous lithium hydroxide (1 N, 0.25 mL, 0.25 mmol) was added to a solution of ester 12 (22 mg, 0.05 mmol) in THF (0.5 mL). After 20 h at room temperature, the solvent was removed under a stream of nitrogen, the residue was diluted with H 2 O (1 mL), acidified with 1.0 M HCl (2 mL) then extracted with EtOAc (3×10 mL). Combined extracts were washed with brine (5 mL), dried (Na 2 SO 4 ), filtered and concentrated in vacuo to afford 21 mg (99%) of the title compound (13).
Example 5
5-[(R)-1-((S)-3-Hydroxyoctyl)-5-oxopyrrolidin-2-ylmethoxymethyl]-thiophene-2-carboxylic isopropyl ester
DBU (9 μL, 0.06 mmol) and 2-iodopropane (62 μL, 0.62 mmol) were added to a solution of acid 6 (12 mg, 0.031 mmol) in acetone (0.3 mL) at room temperature under nitrogen. After 5 days at room temperature, the solvent was removed under a stream of nitrogen. The residue was acidified with 1 N HCl (2 mL) and extracted with EtOAc (3×10 mL). The combined extracts were washed with brine (5 mL) then dried (Na 2 SO 4 ), filtered and concentrated in vacuo. Purification of the residue by flash column chromatography on silica (CH 2 Cl 2 →10% MeOH/CH 2 Cl 2 ) afforded 11.3 mg (85%) of the title compound.
|
Disclosed and described herein is a compound having a formula (I) therapeutic methods, medicaments, and compositions related thereto are also disclosed.
| 2
|
[0001] This invention relates generally to an apparatus for displaying advertising material in an attention getting manner, and deals more particularly with a method of advertising incorporating such apparatus.
SUMMARY OF THE INVENTION
[0002] The apparatus of the present invention provides a graphic image in a window or the like, the image being presented in segments cut from a printed or otherwise produced image, on a substrate medium which may be transparent or opaque. A plurality of vertically elongated slats are provided for pivotal movement, in unison with one another, the end portions being provided in top and bottom horizontal rails for this purpose. Each slat has marginal edges defining front facing elongated grooves for framing the elongated graphic image segments. An important aspect of the present invention is that slats are designed to overlap slightly, but the images on the segments are provided in closely enough spaced relationship to one another so as to present a uniform image to the viewer. Thus, the axis of rotation of each slat is spaced along the rail by a dimension (w) that is at least approximately equal to the width of each graphic image segment. In the closed positions the marginal edges of the slats overlap each other so the slats, and associated graphic image segments, are provided at on small angle relative to the rails.
[0003] A further feature of the present invention is to provide, in each slat, the capability of supporting another image at the backside thereof. Thus, the same or a different image can be presented to persons looking at the window or other opening from either inside or outside a building.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 shows a graphic image printed on a substrate in accordance with the first step in the method of the present invention.
[0005] FIG. 2 shows the image of FIG. 1 cut into elongated segments in accordance with the present invention.
[0006] FIG. 3 shows a slat in accordance with the preferred embodiment of the present invention having the capability of supporting graphic image segments on both the front and rear face thereof.
[0007] FIG. 4 shows the graphic image segments provided in a plurality of side-by-side slats, the slats being mounted in the upper and lower horizontally extending rails, and being movable in unison with one another by a socket tool, activating the transmition chain provided at the right hand side of the assembly. The socket tool and transmition chain can be replaced by other controls for rotating a longitudinally extending shaft in each of these rails that is geared to each of the posts that support each of the individual slats.
[0008] FIG. 5 shows the apparatus at FIG. 4 , but with the slats in the closed position.
[0009] FIGS. 6A , B, and C show sections of the side and lower rail, and illustrate a preferred structure for supporting the side-by-side slats, and for moving these slats.
[0010] FIG. 7 is a horizontal section and shows the rail of FIG. 6 , fitted with side-by-side slats, the slats being shown in the closed position.
[0011] FIG. 8 is a view similar to FIG. 3 , but showing a slat having images mounted both in the front and rear face thereof.
DETAILED DESCRIPTION
[0012] Turning first to FIG. 4 , a display system or apparatus of the present invention is illustrated as comprising as plurality of vertically oriented slats 10 , 10 each slat having upper and lower end portions 10 a and 10 b provided on posts 18 to be described. A frame includes lower and upper rails 12 and 14 . Each post is adapted to support a slat as shown in FIG. 6B , and is provided with pinions 20 that are engaged by longitudinal extending shafts 22 so that rotation of these shafts by the transmition chain 16 causes rotation of the longitudinal shafts, and results in synchronized rotation of the posts to move the slats between the position shown for them in FIG. 4 and that shown in FIG. 5 for example.
[0013] FIG. 6 shows a segment of the lower rail assembly, and illustrates two posts 18 , 18 , of the type adapted to retrieve slats, such as the slat indicated in FIG. 3 . Each slat has an opening 10 c for receiving a tang 18 a provided in a slotted opening at the upper end of the post 18 in order to secure each slat to its associated post. A second opening 10 p provided to hold each graphic segment in slat 10 with a pin (not shown). As mention previously the elongated shaft 22 provided in each of the upper and lower rails, and the transmition chain 16 are designed for opening and closing the pivotably mounted slats provided in the frame F. In addition, the top and bottom rails 12 and 14 , this frame includes inwardly open side channels best shown in FIGS. 5, 6 and 7 .
[0014] An important feature of the present invention can be traced to the fact that the spacing between the posts 18 , indicated generally at W in FIG. 6 , corresponds closely to the inside dimension of the receptacle provided in the slat 10 which receives the segment of the graphic image. This dimension W therefore defines the width of each of these graphic image segments. This geometry provides a continuous graphic image when the slats are dosed as suggested in FIG. 7 .
[0015] FIG. 6A shows a channel shaped side rail suitably shaped for hiding transmition chain 16 (to prevent unauthorized moving of the slats).
[0016] FIGS. 6A , B and C also shows how access to move transmition chain 16 is only possible by inserting a tool (not shown) in to socket 50 for moving there slats.
[0017] In its presently preferred form each of the slats 10 , has marginal edges defining a front facing and a rear facing stat frame. Each slat frame defines grooves for receiving in the marginal edges of the slats, as best shown in FIG. 3 . The graphic image segment shown in FIG. 3 at 50 has a width W corresponding to the spacing W between the posts as described above with reference to FIGS. 6 and 7 . The slat 10 is preferably extruded from a translucent material, and has marginal edges with inwardly opening grooves to receive the marginal edges of the slats. Inwardly facing grooves 10 e and 10 f are provided on the front side of the slat 10 , and defined by the L-shaped projections along each edge in conjunction with the central web portion 10 g of the slat.
[0018] It is a further feature of the present invention that the backside of the slat 10 also includes L-shaped projections that define inwardly facing grooves 10 j and 10 k for receiving additional substrate segments to be described.
[0019] It is an important feature of the present invention that each of the slats 10 , 10 includes laterally projecting extension of the web portion 10 g (illustrated at 10 m and 10 n ) these extensions are so designed that adjacent slats abut one another to determine the dosed position for all of the slats, as best shown in FIG. 7 .
[0020] Thus the slat 10 illustrated in FIG. 3 is intended for supporting a single substrate segment 50 at the front side of each slat so as to present the desired graphic image to a person from one side of the display system. The slat 10 further includes a backside that is similarly configured, but offset slightly from the front side, to receive segments that might be used to display a different or the same image to persons on the other side of the display system. FIG. 7 shows why this offset is necessary, the reason being that the slats, when dosed, are oriented parallel to one another, but at a shallow angle to the longitudinal center-line of the rail 12 ., eliminating any gap between the graphic image segments in the dosed position. In FIG. 7 the arrow A indicates the viewing angle of an observer on the one side of the display system where as the arrow B indicates the angle of the observers view point from the opposite side of the display system. The offset itself is illustrated in FIG. 7 at x. Thus, not only do the slats 10 overlap one another as shown in FIG. 7 , but also, the graphic image segments provided at the front and rear of each slat are angled with respect to the rail 12 .
[0021] FIG. 8 shows a slat 100 generally similar to the slat 10 , but having a slightly greater overall thickness to accommodate not only the substrate image 50 itself but to also accommodate a “flat light” strip 110 . Such a “flat light” strip 110 may be placed in the both front and back of the slat 100 in order to provide illumination to the display on both the front and rear sides thereof. These “flat light” materials are of a type adapted to generate light in response to an electric current. The electroluminescent nature of the material of these “flat light” strips illuminated the image both front and back of the display system of the present invention.
[0022] It is nevertheless a feature of the present invention that even in the absence of such luminous, back lighting, the interior lights of a building afford a “light box effect” on a single image provided on the transparent/translucent slats 10 of FIGS. 1-7 .
[0023] While the above described display system can be adapted and used for presenting a scenic picture as illustrated by the image of FIG. 1 above, it is also the case that a commercial advertising message can also be displayed in a system of the present invention. Furthermore, simply by removing each of the image segments in turn and replacing them with segments cut from a different substrate or image one can change the display. The preferred material for these images is a fade and tear resistant material, which lends itself to easy removable and replacement, a decided advantage when the owner of the display system of the present invention leases or otherwise rents the display to the proprietor of a business for advertising purposes.
[0024] In its presently preferred form the method of present invention entails printing a graphic image on a substrate, preferably a translucent media, followed by cutting the substrate into elongated graphic segments of width “W”. These graphic segments are then inserted into the generally rectangular transparent polymeric extruded slat frames, both front and rear if desired, and the slat frames are mounted on the upper and lower posts provided in the upper and lower rails. The openings in the image segments and slat frames will hold each slat assembly in position for removal and replacement at the end of the agreed to rental period or term. Each of the slats is formed with precisely profiled marginal edges that are designed to allow these slats to overlap, but which are also designed to present to the viewer the graphic segments in accurately indexed relationship to one another so as to avoid any gaps in the resulting image as,seen by the observer. Vertical alignment between adjacent image segments is achieved by an elongated locating strip 24 , which is provided for this purpose in the channel shaped rail 12 . A similar strip is provided in the upper rail 14 . Each strip 24 is resiliently deformable and exerts a spring force on the end portions of the slats to achieve retention of these graphic image segments in relationship to one another.
[0025] In light of the above it is therefore understood that within the scope of the appended claims, the invention may be practiced otherwise in as specifically described.
|
A system for displaying segments of a graphic image in a window or the like, and comprising a plurality of vertically elongated transparent slats, each slat having marginal edges defining inwardly one facing elongated grooves for framing the elongating segments of the graphic image, top and bottom horizontal rails for supporting top and bottom end portions respectively of said slats for rotation on horizontally spaced vertical pivot axes, and means for pivoting said slats in synchronized relationship to each other on vertical slat axes that are spaced along said rails by a dimension W, that is at least approximately equal to the lateral width of said elongated graphic image segments.
| 4
|
BACKGROUND
[0001] The invention concerns a sanitary component that has a jet regulating device in the interior of a mounting housing; said jet regulating device comprises at least one directly-mounted element housed in the mounting housing; said element has ridges transverse to the flow direction that define passageways between them. A jet regulator with a jet-regulator housing is already known from the DE 100 27 987 A1, in whose housing interior a jet regulating device is provided which has additional mounting elements that are directly mounted in the jet regulator housing one after the other in the direction of flow. Each of these mounted elements possesses an outer mounting ring that is aligned with ridges that are spaced together and run approximately parallel. Each of the ridges defines the passage openings that are uni-directionally bounded over the running passage cross section, whereby the passage openings are arranged together next to the mounted elements shifted in the circumference direction of the mounting housing. With the help of the mounted elements designed in the jet regulators already known, complex structures can be created that heavily reduce the flow rate and a smooth bubbling water jet in the form of mesh or cascades, whereby the mounted elements with a low cost that can be manufactured by means of conventional production technologies do not lead to an undesired calcification. In order to achieve an effective speed reduction of the flowing water, it is recommended that the ridges of each mounted element be arranged with one another at the smallest distance possible. If this distance between the ridges of a mounted part is measured as too small, however, the danger exists that the particles of dirt flowing with the supply network cannot slip through between the ridges and thus can increasingly compromise the function of the already-known jet regulator.
[0002] Thus exists the particular objective of creating a sanitary component of the type mentioned at the beginning that can be manufactured in a cost-effective manner and is sure to function, that allows the best possible flow-regulation characteristics and with a comparatively small cross-sectional surface.
[0003] According to the invention, the solution to this objective is provided by the sanitary component of the type mentioned in the beginning, characterized in that the ridges of at least one component are arranged in a grid or mesh and cross at junction points.
SUMMARY
[0004] The component according to the invention possesses a jet regulating device in the interior of its mounting housing that has at least one mounted element that can be directly mounted in the mounting housing. This mounted element, of which there is at least a single instance, possesses ridges oriented transverse to the direction of flow, which, according to the invention, are arranged in a grid or mesh and cross at junction points. By means of this grid or mesh structure the mounted element, of which there is at least a single instance, can also possess a multitude of ridges on a comparatively small cross-sectional surface that divides the flowing water flow into a multitude of individual jets. Consequently, an effective mixture and jet regulation can be achieved with high flow-through capacity on a comparatively small cross-sectional surface with limited manufacturing expense. In addition, a multitude of ridges allows these to be arranged together in a grid or mesh such that the passageways are nevertheless sufficiently large to allow particles of dirt carried along in the fluid flow to pass therethrough.
[0005] The component according to the invention is constructed as a jet regulator in a preferred embodiment. An additional design according to the invention provides that the jet regulating device on the inflow side of a jet separating device is upstream for the separation of the flowing fluid flow into a multitude of individual jets, and at least one mounted element of the jet regulating device is arranged relative to the jet separating device such that the individual jets impinge upon the junction points of at least one of the mounted elements. A deceleration of the flowing fluid and a separation of the individual jets flowing into the jet regulating device can be achieved particularly if the individual jets impinge upon the junction points of at least one of the mounted elements.
[0006] The jet separating device of the mounted element according to the invention can be arranged as a deflector, for example. An inordinate noise development will be avoided if the jet separator device is provided as a perforated plate.
[0007] In order to increase the segmentation of the individual jets even more, and in order to improve the jet regulating characteristics on small cross-sectional surface even more, it is advantageous if at least two neighboring mounted elements are provided with ridges arranged in a grid or mesh. These mounted elements also have crossing ridges at junction points that segment the flowing water flow into a multitude of individual jets. However, the individual water jets are once again effectively divided at the junction points of the mounted elements in such a way that an effective mixing and jet regulation can also be achieved for high flow-through capacities on a comparatively small cross-sectional surface. Thus, the component according to the invention also features the best possible jet regulating characteristics as well as a small cross-sectional surface.
[0008] At the same time, an embodiment according to the invention is provided such that the ridges and the junction points of at least two neighboring mounted elements are aligned with one another. A particular advantage of such an embodiment form is that at least two mounted elements can be constructed in the same way.
[0009] For another embodiment according to the invention that has been studied further that features a particularly effective segmentation of the water jets in the smallest amount of space, it is provided that the passageways of a mounted element are downstream of the junction points of the neighboring mounted element in the direction of the flow.
[0010] An embodiment according to the invention is provided that is simple and that can be manufactured at limited expense that is arranged in the form of a grid on a mounted element, at least on the inflow- and/or outflow side, and possesses two parallel grid ridges that cross groups. A mounted element on the inflow- and/or outflow side can have, in addition or instead, a group of radial ridges that cross circumferentially extending concentric ridges that are in the form of a ring at the junction points with a group. According to an additional embodiment according to the invention it is provided that at least one mounted element on the inflow- and/or outflow side has crossed ridges in the form of a star or a mesh.
[0011] An arrangement of the components according to the invention that also saves space in an axial direction provides that the ridges of at least one of the mounted elements are arranged in a level that is preferably oriented transverse to the direction of flow, and the mounted elements in particular are arranged in the form of discs.
[0012] In order to combine on the outflow side the individual jets that are created in the jet regulating device into a homogenous, aggregate jet that does not spray, it is advantageous if the jet regulating device on the inflow side is downstream of a flow regulator that possesses passage openings whose opening width is smaller than the level in the direction of flow. At the same time it is particularly expedient if the flow regulator is arranged at the discharge end of the mounting housing.
[0013] The flow regulator can be connected in one piece with the mounting housing or be directly mounted as a separate mounted element in the mounting housing. While a flow regulator directly mounted as a separate mounted element in the mounting housing still supports the modular construction of the component according to the invention, a flow regulator connected in one piece also serves as a protection against vandalism on the outflow side of the component.
[0014] The flow regulator of the component according to the invention can be adjusted in its arrangement based on the particular application and the objective of the application. Thus it is provided that the flow regulator has passage openings that are rectangular, in the form of a segment of a circle or in the form of a honeycomb.
[0015] However, it is also possible that the flow regulator and/or the jet regulating device possess at least one metal filter. The component according to the invention is designed as a jet regulator in a preferred form of application.
[0016] An additional design of significance according to the invention that is particularly worthy of protection is provided for a component arranged as a jet regulator, in which the mounting housing is divided into at least two housing parts, the housing parts can be combined with one another, and a housing part on the inflow side is intractably and solidly connected with the jet separating device.
[0017] For this embodiment, the mounting housing is divided into at least two housing parts and thus a housing part on the inflow side as well as the outflow side. From these housing parts a housing part on the inflow side is connected solidly and intractably with the jet separating device. Since a comparatively sensitive jet separating device is also connected securely, solidly and protected with the housing part, no material distortion of the jet separating device that compromises the function is to be expected for hot water temperatures and high water pressures. Since the jet separating device is held solidly and intractably to the housing interior, and since a ring flange is no longer necessary as a support there, the jet regulator can also be shaped for high flow-through capacities with a comparatively small housing diameter, as it was only possible with jet regulators with limited flow-through capacity with the state of the art already known. By means of the jet separating device solidly connected with the mounting housing, the mounting housing experiences a radial stiffening that also makes the mounting housing in the form of sleeves generally stable in form and against ruptures. While for jet regulators already known, in which a separate perforated plate was mounted to the housing exterior as a jet separating device, constant thickness problems occurred between the perforated plate and exterior housings in the form of sleeves; the jet regulator according to the invention offers the material advantage that these thickness problems do not exist on the basis of the one-piece nature between the jet separating device and housing parts on the inflow side. Since the mounting housing is formed of at least two housing parts that can be combined with one another, the jet separating device can nevertheless be introduced in the direction of the flow downstream of the jet regulating device and, if applicable, additionally required functional units can be introduced in the mounting housing. The component designed as a jet regulator according to the invention thus features at the same time a high level of stability in form with limited manufacturing expense.
[0018] Insofar as an intense or less intense deceleration of the water flow is desired in the component according to the invention, an adjustment of the component is possible by means of the substitution of the jet regulating device as well as of its downstream functional units. A preferred embodiment according to the invention thus provides that the mounting housing consisting of at least two housing parts that can be combined with one another is assigned at least two jet regulating devices that can be optionally mounted directly in the mounting housing.
[0019] The housing part on the inflow side of the component arranged as a jet regulator can be manufactured at limited expense as a single-piece plastic injection-molded part if the jet separating device is connected in one piece with the housing part assigned to it.
[0020] The expense connected with the manufacture of the component can be reduced even more if the mounting housing has two housing separable parts that can be combined with one another in an direction that is oriented transverse to the direction of the flow.
[0021] The housing parts of the component according to the invention can be combined with one another particularly simply and conveniently if these housing parts of the mounting housing can be connected in a detachable manner. However, it is also possible instead to solidly connect at least two housing parts with one another, for example, by means of an adhesive- or welded connection.
[0022] A preferred embodiment according to the invention provides that a housing part on the outflow side is arranged in the form of sleeves and that at least one mounted element of the jet regulating device can be mounted directly in this housing part. At the same time it is advantageous if at least one mounted part in the jet regulating device assigned housing part from whose inflow side out up to a plug stop or a support can be directly mounted.
[0023] In order to be able to easily adjust the component according to the invention to the different requirements for use of the same mounting housing, this mounting housing can be assigned additional, optional jet regulating devices that can be directly mounted in the mounting housing. In addition or instead, it is possible that the jet regulating device of the jet regulator is constructed modularly and its multiple, optional mounted elements that can be combined with one another are assigned.
[0024] A preferred embodiment according to the invention provides that the outlet housing part in the area of the water discharge opening possesses at least a soft and/or water-repellent surface. The advantage of this embodiment consists of the freedom from calcification in the area of its water discharge opening. Furthermore it particularly allows for easy cleaning of a soft surface by means of manual removal of possible deposits.
[0025] On the same grounds it can be advantageous if, in addition or instead, the housing part on the outlet side is manufactured out of an elastic material at least in the area of the water discharge opening. At the same time rubber, silicon, thermoplastic elastomers or other flexible materials are preferred for use.
[0026] In order to promote the simple manufacturability of the jet regulator according to the invention in the area of its housing part on the outlet side as well, it is advantageous if the housing part on the outlet side is manufactured principally out of rubber-elastic material and/or a material with a soft or water-repellent surface.
[0027] Also for this reason, a housing part manufactured out of rubber-elastic material is sufficiently stable and can be fixed, for example, to the neighboring housing part by means of a snap-on connection; it is advantageous if the housing part on the outlet side is braced by means of longitudinal ridges in the circumferential direction that are preferably uniformly distributed.
[0028] At the same time a preferred embodiment according to the invention provides that the longitudinal ridges are provided at least in the area of the discharge opening.
[0029] A particularly advantageous additional design according to the invention that is particularly worthy of protection provides that the housing part on the outlet side in the area of the water discharge opening possesses at least a constriction or similar narrowing of its flow-through cross section. This constriction or similar narrowing of the flow-through cross section has a calibrating effect on the out-flowing water jet and the pattern of its jet. The narrowing of the flow-through cross section is in the area of the water discharge opening, and it is consequently provided that possible noise contours are provided in an area downstream in the direction of the flow. By means of the calibration of the water jet, a jet pattern that is homogenous and that does not spray is materially fostered.
[0030] In order to still further simplify the manufacture of the jet regulator according to the invention, it is advantageous if the housing part on the outlet side can be combined with the neighboring housing part on the inflow side, preferably via a particular rotary snap-on connection.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] Additional characteristics of the invention result from the following description of exemplary embodiments according to the invention in connection with the claims as well as the illustration. The individual characteristics can each be realized individually or in combination to form an embodiment according to the invention.
[0032] Shown are:
[0033] FIG. 1 a sanitary component shaped as a jet regulator in a longitudinal section that possesses a jet separating device on the inflow side that is downstream in the flow-through direction of a jet regulating device that has multiple mounted elements spaced apart from one another whereby a flow regulator forms the front side of the outflow side of this jet regulator,
[0034] FIG. 2 a mounted element of the jet regulating device in a top view ( FIG. 2 a ) and in a longitudinal section ( FIG. 2 b ), whereby the mounted element has crossing ridges in the form of a grid at junction points,
[0035] FIG. 3 a mounted element comparable with FIG. 2 in a top view ( FIG. 3 a ) and in a longitudinal section ( FIG. 3 b ),
[0036] FIG. 4 the mounted elements combined with one another on the jet regulating device from FIGS. 2 and 3 in a top view,
[0037] FIG. 5 a mounted element in a top view ( FIG. 5 a ) and in a longitudinal section ( FIG. 5 b ) that has two groups at junction points of crossing ridges, whereby one group possesses concentric rotary ridges while a second group is formed of radial ridges,
[0038] FIG. 6 a mounted element in a top view ( FIG. 6 a ) and in a longitudinal section ( FIG. 6 b ); said mounted element has ridges connected with one another in a mesh at junction points,
[0039] FIG. 7 a mounted element comparable with FIG. 5 in a top view ( FIG. 7 a ) and in a longitudinal section ( FIG. 7 b ),
[0040] FIG. 8 the mounted elements combined with one another at the jet regulating device from FIGS. 5 and 7 in a top view,
[0041] FIG. 9 a flow regulator that can be mounted directly in the housing of the mounted element with honeycombed flow openings in a top view ( FIG. 9 a ) and in a longitudinal section ( FIG. 9 b ),
[0042] FIG. 10 a flow regulator functionally comparable with FIG. 9 in a top view ( FIG. 10 a ) and in a longitudinal section ( FIG. 10 b ), whereby the flow regulator has flow openings in the form of a segment of a circle,
[0043] FIG. 11 a filter mounted part whose ridges are formed by means of a metal filter, whereby the mounted part can be mounted directly in the mounting housing in addition to or instead of the mounted elements illustrated in the FIGS. 2, 3 , 5 , 6 and 7 and/or in addition to or instead of the flow regulator shown in the FIGS. 9 and 10 , in a top view ( FIG. 11 a ) and in a longitudinal section ( FIG. 11 b ),
[0044] FIG. 12 a mounted element functionally comparable with FIG. 11 in a top view ( FIG. 12 a ) and in a longitudinal section ( FIG. 12 b ), whereby the mounted element—as in FIG. 11 —possesses here a metal filter oriented transverse to the direction of flow,
[0045] FIG. 13 a top view of two mounted elements of a jet regulating device constructed in the same way, whereby the ridges and the junction points of these neighboring mounted elements align with one another,
[0046] FIG. 14 a jet regulator located in an outlet nozzle in a partial longitudinal section whose lower housing part is manufactured out of an elastic material in the form of sleeves, and
[0047] FIG. 15 a jet regulator, similar to that in FIG. 1 , whose jet separating device is here shaped as a deflector.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0048] In FIG. 1 a sanitary component is illustrated that can be directly mounted in the outlet nozzle of a sanitary outlet armature. The mounted element is designed here as a jet regulator 1 that serves for the production of a homogeneous, smooth bubbling water jet that does not spray. For this purpose, the jet regulator 1 has a jet separating device 2 that can be designed as a deflector, for example, but preferably—as here—is shaped as a perforated plate and segments the flowing water flow into a multitude of individual jets. For this purpose, the perforated plate 2 has a corresponding number of flow-through holes 3 that narrow in a preferably conical manner at least on a perforated segment on the inflow side in the direction of flow. A pre-filter 17 on the inflow side is provided so that particles of dirt do not penetrate into the component 1 and cannot lead to functional failures there.
[0049] The jet separating device formed by means of the perforated plate 2 is a jet regulating device 4 in the direction of flow downstream. This jet regulating device 4 should strongly slow down the individual jets coming from the jet separating device 2 , segment them into additional individual jets and, as the housing requires, foster an air mixture in order to obtain a smooth bubbling water jet in the end. For this purpose, the jet regulating device 4 possesses two mounted elements 5 a and 5 b that can be directly mounted with distance to one another in the mounting housing.
[0050] In FIG. 1 it is discernible that that the mounting housing 6 is arranged in two parts and has two connectable housing parts 7 and 8 that are detachable from one another. At the same time the housing part 7 on the inflow side is connected in one piece with the perforated plate 2 and for this reason is connected both solid and intractably. These housing parts 7 and 8 are detachably connected with one another in a separation plane oriented transverse to the direction of flow. Because a comparatively thin perforated plate 2 is also securely and solidly connected with the housing part 7 on its circumference edge, no material distortion that impairs the function of the perforated plate 2 is to be expected. Because the perforated plate 2 is held solidly and intractably to the interior of the housing, and because a ring flange as a support for the perforated place is not required there, the jet regulator 1 can also be arranged with a comparatively small housing diameter for high flow-through capacities as was possible with the known state of the art only for jet regulators with limited flow-through capacity. By means of the perforated plate 2 solidly connected with the mounting housing 6 , the mounting housing 6 has a radial stiffening that also makes the mounting housing 6 in the form of a sleeve stable in form and against ruptures as a whole. Because the mounting housing is formed of at least two combinable housing parts 7 and 8 that are detachable from one another, the jet regulating device 4 of the perforated plate downstream in the direction of flow and, if necessary, additional required functional units can nevertheless be mounted in the mounting housing 6 . The jet regulator 1 thus features a high stability in form and, at the same time, small manufacturing expense. The jet regulator 1 can also be arranged with a comparatively small housing diameter for high flow-through capacities. Insofar as different flow-through capacities require a corresponding adjustment of the jet regulator 1 , it is possible by means of the substitution of the perforated plate 2 downstream of the jet regulating device and the similar functional units.
[0051] In FIG. 1 it is discernible that the housing part 8 on the outflow side is provided in the form of a sleeve and that in this housing part 8 the mounted elements 5 a and 5 b of the jet regulating device 4 can be directly mounted up to a plug stop 9 . From a comparison of FIGS. 2 through 8 and in particular from the FIGS. 4 and 9 it is clear that the mounted elements 5 a and 5 b each have crossing ridges 11 at junction points 10 , whereby the passageways 12 of one of these mounted elements are downstream from the junction points 10 of the neighboring mounted element 5 b in the direction of flow, while at the same time the passageways 12 of the mounted element 5 b on the outflow side are upstream from the junction points 10 of the neighboring mounted element 5 a on the inflow side in the direction of flow.
[0052] The water jet on the inflow side that is arranged as a jet regulator of mounted element 1 is segmented at each junction point 10 of the mounted element 5 a on the inflow side into multiple individual jets. These individual jets are again segmented into a multitude of additional individual jets at the junction points 10 of the mounted element 5 b downstream in the direction of flow. The jet regulating device 4 of the jet regulator 1 shows its mounted elements 5 a and 5 b with the junction points 10 arranged in the form of cascades by means of a particularly effective deceleration of the inflowing water jet even for small cross-sectional surfaces.
[0053] The jet regulating device 4 of the jet regulator 1 illustrated here is constructed in a modular manner; the jet regulating device 4 is assigned multiple optional mounted elements 5 that can be combined with one another. Thus the mounted elements 5 a and 5 b illustrated in the FIGS. 2 and 3 possess ridges 11 in the form of a grid. The grid structures of these mounted elements 5 a and 5 b are arranged at an approximately 45° offset to one another, whereby the mounted element 5 b illustrated in FIG. 3 has a smaller grid distance in comparison to the mounted elements 5 a from FIG. 2 . By means of molds or processes appropriate to the situation 13 on the exterior circumference edge of the mounted elements 5 a and 5 b , that cooperate with complementary-shaped molds or processes appropriate to the situation that are oriented in a longitudinal direction on the housing circumference of the housing part 8 , a device of the mounted element 5 that is appropriate to the situation is always ensured for one another in the mounting housing 6 .
[0054] While the mounted element 5 c on the inflow side illustrated in FIG. 5 possesses a group of radial ridges 11 ′ that cross themselves at the junction points with a group of concentric and rotary ridges 11 ′ in the form of a ring, the mounted element 5 d on the outflow side shown in FIG. 6 has radial or mesh crossing ridges 11 . The ridges 11 of each mounted element 5 arranged in the form of a disc are arranged in a layer oriented transverse to the direction of flow.
[0055] It is discernible in FIG. 1 that a flow regulator 14 is downstream from the jet regulating device 4 at the discharge end of the mounting housing 6 . From a comparison of the FIGS. 9 and 10 it is clear that this flow regulator 14 can have passage openings 15 in which the opening width of the passage openings 15 is smaller than the depth in the direction of flow, for example, in the form of a honeycomb ( FIG. 9 ) or in the form of a segment of a circle ( FIG. 10 ).
[0056] Insets serving here as flow regulators are illustrated in FIGS. 11 and 12 , which possess a metal filter in the form of a grid. In FIG. 13 it is shown that the jet regulating device 4 can also possess two neighboring mounted elements 5 a and 5 b , whose ridges 11 and junction points 11 align with one another. At the same time, it is clear from FIG. 13 the mounted elements 5 a and 5 b of one such jet regulating device 4 can also be shaped and constructed in the same manner, whereby the manufacturing expense can be reduced even more. Likewise as in the FIGS. 4 and 8 , it is also implied in FIG. 13 by means of circles shown in bold print that the passage openings of the perforated plate align with the junction points 10 of at least one mounted element downstream in the direction of flow. By means of the circles shown in bold print in FIG. 13 , the discharge point of the individual jets coming out of the jet separating device 2 is illustrated at the junction points 10 of the mounted elements 5 a.
[0057] A jet regulator 1 located in an outlet nozzle 21 is illustrated in FIG. 14 whose housing exterior in the form of a sleeve is formed of two detachable housing parts 7 and 8 that can be connected with one another. At the same time the housing part 7 on the inflow side is connected for this reason both solidly and intractably with the perforated plate 2 in one piece. While the housing part 7 on the inflow side is formed of a comparatively solid plastic material, the housing part 8 on the outlet side is manufactured out of an elastic material and possesses a soft and water-repellent surface. Because the housing part 8 consequently has a water-repellent surface in the area of its water discharge opening and in the area of the flow regulator 14 provided there, the jet regulator 1 illustrated in FIG. 14 features the freedom from calcification of the flow regulator 14 on the outlet side. Because the housing part 8 on the outlet side is manufactured out of rubber, silicon or a thermoplastic elastomer and consequently has an elastic and soft surface, deposited calcification or dirt particles can be easily removed manually, in particular at the flow regulator 14 . In order to further simplify the manual cleaning of the jet regulator 1 , it can be advantageous if the jet regulator 1 protrudes at least slightly over the outlet nozzle 21 with a partition on the outlet side.
[0058] As is clear from FIG. 14 , the housing part 7 on the inflow side and the housing part out on the outflow side are held to one another by means of a detachable snap-on connection. In order to prevent the housing part 8 on the outflow side from being able to be removed axially from the housing part 7 on the inflow side, the support shoulders on which both housing parts 7 and 8 rest are shaped such that sufficiently large forces can be absorbed. Furthermore, the housing part 8 on the outflow side is braced by means of radial longitudinal ridges 22 that are arranged in the area of the flow regulator 14 and consequently equally distributed in the area of the discharge opening in the circumference direction. By means of the provided longitudinal ridges 22 on the flexible housing part 8 that very narrowly apply to the interior contour of the outlet nozzle 21 , the flexible housing part 8 is prevented from widening and thus being removed from housing part 7 . In any housing, the axial forces on the elastic housing part 8 resulting from the water pressure are comparatively small because the water pressure on the perforated plate in the housing part 7 serving as a jet separating device 2 is already almost completely exhausted.
[0059] In FIG. 14 it is discernible that the housing part 8 on the outflow side in the area of the water discharge opening possesses a constriction 23 that produces a narrowing of the flow-through cross section. By means of this narrowing of the flow-through cross section a calibration of the out-flowing water jet and a homogenization of the jet pattern is achieved. The constriction 23 is in the area of the water discharge opening and thus anticipated in an area that is downstream in the direction of flow of the possible noise contours. By means of the calibration of the water jet a spray pattern that is homogeneous and that does not spray is materially fostered.
[0060] In FIG. 15 , a jet regulator 1 that is comparable with FIG. 1 is illustrated. While the jet regulator that is shown in FIG. 1 possesses a perforated plate at a jet separating device 2 , the jet separating device 2 of the jet regulator illustrated in FIG. 15 is designed as a deflector. The use of a jet separating device shaped as a deflector is provided if the noise development connected with it supporting a particularly effective deceleration of the inflowing fluid flow can be disregarded. From the partial longitudinal section in FIG. 15 it is clear that the inflowing fluid flow impinges upon a disc layer 26 that is arranged transverse to the direction of inflow respective to the longitudinal axis of the jet regulator. From this disc layer 26 , the fluid flow flows out in a radial direction to the passage openings 27 that are provided on the rotary circumference wall at the disc layer 26 . The fluid flow that is segmented into individual jets in the passage openings 27 can subsequently flow further to the jet regulating device 4 and/or to the flow regulator 14 that is downstream of the jet separating device 2 in the direction of flow.
[0061] The jet regulator illustrated in FIG. 15 likewise possesses a mounting housing 6 that is divided into two detachable housing parts 7 and 9 that can be connected with one another. While the housing part 7 on the inflow side is solidly and intractably connected with the jet separating device 2 that is shaped as a deflector, in the housing part 8 in the form of a sleeve on the outflow side, two mounted elements are mounted, both of which have flow-through openings in the form of honeycombs. While the mounted element 5 on the inflow side that is comparatively thin and is provided with small flow-through openings to serve as a jet regulating device, the mounted element on the outflow side which, on the other hand, is thicker and is provided with larger flow-through openings, forms a flow regulator that forms the individual jets into a homogeneous aggregate jet. At the same time, the mounted element that forms the outflow side of the flow regulator overlays on a radial circumference edge 28 of the housing part 8 , while the mounted element 5 on the inflow side supports itself with a central spacer 29 .
|
The invention concerns a sanitary component ( 1 ) that has a jet regulating device ( 4 ) in the interior of a mounting housing ( 6 ). The jet regulating device ( 4 ) includes at least one directly-mounted element ( 5 ) housed in the mounting housing ( 6 ), this element being provided with ridges ( 11 ) transverse to the flow direction and defining between them passageways ( 12 ). The invention is characterized in that the ridges ( 11 ) of at least one directly mounted element ( 5 ) are arranged in the form of a grid or network and intersect at junction points. The component ( 1 ) according to the invention, which can be manufactured inexpensively, exhibits the best possible jet regulating characteristics, even if the transverse surface is relatively small; moreover, the component ( 1 ) according to the invention requires little maintenance, without any risk of malfunction resulting from dirt carried by the liquid flow.
| 4
|
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority to U.S. Provisional Patent Application 61/142,797, filed Jan. 6, 2009 by Yuanqiu Luo, et al., and entitled “Field Framing with Built-In Information,” which is incorporated herein by reference as if reproduced in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
REFERENCE TO A MICROFICHE APPENDIX
Not applicable.
BACKGROUND
In communication systems, frame alignment is the process of identifying a beginning and/or end of a transmitted bit stream, e.g. in a frame. Frame alignment may be needed to enable a receiver to synchronize an incoming bit stream in a frame and to extract the data in the frame for further processing. Typically, frame alignment is achieved using a distinctive bit sequence in the frame to distinguish the frame beginning and/or end and to locate the actual data in the frame. The bit sequence for frame alignment may also be referred to as a synchronization pattern or framing bits. The synchronization patterns used in communication systems are usually fixed bit sequences that are located at specified positions in the frame. The synchronization patterns can occur repeatedly in a sequence of frames or bit streams and do not carry additional information besides indicating the beginning and/or end of a frame. Improving such frame alignment schemes may improve frame processing efficiency in communication systems.
SUMMARY
In one embodiment, the disclosure includes an apparatus comprising a frame alignment processor coupled to a receiver, wherein the frame alignment processor is configured to align a first frame and a second frame in the receiver by matching a first synchronization (sync) pattern predicted using a first sync field in the first frame with a second sync pattern obtained from a second sync field in the second frame.
In another embodiment, the disclosure includes an apparatus comprising at least one component configured to implement a method comprising receiving a first frame, subsequently receiving a second frame that was transmitted after the first frame, predicting a first sync pattern from a first sync field in the first frame, obtaining a second sync pattern from a second sync field in the second frame, and determining that the first frame and the second frame are aligned when the first sync pattern matches the second sync pattern.
In yet another embodiment, the disclosure includes a method comprising locking a first received frame and a second received frame after the first in a sync state machine using real time clock (RTC) information in a first sync header of the first received frame and a second sync header of the second received frame.
These and other features will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of this disclosure, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts.
FIG. 1 is a schematic diagram of an embodiment of a passive optical network (PON).
FIG. 2 is an illustration of an embodiment of a synchronization field.
FIG. 3 is an illustration of another embodiment of a synchronization field.
FIG. 4 is an illustration of another embodiment of a synchronization field.
FIG. 5 is an illustration of another embodiment of a synchronization field.
FIG. 6 is an illustration of another embodiment of a synchronization field.
FIG. 7 is an illustration of another embodiment of a synchronization field.
FIG. 8 is an illustration of an embodiment of a synchronization state machine method.
FIG. 9 is a schematic diagram of an embodiment of a general-purpose computer system.
DETAILED DESCRIPTION
It should be understood at the outset that although an illustrative implementation of one or more embodiments are provided below, the disclosed systems and/or methods may be implemented using any number of techniques, whether currently known or in existence. The disclosure should in no way be limited to the illustrative implementations, drawings, and techniques illustrated below, including the exemplary designs and implementations illustrated and described herein, but may be modified within the scope of the appended claims along with their full scope of equivalents.
Disclosed herein is a system and method for improving frame alignment of a bit stream, which may improve frame processing efficiency in a network. Specifically, an improved synchronization pattern for frame alignment may be inserted in a frame or bit stream. The improved synchronization pattern may indicate a beginning and/or end of the frame and additional information about the data in the frame. The additional information may be based on the data and hence may change in different frames that comprise different data. Additionally, a synchronization state machine may be configured to predict a synchronization pattern in a next transported frame, e.g. with high or acceptable accuracy, using a synchronization pattern in at least one previously received frame. The frame alignment scheme may be used in different networks that may be based on different technologies or protocols, including PONS, Gigabit PON (GPON) systems, and Next Generation Access (NGA) systems.
FIG. 1 illustrates one embodiment of a PON 100 , which may be one system for providing network access over “the last mile.” The PON 100 may be a point to multi-point network comprised of an optical line terminal (OLT) 110 , a plurality of optical network units (ONUs) 120 , and an optical distribution network (ODN) 130 that may be coupled to the OLT 110 and the ONUs 120 . For instance, the OLT 110 may be located at a central office (CO), the ONUs 120 may be located at a plurality of customer premises, and the ODN 130 may be positioned between the OLT 110 and the ONUs 120 . The PON 100 may be a communications network that does not require any active components to distribute data between the OLT 110 and the ONUs 120 . Instead, the PON 100 may use the passive optical components in the ODN 130 to distribute data between the OLT 110 and the ONUs 120 .
In an embodiment, the PON 100 may be GPON system, where downstream data may be broadcasted at about 2.5 Gigabits per second (Gbps) and upstream data may be transmitted at about 1.25 Gbps. In another embodiment, the PON 100 may be a NGA system, which may be configured to transport a plurality of data frames with improved reliability and efficiency at higher bandwidths. For instance, the PON 100 may be a ten Gbps GPONs (or XGPONs), which may have a downstream bandwidth of about ten Gbps and an upstream bandwidth of at least about 2.5 Gbps. Other examples of suitable PONS 100 include the asynchronous transfer mode PON (APON) and the broadband PON (BPON) defined by the ITU-T G.983 standard, the GPON defined by the ITU-T G.984 standard, the Ethernet PON (EPON) defined by the IEEE 802.3ah standard, and the Wavelength Division Multiplexed (WDM) PON (WPON), all of which are incorporated herein by reference as if reproduced in their entirety.
In an embodiment, the OLT 110 may be any device that is configured to communicate with the ONUs 120 and another network (not shown). Specifically, the OLT 110 may act as an intermediary between the other network and the ONUs 120 . For instance, the OLT 110 may forward data received from the network to the ONUs 120 , and forward data received from the ONUs 120 onto the other network. Although the specific configuration of the OLT 110 may vary depending on the type of PON 100 , in an embodiment, the OLT 110 may comprise a transmitter and a receiver. When the other network is using a network protocol, such as Ethernet or Synchronous Optical Networking/Synchronous Digital Hierarchy (SONET/SDH), that is different from the PON protocol used in the PON 100 , the OLT 110 may comprise a converter that converts the network protocol into the PON protocol. The OLT 110 converter may also convert the PON protocol into the network protocol. The OLT 110 may be typically located at a central location, such as a central office, but may be located at other locations as well.
In an embodiment, the ONUs 120 may be any devices that are configured to communicate with the OLT 110 and a customer or user (not shown). Specifically, the ONUs 120 may act as an intermediary between the OLT 110 and the customer. For instance, the ONUs 120 may forward data received from the OLT 110 to the customer, and forward data received from the customer onto the OLT 110 . Although the specific configuration of the ONUs 120 may vary depending on the type of PON 100 , in an embodiment, the ONUs 120 may comprise an optical transmitter configured to send optical signals to the OLT 110 and an optical receiver configured to receive optical signals from the OLT 110 . Additionally, the ONUs 120 may comprise a converter that converts the optical signal into electrical signals for the customer, such as signals in the Ethernet protocol, and a second transmitter and/or receiver that may send and/or receive the electrical signals to a customer device. In some embodiments, ONUs 120 and optical network terminals (ONTs) are similar, and thus the terms are used interchangeably herein. The ONUs 120 may be typically located at distributed locations, such as the customer premises, but may be located at other locations as well.
In an embodiment, the ODN 130 may be a data distribution system, which may comprise optical fiber cables, couplers, splitters, distributors, and/or other equipment. In an embodiment, the optical fiber cables, couplers, splitters, distributors, and/or other equipment may be passive optical components. Specifically, the optical fiber cables, couplers, splitters, distributors, and/or other equipment may be components that do not require any power to distribute data signals between the OLT 110 and the ONUs 120 . Alternatively, the ODN 130 may comprise one or a plurality of processing equipment, such as optical amplifiers. The ODN 130 may typically extend from the OLT 110 to the ONUs 120 in a branching configuration as shown in FIG. 1 , but may be alternatively configured in any other point-to-multi-point configuration.
In an embodiment, the OLT 110 and the ONUs 120 may exchange data that may be encapsulated in frames or packets, e.g. Ethernet frames. The frames may comprise payload and header, which may comprise synchronization and configuration information. For instance, a transmission convergence (TC) frame may be used to transmit information downstream, e.g. from the OLT 110 to an ONU 120 , based a GPON Transmission Convergence (GTC) protocol layer. The GTC is defined in ITU-T G.984.3, which is incorporated herein by reference. The TC frame may also comprise a physical synchronization (PSync) field, which may indicate a beginning of the TC frame. Typically, the PSync field may comprise a fixed code, which may have a fixed value of “0xB6AB31E0” (in hexadecimal format) that indicates the beginning of the frame. The size of such field may be equal to about four bytes. A receiver at the OLT 110 or ONU 120 may use the PSync fields in the received frames to delimit, e.g. separate and distinguish, the frames.
In an embodiment, the PSync field may be replaced with an improved synchronization pattern, which may be a modified PSync field. The modified PSync field may indicate the beginning (or end) of the frame and comprise other information. The additional information in the PSync field may further improve frame synchronization, e.g. at a receiver in the OLT 110 or the ONU 120 . For instance, the additional information may be synchronization related information, such as timing information. The synchronization pattern may be processed by a synchronization state machine, which may be coupled to the receiver. The synchronization state machine may be implemented using hardware, software, or both. The synchronization state machine may obtain a plurality of synchronization patterns, which may comprise different but related synchronization information, and use this information to improve data synchronization and frame alignment. As such, the synchronization efficiency in the network may be enhanced and overall system performance may be improved.
FIG. 2 illustrates an embodiment of a PSync field 200 , which may comprise delimiter information and additional synchronization information. The PSync field 200 may be inserted into a frame that comprises data before transmitting the frame, e.g. by a framer at an OLT or an ONU. When received, the information the PSync field 200 may be extracted, e.g. by a receiver at the OLT or the ONU, to synchronize the frame with other received frames. The PSync field 200 may comprise a synchronization (Sync) subfield 202 and a Time subfield 204 . The Sync subfield 202 may indicate the beginning or end of the frame that comprises the PSync field 200 . For instance, the Sync subfield 202 may comprise any known value or bit sequence that may be used to delimit a frame's beginning or end, such as used in Ethernet networks. The Time subfield 204 may comprise time information, e.g. according to a Precision Time Protocol (PTP). For instance, the Time subfield 204 may comprise real time clock (RTC) information, which may be used by the receiver to process the frame or the data in the frame.
In an embodiment, the information in the PSync field 200 may change in a plurality of transmitted frames. For instance, the synchronization pattern or bit sequence in the PSync field 200 may change as the RTC information in the Time subfield 204 changes in a sequence of transmitted frames. The synchronization pattern may be dependent on the RTC information, and hence a change in the synchronization pattern may be dependent on a change in the RTC information. Thus, the RTC information in a first received frame may be used to predict the synchronization pattern of a subsequent frame before receiving the next frame. The next received frame may then be aligned or locked properly after detecting an agreement or match between its synchronization pattern and the expected predicted synchronization pattern. For example, the RTC information may indicate the transmission time of a frame, and each frame may be transmitted after a transmission delay of about 125 microseconds (μs) from a previous frame. Hence, the transmission time of a first received frame may be obtained from the Time subfield 204 , and then added to the transmission delay between frames (e.g. about 125 μs) to obtain an expected synchronization pattern of a second transmitted frame. The expected synchronization pattern may then be matched with an actual synchronization pattern in the second transmitted frame, which may be the Time subfield 204 of the second transmitted frame. As such, the expected synchronization pattern may be used to lock or align a next received frame with substantially high accuracy, e.g. using a synchronization state machine.
In an embodiment, the length of the PSync field 200 may be equal to about 12 bytes, the length of the Sync subfield 202 may be equal to about two bytes, and the length of the Time subfield 204 may be equal to about ten bytes. The length of the PSync field 200 may be increased in comparison to a typical length of about four bytes in current systems. At the length of about 12 bytes, the probability of having a mismatch between a properly predicted synchronization pattern of a frame and the actual synchronization pattern for that frame may be substantially small, e.g. equal to about 2 −96 per frame. Additionally, at this length, it may require a substantially long time to encounter a false match, e.g. equal to about 10 25 seconds, which may be longer than the lifetime of the universe. Due to the substantially low probability of having a mismatch in the synchronization pattern, a single attempt to match the synchronization pattern may be sufficient and repeated attempts for matching per frame may not be needed. Accordingly, a mismatch in the synchronization pattern may indicate an error in the sequence of transmitted frames with a substantially high probability. Further, errors in the frame header, e.g. PSync field 200 , may have substantially low occurrence or error rate, e.g. equal to about 10 −4 in about 100 frames. Such low error rate may be accounted for by a synchronization state machine.
In another embodiment, the Sync subfield 202 may be optional and the PSync field 200 may comprise the Time field 204 . As such, when the Time field 204 is received, a synchronization pattern may be obtained based on the Time field 204 . For instance, the synchronization pattern may be a CRC-16 pattern that may be computed using the Time field 204 information. Such scheme may also provide error detection and possibly error correction capability in the receiver.
FIGS. 3 , 4 , 5 , 6 , and 7 illustrate other embodiments of PSync fields 300 , 400 , 500 , 600 , and 700 , respectively, which may comprise delimiter information and additional synchronization information. The PSync fields 300 , 400 , 500 , 600 , and 700 may be inserted into a frame that comprises data before transmitting the frame, and may then be received and used to improve frame synchronization efficiency. For instance, the PSync fields 300 , 400 , 500 , 600 , and 700 may be used in GPONs and XG-PONs. The PSync field 300 may comprise a Sync subfield 302 and a Key Index subfield 304 . The PSync field 400 may comprise a Sync subfield 402 and a PON ID subfield 404 . The PSync field 500 may comprise a Sync subfield 502 and a Burst Profile Index subfield 504 . The PSync field 600 may comprise a Sync subfield 602 and an OLT Transmitter Power subfield 604 . The PSync field 700 may comprise a Sync subfield 702 and an OLT Version subfield 704 . The Sync subfields 302 , 402 , 502 , 602 , and 702 may be configured and comprise information substantially similar to the Sync subfield 202 . The Key Index subfield 304 , the PON ID subfield 404 , and the Burst Profile Index subfield 504 may comprise different non-trivial information related to the PON components and operations. The OLT Transmitter Power subfield 604 may comprise parameters related to the power of the OLT's transmitter. The OLT Version subfield 704 may comprise parameters related to the OLT version, including hardware major and minor versions, firmware major and minor versions, and supported link layer identifier (LLID) number. The lengths of the PSync fields 300 , 400 , 500 , 600 , and 700 and subfields contained therein may be different. The PSync fields 300 , 400 , 500 , 600 , and 700 may also comprise additional subfields that comprise non-trivial information (not shown). Other embodiments of the PSync fields 300 , 400 , 500 , 600 , and 700 , which may comprise a plurality of subfields and have different lengths, may also be used in other networks.
FIG. 8 illustrates an embodiment of a synchronization state machine 800 , which may be used to process a synchronization field, such as the PSync field 200 , 300 , 400 , 500 , 600 , and 700 , and align or lock a plurality of received frames. The synchronization state machine 800 may be used in a receiver in an OLT and/or ONU. The synchronization state machine 800 may comprise a plurality of states, including an Initialization state 802 , a Hunt state 804 , a Pre-Synchronization (PreSync) state 806 , a Sync state 808 , a Correct state 810 , and an Error state 812 . The synchronization state machine method 800 may be started at the Initialization state 802 . During the Initialization state 802 , a plurality of parameters may be initialized. For instance, a Time parameter that indicates a received frame time may be set to about zero. Additionally, a NextTime parameter that indicates a received time of a next frame and a FrmErr parameter that indicates a count of encountered errors may each be set to about zero. A SetLocalTime( ) procedure may also be implemented, which may reset the receiver's local time to about zero. The synchronization state machine 800 may then proceed to the Hunt state 804 .
During the Hunt state 804 , a Slip( ) procedure may be implemented, which may cause a framer, e.g. in the receiver, to slip or shift to a new bit position in a bit sequence of the received frame. A Get2 Bytes( ) procedure may then be implemented to load about two bytes from the frame, e.g. starting from the new bit position. The two bytes may then be assigned to a Sync parameter. Next, a Get10 Bytes( ) procedure may be implemented to load about 10 bytes from the frame, e.g. after the previously loaded two bytes. The 10 bytes of data may then be assigned to the Time parameter. The data loaded in the Hunt state 804 may correspond to the information in a PSync field of the received frame, as shown above. The synchronization state machine 800 may then proceed to the PreSync state 806 if the obtained Sync parameter comprises a fixed pattern (FP), which may be known or standardized. Alternatively, the synchronization state machine 800 may return to the Hunt state 804 if the Sync parameter does not comprise the FP. Hence, a new Sync parameter and Time parameter may be loaded from the next bytes in the received frame.
During the PreSync state 806 , the sum of the Time parameter value and a transmission delay between frames (e.g. 125 microseconds (μs)) may be assigned to the NextTime parameter. As such, the NextTime parameter may comprise a predicted arrival time for a next received frame. A WaitUntilNextHeader( ) procedure may then be implemented, which may cause the synchronization state machine 800 to wait until a next header is received in a next received frame. Next, the Get2 Bytes( ) and Get10 Bytes procedures may be implemented in that sequence to load a new Sync parameter and a new Time parameter from the next frame or header. The synchronization state machine 800 may then proceed to the Sync state 808 if the obtained Sync parameter comprises the FP and if the Time parameter value is equal to about the NextTime parameter value. This condition may indicate that the synchronization information in the currently received frame may match to the expected or predicted synchronization information. Alternatively, the synchronization state machine 800 may return to the Hunt state 804 if the Sync parameter does not comprise the FP or if the Time parameter value is not equal to about the NextTime parameter value.
During the Sync state 808 , the NextTime parameter may be updated to comprise the sum of the current Time parameter value and the transmission delay between frames (e.g. 125 μs). Next, the WaitUntilNextHeader( ) the Get2 Bytes( ) and the Get10 Bytes procedures may be implemented in that sequence. If the currently obtained Sync parameter comprises the FP and if either: the Time parameter value is equal to about the NextTime parameter value or about the LocalTime parameter value, the synchronization information in the currently received frame may match the expected or predicted synchronization information. As such, the currently received frame may be locked or aligned properly, and the synchronization state machine 800 may then proceed to the Correct state 810 . Alternatively, the synchronization state machine 800 may proceed to the Error state 808 if the condition above is not met.
During the Correct state 810 , the FrmErr parameter that indicates the count of encountered errors may be reset to about zero, and the SetLocalTime( ) procedure may be implemented to reset the local time. The synchronization state machine 800 may then return to the Sync state 808 to resume the synchronization procedure of subsequent frames in the absence of detected errors.
During the Error state 812 , the FrmErr parameter may be incremented, e.g. by about one, to indicate that a matching error was encountered. The synchronization state machine 800 may then return to the Initialization state 802 if the FrmErr parameter value has exceeded about a maximum tolerated value M 2 , which may be equal to about eight or any other number. In this case, the frames may be considered in wrong alignment and the synchronization state machine 800 may be restarted to check the frame's alignment again. Alternatively, if the FrmErr parameter value has not exceeded the maximum tolerated value M 2 , the synchronization state machine 800 may return to the Sync state 808 to continue the synchronization procedure. As such, relatively few isolated or random errors, which may not be alignment errors, may not stop frame alignment. For example, some errors may be caused due to changes in local time and may not affect frame alignment in the long run.
Note that the real time clock will be modified (e.g. at the OLT) from time to time (e.g. leap seconds, etc.) When this happens, other components (e.g. the ONUs) may detect a single framing error, but due to the state machine, it will not fall out of lock. On the next frame, the Time will match the NextTime, and the local time on the ONU will be adjusted.
The network components described above may be implemented on any general-purpose network component, such as a computer or network component with sufficient processing power, memory resources, and network throughput capability to handle the necessary workload placed upon it. FIG. 9 illustrates a typical, general-purpose network component 900 suitable for implementing one or more embodiments of the components disclosed herein. The network component 900 includes a processor 902 (which may be referred to as a central processor unit or CPU) that is in communication with memory devices including secondary storage 904 , read only memory (ROM) 906 , random access memory (RAM) 908 , input/output (I/O) devices 910 , and network connectivity devices 912 . The processor 902 may be implemented as one or more CPU chips, or may be part of one or more application specific integrated circuits (ASICs).
The secondary storage 904 is typically comprised of one or more disk drives or tape drives and is used for non-volatile storage of data and as an over-flow data storage device if RAM 908 is not large enough to hold all working data. Secondary storage 904 may be used to store programs that are loaded into RAM 908 when such programs are selected for execution. The ROM 906 is used to store instructions and perhaps data that are read during program execution. ROM 906 is a non-volatile memory device that typically has a small memory capacity relative to the larger memory capacity of secondary storage 904 . The RAM 908 is used to store volatile data and perhaps to store instructions. Access to both ROM 906 and RAM 908 is typically faster than to secondary storage 904 .
At least one embodiment is disclosed and variations, combinations, and/or modifications of the embodiment(s) and/or features of the embodiment(s) made by a person having ordinary skill in the art are within the scope of the disclosure. Alternative embodiments that result from combining, integrating, and/or omitting features of the embodiment(s) are also within the scope of the disclosure. Where numerical ranges or limitations are expressly stated, such express ranges or limitations should be understood to include iterative ranges or limitations of like magnitude falling within the expressly stated ranges or limitations (e.g., from about 1 to about 10 includes, 2, 3, 4, etc.; greater than 0.10 includes 0.11, 0.12, 0.13, etc.). For example, whenever a numerical range with a lower limit, R l , and an upper limit, R u , is disclosed, any number falling within the range is specifically disclosed. In particular, the following numbers within the range are specifically disclosed: R=R l +k*(R u -R l ), wherein k is a variable ranging from 1 percent to 100 percent with a 1 percent increment, i.e., k is 1 percent, 2 percent, 3 percent, 4 percent, 5 percent, . . . , 50 percent, 51 percent, 52 percent, . . . , 95 percent, 96 percent, 97 percent, 98 percent, 99 percent, or 100 percent. Moreover, any numerical range defined by two R numbers as defined in the above is also specifically disclosed. Use of the term “optionally” with respect to any element of a claim means that the element is required, or alternatively, the element is not required, both alternatives being within the scope of the claim. Use of broader terms such as comprises, includes, and having should be understood to provide support for narrower terms such as consisting of, consisting essentially of, and comprised substantially of. Accordingly, the scope of protection is not limited by the description set out above but is defined by the claims that follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated as further disclosure into the specification and the claims are embodiment(s) of the present disclosure. The discussion of a reference in the disclosure is not an admission that it is prior art, especially any reference that has a publication date after the priority date of this application. The disclosure of all patents, patent applications, and publications cited in the disclosure are hereby incorporated by reference, to the extent that they provide exemplary, procedural, or other details supplementary to the disclosure.
While several embodiments have been provided in the present disclosure, it should be understood that the disclosed systems and methods might be embodied in many other specific forms without departing from the spirit or scope of the present disclosure. The present examples are to be considered as illustrative and not restrictive, and the intention is not to be limited to the details given herein. For example, the various elements or components may be combined or integrated in another system or certain features may be omitted, or not implemented.
In addition, techniques, systems, subsystems, and methods described and illustrated in the various embodiments as discrete or separate may be combined or integrated with other systems, modules, techniques, or methods without departing from the scope of the present disclosure. Other items shown or discussed as coupled or directly coupled or communicating with each other may be indirectly coupled or communicating through some interface, device, or intermediate component whether electrically, mechanically, or otherwise. Other examples of changes, substitutions, and alterations are ascertainable by one skilled in the art and could be made without departing from the spirit and scope disclosed herein.
|
An apparatus comprising a frame alignment processor coupled to a receiver, wherein the frame alignment processor is configured to align a first frame and a second frame in the receiver by matching a first synchronization (sync) pattern predicted using a first sync field in the first frame with a second sync pattern obtained from a second sync field in the second frame. Included is an apparatus comprising at least one component configured to implement a method comprising receiving a first frame, subsequently receiving a second frame that was transmitted after the first frame, predicting a first sync pattern from a first sync field in the first frame, obtaining a second sync pattern from a second sync field in the second frame, and determining that the first frame and the second frame are aligned when the first sync pattern matches the second sync pattern.
| 7
|
TECHNICAL FIELD
The present invention relates to a substrate inspecting apparatus and, in particular to an apparatus for inspecting wafers.
BACKGROUND ART
As for semiconductor wafer inspecting apparatuses, there are two kinds: an inspecting apparatus which inspects a wafer while rotating the wafer and an inspecting method while scanning a wafer in the X and Y directions. A method according to the present invention relates to a method for optically irradiating a wafer with a beam while rotating the wafer and moving the wafer rectilinearly in a radial direction, and detecting a defect on the wafer such as a foreign object by utilizing scattered light reflected on the wafer.
As a method for detecting intensity of scattered light of the wafer, using a signal which is output from an angle detector (encoder) attached to a rotational stage, the detection signal is subject to A/D conversion and subsequent signal processing such as filtering to detect a size and coordinates of a foreign object or a defect.
In a foreign-object/defect inspecting apparatus which inspects a surface by rotating a wafer to scan a beam spirally, an elliptical beam which is oblong in the radial direction as for a shape of the beam to be casted with is used.
In a conventional technique, scattered light of the elliptical shape is detected by a single photodetector (for example, a photomultiplier) to detect a foreign object or a defect on a wafer. There is also an example in which a photodetector of the multi-anode type is used instead of a photomultiplier as a method of scattered light detection; however, it becomes necessary to calibrate the optics system with high accuracy such that it is necessary to align the optical axis of the elliptical beam with the multi-anode direction.
As a conventional example concerning a detecting method using a multi-anode, there is an optical inspecting apparatus described in Patent Literature 1 (JP-A-2005-3447). According to Patent Literature 1, it is described that a multi-anode detector is arranged in a long side direction of a beam of an elliptic shape.
CITATION LIST
Patent Literature
Patent Literature 1: JP-A-2005-3447
SUMMARY OF INVENTION
Technical Problem
In an inspecting apparatus for detecting defects by rotating a wafer and using a light beam of an elliptic shape having a long side in the radial direction, it is necessary to align an optical axis of the light beam with an axis in the radial direction. Conventionally, an optical image detection unit for observing the optical axis is disposed separately from a scattered light detection unit to be used for inspection, and the optical axis detection is conducted using the optical image detection unit whereas defect detection is conducted using the scattered light detection unit. Not taken into consideration is the point that, when two separate detectors are used in this way, even if the optical axis is adjusted in the optical image detection unit, the optical axis is not necessarily in alignment in the scattered light detection unit and the accuracy of the position of the defect detection is not improved.
The present invention provides a method for using a multi-anode detector as a scattered light detecting method and aligning an optical axis of an elliptical beam with a light receiving axis of a one-dimensional sensor of a multi-anode.
Solution to Problem
A first feature of the present invention is to have an irradiation optics system which irradiates a wafer with first light of an elliptical shape, a multi-anode detection system which detects second light from the wafer, and an adjustment unit which adjusts an optical axis of the first light using a detection result of the multi-anode detecting system.
A second feature of the present invention is to have a correction unit which corrects the detection result using the detection result of the multi-anode detection system.
A third feature of the present invention is that a length of the first light from the irradiation optics system in its long side direction is longer than a scanning pitch of a transfer system and a length of detection elements of the multi-anode detection system is longer than a length of the second light from a substrate in its long side direction.
A fourth feature of the present invention is that the correction unit conducts rotation correction or amplitude correction of the first light.
A fifth feature of the present invention is that an intensity distribution of the first light is a Gaussian distribution or a distribution which is constant in the radial direction or the θ direction.
Advantageous Effects of Invention
According to the present invention, it is possible to improve the accuracy of defect detection.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a diagram showing a configuration of a defect detecting method according to the present invention;
FIG. 2 is a diagram showing a relation between scattered light and a multi-photodetector;
FIG. 3 is a diagram showing a relation between a feed pitch of a wafer and a beam shape;
FIG. 4 is a diagram showing signal intensities of light received by the multi-photodetector;
FIG. 5 is a diagram showing examples of an irradiation light beam;
FIG. 6 shows examples in cases where a two-dimensional image is generated from signals detected by the multi-photodetector;
FIG. 7 shows an example of an irradiation beam having a nearly constant light intensity in the radial direction and the θ direction;
FIG. 8 is a diagram showing a system configuration as a first embodiment of the present invention;
FIG. 9 is a diagram showing a system configuration as a second embodiment of the present invention;
FIG. 10 is a diagram showing a system configuration as a third embodiment of the present invention;
FIG. 11 is a diagram showing relations between a distribution measurement of a light beam and GUI display;
FIG. 12 is a diagram showing an overall configuration of a foreign object/defect inspecting apparatus according to the present invention;
FIG. 13 is a diagram showing a method for conducting rotation correction of foreign object/defect information;
FIG. 14 is a diagram showing a method for conducting amplitude correction of foreign object/defect information; and
FIG. 15 is a diagram showing relations between two-dimensional input data and correction coefficients.
DESCRIPTION OF EMBODIMENTS
Hereafter, embodiments of the present invention are described with reference to the drawings.
First, a configuration example of a semiconductor wafer foreign object/defect detecting apparatus is described.
FIG. 12 is a diagram showing an overall configuration of a foreign object/defect inspecting apparatus using a foreign object/defect inspecting method according to the present invention. A semiconductor wafer 1 , which is an object to be inspected, is vacuum-adsorbed to a chuck 1204 and the chuck 1204 is mounted on a moving stage for the to-be-inspected object 1205 , composed of a rotating stage 1206 and a translating stage 1207 , and a Z stage 1208 . An illuminating/detecting optics system 1201 arranged above the semiconductor wafer 1 is an optics system for illumination and detection. A laser light source is used as a light source 2 of illumination light, an irradiation beam exiting from the light source 2 passes through an irradiation lens 801 to form a beam of an elliptical shape which is oblong in a direction of a radius r, the wafer 1 is irradiated with it, and light scattered upon hitting a foreign object or a defect 1200 is detected by a photodetector 1203 and input to an amplifying circuit 1211 after being converted to an electric signal.
The moving stage for the to-be-inspected object 1205 causes an illumination spot relatively scan in spiral on the whole surface of the semiconductor wafer 1 by changing a rotating movement θ which is a primary scanning and a translating movement R which is an auxiliary scanning in combination with time.
While the rotating stage makes one revolution, the auxiliary scanning moves by Δr. In the present embodiment, scanning of the illumination spot is conducted from an inner circumference toward an outer circumference of the semiconductor wafer 1 ; however, it may be conducted in reverse. Furthermore, in the present embodiment, the rotating stage 1206 is driven with an approximately constant angular velocity and the translating stage 1207 is driven with an approximately constant linear velocity over the whole area from an inner circumference to an outer circumference of the semiconductor wafer 1 . As a result, the relative linear velocity of movement of the illumination spot with respect to the surface of the semiconductor wafer 1 becomes faster on an outer circumference compared with on an inner circumference. To detect the coordinate position of the primary scanning θ and the coordinate position of the auxiliary scanning r during inspection, an inspection coordinate detecting mechanism 1214 is attached to the moving stage for the to-be-inspected object 1205 . In the present embodiment, a rotary encoder of the optical reading type is used to detect the coordinate position of the primary scanning θ and a linear encoder of the optical reading type is used to detect the coordinate position of the auxiliary scanning r; those using other detection principles may also be used as long as they are sensors capable of detecting an angle or a position on a straight line with high accuracy.
An output of the amplifying circuit 1211 is converted to a digital signal by an A/D converter circuit 1212 ; a defect size and a defect position are calculated by a defect detection circuit 1213 using coordinate data of r and θ which are output from the inspection coordinate detecting mechanism 1214 , and output to a controller 1210 .
In this configuration, a foreign object or a defect 1200 passes the illumination spot and a scattered light signal is obtained from the photodetector 1203 . In the present embodiment, a photomultiplier tube is used as the photodetector 1203 ; a photodetector according to another detection principle may be applicable as long as it is a photodetector which can detect scattered light from a foreign object with high sensitivity.
FIG. 1 is a diagram showing a configuration of a defect detecting method according to the present invention.
By a light beam of the light source 2 being casted onto the wafer 1 with a shape of an irradiation light beam 3 and hitting a radial pattern 6 , a scattered light beam shape 5 is generated and is input to a multi-photodetector 4 .
The multi-photodetector 4 is a one-dimensional photodetector having a plurality of detecting elements arranged in a radial direction.
As the irradiation light beam 3 , a light beam of an elliptical shape having a long side in the radial direction of the wafer is used. The casted irradiation light beam 3 generates the scattered light beam shape 5 when it hits a foreign object or a defect (unevenness on the wafer). When there is radial unevenness or a radial pattern, scattered light becomes a signal projecting a shape of an irradiation beam. When a beam is shone onto a radial pattern, therefore, the multi-photodetector detects beam intensity in the radial direction.
FIG. 2 is a diagram showing a relation between scattered light and the multi-photodetector.
The scattered light beam shape 5 scattered upon hitting a radial pattern on the wafer is an elliptical shape as shown in FIG. 2 and a signal of beam intensities as represented by contour lines is obtained.
In the multi-photodetector 4 , elements are arranged along the long side direction of the light beam and it can obtain data 204 corresponding to one column in a longitudinal direction of a beam intensity distribution 7 . By rotating the wafer, the irradiation beam is rendered to scan on the radial pattern in a lateral direction in the present figure; by fetching data obtained from the multi-photodetector at constant time intervals, converting to digital signals, and storing in a memory or the like, a two-dimensional intensity distribution signal consisting of signals of data 201 to data 206 shown in the beam intensity distribution 7 is obtained. A length of the irradiation beam in the long side direction is equivalent to a scanning pitch with which light scans the wafer in spiral and a size of the elliptical beam in the short side is approximately in the range of 10 to several tens of μm. For example, in order to take in a beam having a width of 10 μm at constant intervals and obtain a two-dimensional intensity distribution signal, sampling is conducted to acquire data so that 10 μm is divided approximately into five to ten sections.
FIG. 3 is a diagram showing a relation between a feed pitch of the wafer and a beam shape.
In the apparatus which conducts defect inspection while rotating the wafer, the wafer is moved with a constant feed pitch while casting the irradiation light beam 3 to the wafer 1 to perform inspection in spiral. Part (a) of FIG. 3 is an enlarged view of Part A which is irradiated with the light beam. Reference numerals 301 to 303 denote tracks which the laser beam has passed (or is going to pass) when the wafer is moved with a constant feed pitch. The feed pitch of the wafer, namely, the scanning pitch of light becomes P. Furthermore, denoting the length of the casted light beam in the long side direction by B 1 , there is a relation of B 1 >P. Moreover, denoting a length of scattered light in the long side direction by B 2 and a length of arrangement of the detecting elements in the multi-photodetector by L, it is configured to satisfy a relation of L>B 2 . By doing so, it is possible to optically receive and convert signals of the elliptical light beam in the long side direction with the multi-photodetector 4 at once.
FIG. 4 is a diagram showing signal intensities of light received by the multi-photodetector.
The irradiation light beam 3 scans over the radial pattern 6 on the wafer in a direction of an arrow 404 so that the scattered light beam shape 5 is obtained with the multi-photodetector 4 .
The intensity of the irradiation light typically takes a shape of a Gaussian distribution and an R-direction waveform of the scattered light beam intensity in the long side direction (the vertical direction in FIG. 4 or the radial direction on the wafer) of the beam of the elliptical shape becomes one as represented by a reference numeral 401 . Further, a signal waveform in the short side direction (the horizontal direction in FIG. 4 or the circumference (θ) direction on the wafer) becomes one shown by a reference numeral 402 . As output signals of the multi-photodetector 4 , output signals from respective detectors are obtained as shown as an output signal 403 .
FIG. 5 is a diagram showing examples of the irradiation light beam.
Part (a) of FIG. 5 is a diagram in a case where scattered light with irradiation light having a nice Gaussian distribution is received in the same way as FIG. 4 ; a center of the beam intensity is located at a beam center C 1 , and both the R-direction waveform 401 and the θ-direction output 402 form undistorted Gaussian distribution waveforms. Part (b) of FIG. 5 and Part (c) of FIG. 5 show examples of cases where the light intensity distribution is distorted. Part (b) of FIG. 5 shows an example in which the center C 2 of the light beam intensity is not the center of the elliptical beam; each of the R-direction output 501 and the θ-direction output 502 is not a Gaussian distribution but has a distorted shape. When the irradiation light beam is distorted, then the scattered light is similarly distorted and a position of the maximum value of a defect signal is shifted. If the light distribution is distorted as in FIG. 5( b ), even though there is a foreign object in the center position C 1 of the beam in itself, the maximum value of the detection signal is in a position of C 2 when a position and a size of the foreign object on the wafer is detected and, consequently, it would be falsely detected as if the position of the foreign object were located near C 2 . Further, Part (c) of FIG. 5 shows a waveform in a case where the irradiation light beam has inclination with respect to the radial direction. In a case where the light beam is tilted in this way as well, the position of the detection result of the foreign object is detected with a shift in the rotation direction or the like so that it causes deterioration of accuracy of the detection position.
FIG. 6 shows examples in cases where a two-dimensional image is generated from signals detected by the multi-photodetector. A two-dimensional image 604 is a signal which is made as a two-dimensional image by arranging several data of signals detected from the multi-photodetector in the θ direction. A scattered light intensity two-dimensional image 601 is an image corresponding to the photo-detection signal shown in Part (a) of FIG. 5 . A scattered light intensity two-dimensional image 602 corresponds to the photo-detection signal shown in Part (b) of FIG. 5 and it is an image in which the maximum value of the signal intensity is shifted from the center of the beam. Further, a scattered light intensity two-dimensional image 603 corresponds to the photo-detection signal shown in Part (c) of FIG. 5 , and it is an image in which the light beam is rotated.
In the present invention, examples having light intensities of Gaussian distributions have been described; in many of irradiation beams used for defect detection, there are cases where a beam having a constant (flat) light intensity in the radial direction and the θ direction is used besides a beam of a light intensity having a Gaussian distribution.
FIG. 7 shows an example of an irradiation beam having a nearly constant light intensity in the radial direction and the θ direction.
Part (a) of FIG. 7 shows a detection signal in a case where a beam having a constant normal intensity is casted. As for the beam waveforms of a constant intensity irradiation beam 701 , an R (radial) direction waveform 702 and a θ (circumference) direction waveform 703 are obtained. Part (b) of FIG. 7 shows a detection signal in a case where a beam having non-uniform normal intensities is shone. As for the beam waveforms of a non-uniform intensity irradiation beam 704 , an R (radial) direction waveform 705 and a θ (circumferential) direction waveform 706 are obtained.
Also in the case where a beam of a constant intensity is used, the beam shape can be measured in this way and it becomes possible to correct the beam intensity or correct the rotation of the irradiation beam.
FIG. 8 is a diagram showing a system configuration as a first embodiment of the present invention.
A light beam radiated from a light source 2 passes through an optical axis correction mechanism 801 and is casted on a wafer 1 . A radial pattern 6 is engraved on the wafer and scattered light which strikes and is reflected from the radial pattern is converted from optical signals to electric signals at respective elements by a plurality of elements by the multi-photodetector 4 . The detection signals converted to the electric signals are amplified by amplifiers 10 disposed for respective elements and convert to digital signals by A/D converters 11 in respective signals. Respective signals obtained from the multi-photodetector are subjected to A/D conversion and, then, input to a memory circuit 12 to be stored in a form of a two-dimensional image. The image input to the memory is subjected to signal processing with a scattered light detection processing circuit 13 and transmitted to a controller 14 . In the scattered light detection processing circuit 13 , while conducting detection processing for a position of a foreign object or a defect from scattered light, discrimination of sizes of foreign objects and the like are conducted. In addition, in the present invention, intensity distribution information of the beam is calculated in the scattered light detection processing circuit 13 from the two-dimensional image signal and its result is transmitted to the controller 14 . The controller 14 finds magnitude of the maximum value of the irradiation beam, position information, and inclination angle information of the scattered light with a radius R taken as reference from information of the scattered light intensity distribution; it further generates data for adjusting an optical axis, controls the optical axis correction mechanism 801 via an optical axis adjustment/control circuit 802 , and conducts adjustment so that the irradiation light beam has original intensities of a Gaussian distribution and the long side of the elliptical beam coincides with the radial direction.
FIG. 9 is a diagram showing a system configuration as a second embodiment of the present invention.
Whereas, in the embodiment shown in FIG. 8 , detection of the magnitude of the maximum value of the irradiation beam, the position information, and the inclination angle information of the scattered light with the radius R taken as reference is conducted by the controller 14 , in the embodiment shown in FIG. 9 , a beam center position coordinate detection circuit 15 and a beam intensity distribution coefficient calculation circuit 17 are provided in a stage subsequent to the scattered light detection processing circuit 13 , intensity distribution coefficients are transmitted to the controller 14 , correction data for defect detection positions are generated by the controller 14 , and correction of the light intensity of scattered light and correction of rotation are conducted by a defect position coordinate correction circuit 16 .
In the present embodiment, although a circuit for optical axis correction shown in FIG. 8 is not illustrated, the position of a foreign object or a defect can be detected with high accuracy by using together the optical axis correction mechanism 801 and the defect position coordinate correction circuit 16 .
Also, a shape of the light beam and calculated correction data are displayed on a GUI interface 20 based on data transmitted to the controller 14 . By displaying the beam shape and the correction data and thereby informing a user of the state of the light beam, adjustment of the optics system is facilitated.
FIG. 10 is a diagram showing a system configuration as a third embodiment of the present invention.
In the present embodiment, a beam intensity correction circuit 18 is provided in a stage subsequent to the defect position coordinate correction circuit 16 to conduct signal amplitude correction especially for distortion of the light beam in the radial direction based on data from the beam intensity distribution coefficient calculation circuit 17 . Contents of the defect position coordinate correction circuit 16 and the beam intensity correction circuit 18 are described with reference to FIG. 13 and FIG. 14 .
FIG. 11 is a diagram showing relations between a distribution measurement of the light beam and GUI display.
Outputs of the multi-photodetector 4 are converted to digital signals by amplifiers 10 and A/D converters 11 which are disposed for respective detectors and input to a memory circuit 12 .
While inputting one-dimensional data of the radial direction scattered from a radial pattern on the wafer, as described earlier, the multiphotodetector 4 stores data of the θ direction centered around the maximum value of the scattered light intensity into the memory circuit 12 . Data are stored in the memory as two-dimensional image data as indicated by a reference numeral 1101 . The data stored in the memory circuit 12 are transmitted to the controller 14 and the controller 14 displays the light beam shape and the like using the GUI interface (display device) 20 .
An example of display on the GUI interface (display device) 20 is shown as a reference numeral 21 . On the GUI interface, contour line display 1101 of the intensities corresponding to the intensity distribution of the light beam and display of correction data of the light beam obtained from the intensity distribution data or the like are conducted.
As examples of the correction data of the light beam data, there are rotation correction data and level (amplitude) correction data. An example set of correction equations and correction coefficients is shown below.
Rotation correction of light beam:
P (θ)= Ax+By (Equation 1)
x/y . . . XY coordinates of a two-dimensional image A/B . . . correction amounts (correction coefficients) in the X and Y directions
Level (amplitude) correction:
Z ( c )= Gz+C (Equation 2)
z . . . an amplitude value at each point of a two-dimensional image G/C . . . a gain correction coefficient and a shift correction amount
Rotation correction and amplitude correction of the light beam are conducted by conducting correction calculations at each point of two-dimensional image data using the above-described correction data.
FIG. 15 is a diagram showing relations between two-dimensional input data and correction coefficients. A shift amount of the center position of the light beam, rotation angle data with respect to the radial direction, and the like are calculated using a two-dimensional image 1501 which is input, and a correction coefficient table 1502 is provided as data for correcting them. The correction coefficient table 1502 is a two-dimensional correction coefficient data table (memory) which contains the beam shape, and correction coefficients kij (i=1˜6, j=1˜n) are stored for respective points. Each correction coefficient has contents as indicated by coefficient data 1503 . The coefficient data 1503 indicates, for example, contents of k 11 , and A 11 and B 11 are stored as coefficients of the rotation correction (Ax+By) and G 11 and C 11 are stored as coefficients of the amplitude correction (Gz+C).
Rotation correction and amplitude correction for a detected foreign object or a defect are conducted using the correction coefficients described with reference to FIG. 15 .
FIG. 13 is a diagram showing a method for conducting rotation correction of foreign object/defect information.
By a defect position coordinate detection circuit 19 coordinates of a defect 1200 are detected with an input of a defect detection signal 1302 . On the other hand, by an intensity distribution coefficient detection circuit 17 - 1 data (An and Bn shown in FIG. 15 ) for conducting rotation correction are taken out of beam intensity distribution correction data 1301 , coefficients for rotation correction corresponding to foreign object/defect coordinates obtained with the aforementioned defect [position coordinate detection circuit 19 are taken out, and a correction calculation is conducted with the defect position coordinate correction circuit 16 . By performing rotation correction with the defect position coordinate correction circuit, a detected defect position 1305 is corrected by an angle θ and position information is corrected to a true defect position 1306 to obtain defect detection data 1303 .
FIG. 14 is a diagram showing a method for conducting amplitude correction of foreign object/defect information.
By the defect position coordinate detection circuit 19 , coordinates of the defect 1200 are detected with a defect detection signal 1402 as an input. On the other hand, by an intensity distribution coefficient detection circuit 17 - 2 data Gn and Cn shown in FIG. 15 ) for conducting amplitude correction are taken out of beam intensity distribution correction data 1401 , coefficients for amplitude correction corresponding to foreign object/defect coordinates obtained with the aforementioned defect position coordinate detection circuit 19 are taken out, and a correction calculation is conducted with the beam intensity correction circuit 18 . By performing amplitude correction with the beam intensity correction circuit, the magnitude of a detected defect signal 1405 is corrected by a gain G, resulting in correction to a true defect amplitude 1406 to become corrected defect detection data 1403 .
Incidentally, the shape of the irradiation beam may not be an elliptical shape but may be the shape of a spot. Furthermore, the configuration of the inspecting apparatus is not limited to that of the present embodiment; the detector may be a sensor having a plurality of pixels such as CCD's, or a scheme of condensing scattered light using an ellipsoid may be used. In addition, the inspection object is not restricted to a wafer, but it may be a hard disk substrate or the like.
Reference Signs List
1 wafer,
2 light source,
3 irradiation light beam,
4 multi-photodetector,
5 scattered light beam shape,
6 radial pattern,
7 beam intensity distribution,
10 amplifier,
11 A/D converter,
12 memory circuit,
13 scattered light detection processing unit,
14 controller,
15 beam center position coordinate detection circuit,
16 defect position coordinate correction circuit,
17 beam intensity distribution coefficient calculation circuit,
18 beam intensity correction circuit,
19 defect position coordinate detection circuit,
20 GUI interface,
21 GUI display example,
401 R-direction waveform,
601 , 602 and 603 scattered light intensity two-dimensional image,
701 constant intensity irradiation beam,
801 optical axis correction mechanism,
802 optical axis adjustment/control circuit,
1200 defect,
1203 photodetector,
1205 moving stage for to-be-inspected object,
1208 Z stage.
|
Provided is a method wherein a multi-anode detector is used for the purpose of detecting scattered light from a wafer, data obtained from the detector (multi-anode) for detecting defects is used, the shape of a beam radiated to the wafer, a rotational shift between the radius direction and the beam long side, and the like are calculated, and the optical axis of the irradiation beam is adjusted. Furthermore, the method is provided with a technique which feeds back the correction quantities for rotation and amplitude to inspection signal data, on the basis of the correction data, and corrects inspection data. Since fine correction with the adjustment of an optics system and signal processing is made possible, positional accuracy of defect inspection and accuracy of defect level (defect size) are improved.
| 7
|
BACKGROUND OF THE INVENTION
The present invention relates to the art of rock boring and more particularly to a rotary bit which comprises three toothed conical rotary elements on which are disposed hard metal tips. The tips may be inserts. Such bits are typically rotated under the weight of a drill collar and drill pipe. This weight forces the bits into the rock or other ground formations and the rotation causes the rotatably mounted cones to rotate about their own axes. The teeth or tips chip and crush the rock or other formations.
While particularly adapted for drilling oil wells, it will be understood that it also has application for other ground boring requirements.
The prior art drill bit assemblies have usually been constructed with channels or other non-cutting areas between rings of teeth. These areas have been provided, in the prior art devices, for the purpose of providing cleaning clearance for the cutting teeth. The present inventor has found that this theory and construction are based on an incorrect theoretical basis. More particularly, such cleaning clearances result in recompressing material which has been cut off and chewed up by adjacent teeth or rows of teeth. The practical effect of the use of such grooves is to substantially reduce the number of cutting teeth which may be disposed on a given size cone, thus reducing rates of penetration in drilling operations.
The prior art drill bit also typically has teeth which have elongated cutting edges which are disposed in generally parallel relationship to the axis of rotation of the cone. A difficulty with these prior art drill bits, is that the resultant force on the cone is inclined substantially from the axis of rotation. This results in a spiralling action of the drill bit, as it drills down into the ground.
Various drill bit constructions, such as those shown in U.S. Pat. Nos. 3,385,385, 4,187,922, and 2,990,025, have not proven wholly satisfactory.
It is an object of the invention to provide apparatus which will provide more rapid drilling and improved penetration rates, even when drilling relatively hard rock.
An object of the invention is to provide apparatus which will inherently tend to move in a more rectilinear path as it passes down into the ground, and which tends to avoid the spiralling action of the prior art drill bits, while accomplishing the other objects of the invention.
An object of the invention is to provide apparatus which distribute the wear of the cutting teeth over substantially all the cutting teeth of each cone so that the life of the cone is maximized.
Another object of the present invention is to provide drill bit apparatus which will provide improved durability and longer service life.
Another object of the invention is to provide a construction which reduces overloading, shock loads and load variations imposed on the cone bearings so that the bearing life will be substantially increased over the prior art construction.
SUMMARY OF THE INVENTION
A rock boring bit assembly which includes a body configured for engagement with associated rotating mechanism. At least one roller cutter is rotatably mounted on a leg on a bearing pin. The roller cutter includes a plurality of cutting edges disposed over the face thereof in generally upstanding relationship to the face thereof. The cutters are so arrayed or arranged as to define no channel between adjacent arrays, pluralities or rings of cutters. The cutters have an edge which is generally rectilinear and each of the rectilinear edges are disposed in substantially oblique relationship to the plurality of other rectilinear edges of other cutting members disposed proximate thereto.
The cutting members may be arrayed over the entire surface of the roller cutter or cone, and may be arrayed in rows of staggered, offset cutting members.
The apparatus may have the cutting members or inserts disposed in rings or ring areas. Each of the rings may extend through a plane which is substantially perpendicular to the axis of the cone. The inserts in adjacent rings may be disposed with substantially no space intermediate adjacent rings. Each cone may further include an additional ring of inserts disposed most remote from the apex of each cone and has the geometric axis of each insert disposed in substantially normal relationship to the geometric axis of the cone.
The apparatus may further include still another ring of inserts which are each disposed with the axis of each at an angle which is intermediate the normal relationship (to the axis) of the ring of cutter inserts which are most remote from the apex and the inserts which are disposed in normal relationship to the surface of the cone. The additional ring of inserts may be disposed axially intermediate the ring which is most remote from the apex and the cutter inserts disposed elsewhere on the cone.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
FIG. 1 is a fragmentary perspective view of the drill bit assembly in accordance with the invention, in which one cone and the associated mounting structure has been omitted to improve the clarity of the view;
FIG. 2 is a simplified elevational view of one of the cones illustrated in FIG. 1;
FIG. 3 is a broken away elevational view of a cone which is similar to that of FIG. 2 and which better illustrates the internal construction of the cone;
FIG. 4 is an elevational view of the pin portion of the internal structure of the cone illustrated in FIGS. 1-3, and which omits the bearing rollers illustrated in FIG. 3;
FIG. 5 is a fragmentary perspective view of the internal construction of the cone illustrated in FIGS. 1-4;
FIG. 6 is a fragmentary elevational view of a section of cone, illustrating the geometric relationship between the successive inserts in a ring shaped array in one embodiment of the invention;
FIG. 7 is a perspective view of the drill bit assembly of FIG. 1, showing the bit and teeth during drilling operation;
FIG. 8 is a fragmentary elevational view, similar to that of FIG. 6, showing another embodiment of the invention; and
FIG. 9 is a fragmentary elevational view, similar to that of FIG. 8, illustrating another embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1-7 there is shown a drill bit assembly 10 which includes a body 12 having threaded surfaces thereon (not shown) for attachment to the lower end of a rotary drill string (not shown). The drill bit assembly includes three cones or cutters 14 (two shown in FIGS. 1 and 7). Each cone or cutter 14 is provided with a threaded pin or support shaft 18 which engages the leg 16 on which the cone 14 is mounted. A recess 19 in the threaded surface of the pin 18, is provided for cooperation with a dowel pin and safety screw (not shown) to more positively secure the pin 18 to the leg 16. Each leg 16 is dimensioned and configured for engaging a recess 20, in the body 12. The legs 16 are fastened to the body 12 by means of socket bolts 17. The body 12 is bolted to the threaded pin 13 by socket bolts 15.
Each cone is provided with a plurality of bearing systems which cooperate with the bearing pin or support shaft 18. The bearing systems include a roller bearing 24 on the pin 18 which cooperates with the surface 26 of the cone and the pin shaft. The pin 18 is also provided with an inner bearing race 28 which cooperates with ball bearing 30 which are in turn carried in an outer race 32. Another roller bearing 34 cooperates with a bearing surface 36 in the interior of the cone (which is best seen in FIG. 5). A thrust plate 39 is provided in the cone 14 to absorb thrust forces in the multiple bearing and is positioned against the end face of the pin shaft, as shown in FIG. 4. Grooves 41 are provided in the thrust plate 39 to insure positive lubrication. Although this combination of bearing systems has been illustrated, it will be understood that the invention also contemplates the use of other bearing systems, such as axially tapered journal bearings and tapered roller bearings.
Disposed on the outer face of each cone 14 are a plurality of metal inserts 38 which are generally arrayed in circumferential rows which are disposed very generally in planes which extend substantially at right angles to the geometric axis of the cone. As best seen in FIGS. 2, 7 and 8, the inserts are generally disposed so that there is substantially no space or channel left intermediate adjoining rows (contrary to the usual prior practice for such drill bits). The inserts 38 are ordinarily welded in bores or recesses in the cone 14. As is best seen in FIG. 6, the free end of each insert 38 (which may be manufactured of hardened steel or tungsten carbide) includes a generally rectilinear edge 40. In the embodiment shown in FIGS. 1-7, the orientation of the edge 40 of each insert 38 in any one row or ring is in general not parallel to and is oblique to the axis of the cone, and to the edge 40 of the adjacent inserts 38 in the same array or ring, the insert edges of which follow or track each other in successively engaging an area of rock or material being drilled. Ordinarily, each edge 40 of each insert 38 will also be disposed in oblique relationship to each other edge 40 of each insert 38 which is adjacent thereto even if it is in a different row or ring. Similarly, in the embodiments of FIGS. 6 and 9, successive insert edges are in oblique or inclined relation to each other and to a plurality of other proximate insert cutting edges. Successive cutting edges in a ring or array therefore engage or impact an area of the formation or rock being drilled at varying successive relative directions, thus resulting in more effective breakage, more rapid penetration by the drill bit, and reduction of tracking and stumbling of the successive cutting edges.
With cutting edges inclined to the axis of the cone, as shown in FIGS. 6, 8 and 9, end portions of cutting edges first engage the rock or material being broken, thus effecting high penetration pressure and reducing the tracking, stumbling, jumping, and breaking of cutting members which otherwise results from engagements or impacts of full cutting edges with the rock or formation. In the embodiment of FIG. 9, all cutting edges are so inclined in order to provide this advantageous result.
Stated otherwise, the oblique orientation of successive teeth in a ring of inserts 38, as well as the rings of inserts 46 and 44, has the effect that successive teeth impact the rock at different angles, much as the application of a chisel by a sculptor at many different angles would more rapidly chip away a piece of granite. Each insert 38, 46 and 44 is disposed in a cavity of substantially uniform depth. The relatively short height of the teeth, with respect to the face 42, of the cone 14, is a significant factor in reducing vibration. In contrast to the prior art structures which have teeth disposed with their cutting edges parallel to the center line or axis of rotation of the cone 14, the apparatus in accordance with the invention has the teeth or cutting edges disposed at different angles and this produces more rapid cutting.
In general the inserts 38 are disposed with the axis of each in generally perpendicular relationship to the face 42 of the cone 14. In the embodiment illustrated in FIGS. 1-7, the inserts 38 extend approximately one-half inch above the face 42. This size has been found satisfactory for hard packed ground. Other sizes will be desirable for soft soil and rock conditions. The primary exception to this generally perpendicular relationship to the face 42, of the cone 14, is the rings of inserts 44 and 46. The inserts 44, 46 are otherwise identical to the inserts 38 except that they are oriented differently, as best seen in FIGS. 2 and 3. Specifically, the rightmost rings or rows of inserts 44 are disposed at increasing angles to the axis of the pin 18. The row or ring of inserts identified by the numeral 46 is disposed with the axes thereof at an angle which is intermediate the angular orientation of the inserts 38 and the inserts 44, as best seen in FIG. 3.
Disposed around the face of the cone 14 (on the right in FIG. 3) are a seal groove and seal 50 which are provided to keep contamination out of the bearings 24, 30, 34. It will be understood that this seal 50 cooperates with the leg 16 in which the cone 14 is mounted.
The apparatus in accordance with the invention provides much faster cutting and drilling than was provided by the prior bit assemblies. In part, this results from the elimination in the apparatus in accordance with the invention of the grooves separating pluralities of teeth. There are therefore a greatly increased number of teeth acting on the rock or formation, thus greatly increasing the rate of downward penetration of the drill bit.
Referring to the embodiments of FIGS. 8 and 9, rings of inserts 44A are provided in which successive inserts 44A are alternately offset or staggered, preferably being offset one-half diameter or more in alternate lateral directions. This construction is advantageous in that it provides better cutting and reduced teeth damage. Damage is otherwise more likely to occur in more conventional constructions, because a depression or "hole" may be produced in a portion of the bottom of the bore being drilled in which depression a tooth may bottom under the heavy pressures applied, and then be broken by the forces applied to the tooth against a surface or wall of such depression or hole. In other respects, the cone 42 is generally similar to the embodiment illustrated in FIGS. 1-7. The similarities include the rectilinear edge 40a orientations.
With inserts extending varying effective distances from the cone, as shown in FIGS. 3 and 7, as may be provided by inserts of varying lengths in cavities of equal depth, when the outermost cutting edges become worn or broken, other edges come into action, thereby providing improved drill bit performance throughout a longer service life.
The use of a relatively large number of individual teeth insures that even if one tooth were to wear abnormally, substantial cutting will continue, since the wear of any one tooth will merely place other teeth in more positive engagement with the rock formation which is being drilled. A single cone 14, in accordance with the invention, has more inserts 38 than the entire drill bit assembly, in accordance with the prior art. Stated another way, the number of inserts 38 is about four times the number of inserts in prior art structures. Another benefit of the relatively large number of inserts 38, 46, and 44 is more uniform and lower-magnitude shocks and vibrations on the bearings, thus resulting in substantially reduced bearing overloading and fatigue, thereby increased bearing life.
Still another benefit of the construction, in accordance with the invention, is that the resultant force on each cone 14 results in a force disposed generally along the axis of rotation of the drill bit. This tends to avoid a spiralling movement of the drill bit assembly into the earth, and thus results in a more efficient and faster drilling action. The resultant force is more closely aligned with the axis of the cone 14, than in the prior art structures, primarily because the greater number of teeth insure a distribution of forces which are substantially uniform about the circumference of the cone 14.
The angular orientation of the ring of inserts 46 and the rings of inserts 44 tends to maintain the size of the hole being bored by the drill bit and thus provides more clearance for the drill bit. A slight enlargement also tends to increase bearing and seal life because the load on the bit 10 is decreased. Contrary to the practice conventionally used, reaming of the hole is not necessary to accommodate a new drill bit, merely because the bit that was used previously was worn and thus cut a hole of reduced diameter.
The drill bit assembly 10 illustrated in FIG. 1 has a height of about eighteen inches and has an outside diameter of about eight and three-quarter inches. Various other embodiments may have substantially larger dimensions.
The boring bit assemblies according to the invention are more durable and provide longer service life than bits of the prior art, and are capable of drilling faster and farther before it is necessary to replace the drill bit.
The invention has been described with reference to its illustrated preferred embodiment. Persons skilled in the art of constructing rock drill bits may, upon exposure to the teachings herein, conceive variations in the mechanical development of the components therein.
|
A rock boring bit assembly which includes a body configured for engagement with associated driving mechanism. At least one roller cutter is rotatably mounted on the body. The roller cutter includes a plurality of cutting member disposed about the entire face or surface thereof in generally upstanding relationship. The cutting members are arrayed over the roller cutter surface with no channel between adjacent arrays of cutting members. The cutters have generally rectilinear edges and each of the edges is disposed in substantially oblique relationship to a plurality of other rectilinear edges of other cutting members disposed proximate thereto.
| 4
|
TECHNICAL FIELD
[0001] The present invention relates to a feed system for a continuous digester in which wood chips are cooked for the production of cellulose pulp according to the preamble to Claim 1 .
PRIOR ART
[0002] In older conventional feed systems for continuous digesters, high-pressure pocket feeders have been used as sluice feeders for pressurisation and transport of a chips slurry to the top of the digester.
[0003] The Handbook of Pulp , (Herbert Sixta, 2006) discloses this type of feeding with high-pressure pocket feeders ( High Pressure Feeder ) on page 381. The big advantage with this type of feed is that the flow of chips does not need to pass through pumps, but is instead transferred hydraulically. At the same time it is possible to maintain a high pressure in the transfer circulation to and from the digester without losing pressure. The system has however demonstrated some disadvantages in that the high-pressure pocket feeder is subjected to wear and must be adjusted so that the leakage flow from the high-pressure circulation to the low-pressure circulation is minimized. Another disadvantage is that during transfer the temperature must be kept low so that bangs due to steam implosions do not occur in the transfer.
[0004] As early as 1957, U.S. Pat. No. 2,803,540 disclosed a feed system for a continuous chip digester where the chips are pumped from an impregnation vessel to a digester in which the chips are cooked in a steam atmosphere. Here, a part of the cooking liquor is charged to the pump to obtain a pumpable consistency of 10%. However, this digester was designed for small scale production of 150-300 tons pulp per day (see col. 7, r. 35).
[0005] Also, U.S. Pat. No. 2,876,098 from 1959 discloses a feed system for a continuous chip digester without a high-pressure pocket feeder. Here the chips are suspended in a mixer before they are pumped with a pump to the top of the digester. The pump arrangement is provided under the digester and here the pump shaft is also fitted with a turbine in which pressurised black liquor is depressurised to reduce the required pump power.
[0006] U.S. Pat. No. 3,303,088 from 1967 also discloses a feed system for a continuous chip digester without a high-pressure pocket feeder, where the wood chips are first steamed in a steaming vessel, followed by suspension of the chips in a vessel, whereafter the chips suspension is pumped to the top of the digester.
[0007] U.S. Pat. No. 3,586,600 from 1971 discloses another feed system for a continuous digester mainly designed for finer wood material. Here, a high-pressure pocket feeder is not used either, and the wood material is fed with a pump 26 via an upstream impregnation vessel to the top of the digester.
[0008] Similar pumping of finer wood material to the top of a continuous digester is also disclosed in EP157279.
[0009] Typical for these digester house embodiments from the late 50's to the beginning of the 70's is that these were designed for small digester houses with a limited capacity of about 100-300 tons pulp per day.
[0010] U.S. Pat. No. 5,744,004 shows a variation of feeding wood chips into a digester where the chips mixture is fed into the digester via a series of pumps. Here, so called DISCFLO™ pumps are used. A disadvantage with this system is that this type of pump typically has a very low pump efficiency.
[0011] The previously mentioned Handbook of Pulp also discloses on page 382 an alternative pump feed of chips mixtures called TurboFeed™. Here three pumps are used in series to feed the chips mixture to the digester. This type of feed has been patented in U.S. Pat. No. 5,753,075, U.S. Pat. No. 6,106,668, U.S. Pat. No. 6,325,890, U.S. Pat. No. 6,336,993 and U.S. Pat. No. 6,551,462; however in many cases, U.S. Pat. No. 3,303,088 for example, has not been taken into consideration.
[0012] U.S. Pat. No. 5,753,075 relates to pumping from a steaming vessel to a processing vessel.
[0013] U.S. Pat. No. 6,106,668 relates specifically to the addition of AQ/PS during pumping.
[0014] U.S. Pat. No. 6,325,890 relates to at least two pumps in series and the arrangement of these pumps at ground level.
[0015] U.S. Pat. No. 6,336,993 relates to a detail solution where chemicals are added to dissolve metals from the wood chips and then drawing off liquor after each pump to reduce the metal content of the pumped chips.
[0016] U.S. Pat. No. 6,551,462 essentially relates to the same system already disclosed in U.S. Pat. No. 3,303,088.
[0017] A big disadvantage with the systems with multiple pumps in series is limited accessibility. If one pump breaks down, the whole digester system stops. With 3 pumps in series and a normal accessibility for each pump of 0.95, the total systems accessibility is just 0.86 (0.95*0.95*0.95=0.86).
[0018] Today's modern continuous digestion houses with capacities over 4000 tons pulp per day use digesters that are 50-75 meters high and where a gauge pressure of 3-8 bar is established in the top of the digester in the case of a steam phase digester or 5-20 bar in the case of a hydraulic digester. The continuous digester systems are designed to, during the main part of operation, typically well over 80-95% of operation, run at nominal production, which makes it necessary, in regard to operational costs, for the pumps to be optimized for nominal production.
[0019] A typical digester system with a capacity of about 3000 tons with a feed system with the so called “TurboFeed™” technology requires about 800 kW of pumping power. It is obvious that these systems must have pumps that run at an optimized efficiency close to their nominal capacity. Such a feed system requires 19,200 kWh (800*24) per 24 hours, and at a price of 50 Euro per MWh, the operational cost comes to 960 Euro per 24 hours or 336,000 Euro per year.
[0020] The systems must also be operational within 50-110% of nominal production which places great demands on the feed system.
[0021] This means that a system supplier must offer pumps that are large enough to handle 4000 ton but can also be operated within a 2000-4400 ton interval. Such a pump operated at 50% of its capacity is far from optimised, but it is necessary to at least temporarily be able to operate the pump at limited capacity in case of temporary capacity problems, for example further down the fibre line.
[0022] If this system supplier offers digester systems that can handle nominal capacities of 500-5000 tons, then pumps must be designed in a number of different pump sizes so that each individual installation can offer, from a power consumption and energy perspective, optimised transfer at nominal production. This makes the pumps very expensive, as normally a very limited series of pumps are manufactured in each size. To be able to meet demands of reasonably short delivery times, the system supplier must stock pumps in all pump sizes which is very expensive.
[0023] The digester feed should also be able to guarantee optimal feeding to the top of the digester even if the flow in the transfer line is reduced to 50% of nominal flow.
[0024] This is difficult, because the flow rate in the transfer lines should be maintained above a critical level, as well-steamed chips have a tendency to sink against the direction of the transfer flow if the speed becomes too low.
[0025] A corrective measure that can be used at low rates is to increase the dilution before pumping so that a lower chip concentration is established. However, this is not energy efficient as this force the feed systems to pump unnecessarily high volumes of fluid which increases the required pump power per produced unit of pulp.
[0026] Each pump has a construction point (Best Efficiency Point/“BEP”) at which the pump is intended to work. At this “BEP”, shock induced loss and frictional loss are, in the case of centrifugal pumps, at their lowest which in turn leads to that the pumps efficiency is highest at this point.
AIM OF THE INVENTION
[0027] A first aim of the present invention is to provide an improved feed system for wood chips wherein optimal transfer can be achieved within a broader interval around the digesters design capacity.
[0028] Other aims of the present invention are;
improved efficiency of the feed system; improved accessibility; lower operational costs per pumped unit of chips; constant chip concentration during pumping regardless of production level; a limited range of pump sizes that can cover a broad span of the digester's production capacity; simplified maintenance; lower installation costs compared to feed systems with high-pressure pocket feeders or multiple pumps in series;
[0036] The above mentioned aims may be achieved with a feed system according to the characterizing part of Claim 1 .
FIGURES
[0037] FIG. 1 shows a first system solution for feed systems for digesters with a top separator;
[0038] FIG. 2 shows a second system solution for feed systems for digesters without a top separator;
[0039] FIGS. 3-6 shows different ways of attaching pumps to an outlet in a pre-treatment vessel;
[0040] FIG. 7 shows the feed system's connection to the top of a digester without a top separator; and
[0041] FIG. 8 shows a top view of FIG. 7 ;
DETAILED DESCRIPTION OF THE INVENTION
[0042] In the following detailed description, the phrase “feed system for a continuous digester” will be used. “Feed system” herein means a system that feeds wood chips from a low pressure chips processing system, typically with a gauge pressure under 2 bar and normally atmospheric, to a digester where the chips are under high pressure, typically between 3-8 bar in the case of a steam phase digester or 5-20 bar in the case of a hydraulic digester.
[0043] The term “continuous digester” herein means either a steam phase digester or a hydraulic digester even though the preferred embodiments are exemplified with steam phase digesters.
[0044] A basic concept is that a feed system comprises at least 2 pumps in parallel, but preferably even 3, 4 or 5 pumps in parallel. It has been shown that a single pump can feed a chips suspension to a pressurised digester, and it is therefore possible to exclude conventional high-pressure pocket feeders or complicated feed systems with 2-4 pumps in series.
[0045] The pumps are arranged in a conventional way on the foundation at ground level to facilitate service.
[0046] With the solution outlined above it is possible to provide feed systems for digester production capacities from 750 to 6000 tons pulp per day, with only a few pump sizes. This is very important, as these pumps for feeding wood chips at relatively high concentration are very specific in regard to their applications, and pumps that are able to handle production capacities of 4000-6000 tons pulp per day are very large and only manufactured in very limited series of a few pumps per year. The cost for these pumps therefore becomes a crucial factor for a digester system.
[0047] The table below shows an example of how it is possible to cover a production interval of 750-6000 tons with only two pump sizes optimised for 750 and 1500 tons pulp, respectively, per day;
[0000]
PUMP PROGRAM (X unit* = 1:st alternative)
Nominal Production
Capacity (ton per day)
750 pump
1500 pump
750
1
unit
1500
2
units
2250
1
unit
1
unit
(2250 alt)
(3
units*)
—
3000
—
2
units
(3000 alt)
(4
units*)
3750
1
unit
2
units
4500
—
3
units
(4500 alt)
(2
units*)
(2
units*)
5250
1
unit
3
units
6000
4
units
[0048] This table clearly shows how it is possible to, with the concept according to the present invention, cover production capacities between 1500-6000 tons with only 2 optimised pump sizes while using a single pump installation in smaller digester systems with a capacity below 750 tons. Continuous digesters with a capacity of 750 tons are seldom used for new installations today, because batch digester systems are often more competitive for these capacities. A certain after market may exist for older digester systems with a low capacity where expensive feed systems with high-pressure pocket feeders are still used.
First Embodiment
[0049] FIG. 1 shows an embodiment of the feed system with at least 2 pumps in parallel. The chips are fed with a conveyor belt 1 to a chips buffer 2 arranged on top of an atmospheric treatment vessel 3 . In this vessel, a lowest liquid level, LIQ LEV , is established by adding an alkali impregnation liquid, preferably cooking liquor (black liquor) that has been drawn off in a strainer screen SC 2 in a subsequent digester 6 , and with possible addition of white liquor and/or another alkali filtrate.
[0050] The chips are fed with normal control of the chip level CH LEV which is established above the liquid level LIQ LEV .
[0051] The remaining alkali content in the black liquor is typically between 8-20 g/l. The amount of black liquor and other alkali liquids that are added to the treatment vessel 3 is regulated with a level transmitter 20 that controls at least one of the flow valves in lines 40 / 41 . With this alkali impregnation liquor the wood acidity in the chips may be neutralised and impregnated with sulphide rich (HS − ) fluid. Spent impregnation liquor, with a remaining alkali content of about 2-5 g/l, preferably 5-8 g/l, is drawn off from the treatment vessel 3 via the withdrawal strainer SC 3 and sent to recovery REC. If necessary, white liquor WL may also be added to the vessel 3 , for example as shown in the figure to line 41 . The actual remaining alkali content depends on the type of wood used, hardwood or softwood, and which alkali profile that is to be established in the digester.
[0052] In the case where a raw wood material that is easy to impregnate and neutralize is used, for example raw wood material such as pin chips or wood chips with very thin dimensions and quick impregnation, vessel 3 may in extreme cases be a simple spout with a diameter essentially corresponding to the bucket formed outlet 10 in the bottom of the vessel. Required retention time in the vessel is determined by the time it takes for the wood to become so well impregnated that it sinks in a free cooking liquor.
[0053] After the chips have been processed in vessel 3 they are fed out from the bottom of the vessel where also a conventional bottom scraper 4 is arranged, driven by a motor M 1 .
[0054] According to the invention, the chips are fed to the digester via at least 2 pumps 12 a , 12 b in parallel, and these pumps are connected to a bucket formed outlet 10 in the bottom of the vessel. The bucket formed outlet 10 has an upper inlet, a cylindrical mantle surface, and a bottom. The pumps are connected to the cylindrical mantle surface.
[0055] To facilitate pumping of the chip mixture, the chips are suspended in a vessel 3 to create a chips suspension, in which vessel is arranged a fluid supply via lines 40 / 41 , controlled by a transmitter 20 which establishes a liquid level LIQ LEV in the vessel, and above the pump level by at least 10 meters, and preferably at least 15 meters and even more preferably at least 20 meters. Hereby a high static pressure is established in the inlet to pumps 12 a and 12 b so that one single pump can pressurise and transfer the chips suspension to the top of the digester without cavitation of the pump. The top of the digester is typically arranged at least 50 meters above the level of the pump, usually 60-75 meters above the level of the pump, while a pressure of 5-10 bar is established in the top of the digester.
[0056] To further facilitate the feeding to the pumps, a stirrer 11 is arranged in the bucket formed outlet. The stirrer 11 is preferably arranged on the same shaft as the bottom scraper and driven by the motor M 1 . The stirrer has at least 2 scraping arms that sweep over the pump outlets arranged in the bucket formed outlet's mantle surface. Preferably a dilution is arranged in the bucket formed outlet, which may be accomplished by dilution outlets (not shown) connected to the upper edge of the mantle surface.
[0057] FIGS. 3-6 show how a number of pumps 12 a - 12 d may be connected to the outlet's cylindrical mantle surface and how the stirrer 11 may be fitted with up to 4 scraping arms. The pumps may preferably be arranged symmetrically around the outlet's cylindrical mantle surface with a distribution in the horizontal plane of 90° between each outlet if there are 4 pump connections (120° if there are 3 pump connections and 180° if there are 2 pump connections). This way it is possible to avoid an uneven distribution of the load on the bottom of the vessel and its foundation. In practice, a shut-off valve (not shown) is also arranged between the outlet's 10 mantle surface and the pump inlet and a valve directly after the pump to make it possible to shut off the flow through one pump if this pump is to be replaced during continued operation of the remaining pumps.
[0058] In FIG. 1 the chips are fed by pumps 12 a , 12 b via transfer lines 13 a , 13 b (only two shown in FIG. 1 ) to the top of the digester 6 . FIG. 1 shows a conventional top separator 51 arranged in the top of the digester. The transfer lines 13 a , 13 b , preferably 2, both open into the bottom of the top separator, where, driven by motor M 3 , a feeding screw 52 drives the chips slurry up under a dewatering process against the top separator's withdrawal strainer SC 1 . Drained chips will then be fed out from the upper outlet of the separator in a conventional way and fall down into the digester. In the case a hydraulic digester is used, the top separator is turned up-side down and feeds the chips down into the digester.
[0059] The, from the top separator 51 , drained liquid is led through a line 40 back to the processing vessel 3 , and may preferably be added to the bottom of the processing vessel, to there facilitate feeding out under dilution.
[0060] Alternatively, the line 40 may be connected to the position for the outlet of line 41 in the processing vessel 3 and line 41 may be connected to the position for the outlet of line 40 in the processing vessel 3 , according to the concept CrossCirc™ marketed by Metso Paper. In a variation, the flow of line 40 and 41 may be mixed at the intersection of lines 40 and 41 in FIG. 1 .
[0061] The digester 6 may be fitted with a number of digester circulations and a supply of white liquor to the top of the digester or to the digester's supply flows (not shown). The figure shows a withdrawal of cooking liquor via strainer SC 2 . The cooking liquor drawn off from strainer SC 2 is known as black liquor and may have a somewhat higher content of remaining alkali than black liquor that is normally sent directly to recycling and normally drawn off further down in the digester. The cooked chips P are then fed out from the bottom of the digester with the help of a conventional bottom scraper 7 and the cooking pressure.
Second Embodiment
[0062] FIG. 2 shows an alternative embodiment which does not include a top separator. Instead the transfer lines 13 a , 13 b (only two are shown in FIG. 1 ) open directly into the top of the digester. Excess liquid is then drawn off with a digester strainer SC 1 arranged in the digester wall. FIGS. 7 and 8 show this in more detail. The remaining parts of this embodiment correspond to the digester system shown in FIG. 1 .
[0063] FIG. 8 shows how 4 transfer lines 13 a , 13 b , 13 c and 13 d may open directly into the top of the digester. These outlets may preferably be arranged symmetrically in the top of the digester with a distribution in the horizontal plane of 90° between each outlet if there are 4 outlets (120° if there are 3 outlets and 180° if there are 2 outlets). The outlets are suitably arranged at a distance of 60-80% of the digester radius. FIG. 7 shows how the transfer lines 13 a , 13 b and 13 c open directly down into the top of the digester and thereby distribute the chips over the cross section of the digester. In this case a steam phase digester is shown where steam ST and/or pressurised air P AIR is added to the top of the digester, in which a chips level CH LEV is established above the liquid level LIQ LEV in the top of the digester. Excess liquid is drawn off with a strainer SC 2 and collected in a withdrawal space 51 before being led back in line 41 .
[0064] An advantage with the second embodiment, but also with the first embodiment, is that each pump may be closed independently while the remaining pumps may continue pumping at optimal efficiency and without requiring modification of the feed system itself.
[0065] The invention is not limited to the above mentioned embodiments. More variations are possible within the scope of the following claims.
[0066] In the embodiment shown in FIG. 2 , in some applications the strainer SC 1 and the return line 40 may for example be omitted, preferably for cooking of wood material with a higher bulk density, such as hardwood (HW), that for a corresponding production volume require less liquid during transfer.
[0067] In the case where a raw wood material that is easy to impregnate and neutralise is used, for example raw wood material such as pin chips or wood chips with very weak dimensions and a quick impregnation time, vessel 3 may in extreme cases be a simple spout with a diameter essentially corresponding to the bucket formed outlet 10 in the bottom of the vessel.
[0068] If the chips fed into the vessel 3 are already well steamed, the liquid level LIQ LEV may be established above a chips level CH LEV .
[0069] In the embodiments shown, an alkali pre-treatment was used in vessel 3 , but it is also possible to use a process where this pre-treatment comprises acid pre-hydrolysis.
|
The feed system is for a continuous digester where at least two pumps are arranged in parallel at the bottom of a pre-treatment vessel. Each pump has its own independent transfer line extending to the top of the digester. The system makes it possible to provide a feed system with an improved accessibility and operational reliability, and to operate the main part of the pumps at optimal efficiency even if the production capacity is reduced.
| 3
|
[0001] This application is a continuation of U.S. patent application Ser. No. 12/355,619, filed on Jan. 16, 2009, which claims priority to U.S. Provisional Application Serial No. 61/021,404, filed Jan. 16, 2008.
BACKGROUND
[0002] The present invention relates generally to large containers, in particular dumpsters that can be lifted and dumped by forks of a refuse or recycling truck. Traditionally, these dumpsters were constructed of metal with metal pockets welded to side walls for receiving the forks of the truck. A more recent dumpster is constructed entirely of plastic. The pockets on the side walls are integrally molded with the walls of the dumpster in a rotomolding process.
SUMMARY
[0003] The present invention provides several embodiments of plastic dumpsters with improved strength and durability.
[0004] In one embodiment, gussets connect pockets to bevel walls, connecting the side walls to front and rear walls of the dumpster. The bevel walls are stronger than the side walls of the dumpster. Other embodiments disclose gussets integral with front and rear walls of the dumpster for improved strength. Other embodiments disclose removable, separately formed sleeves that are secured to the sides of the dumpster to form pockets for receiving the forks of a truck.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a perspective view of a dumpster according to a first embodiment.
[0006] FIG. 2 is a front view of the dumpster of FIG. 1 .
[0007] FIG. 3 is a side view of the dumpster of FIG. 1 .
[0008] FIG. 4 is a section view of the dumpster of FIG. 1 .
[0009] FIG. 5 is a section view through one of the pockets of the dumpster of FIG. 1 .
[0010] FIG. 6 is a front view of the dumpster of FIG. 1 .
[0011] FIG. 7 is a rear view of the dumpster of FIG. 1 .
[0012] FIG. 8 is a top view of the dumpster of FIG. 1 .
[0013] FIG. 9 is a bottom view of the dumpster of FIG. 1 .
[0014] FIG. 10 is a perspective view of a dumpster according to a second embodiment.
[0015] FIG. 11 is a section view through one of the pockets of the dumpster of FIG. 10 .
[0016] FIG. 12 is a perspective view of a dumpster according to a third embodiment.
[0017] FIG. 13 is a side view of the dumpster of FIG. 12 .
[0018] FIG. 14 is a section view through one of the pockets of the dumpster of FIG. 12 .
[0019] FIG. 15 is a perspective view of a dumpster according to a fourth embodiment.
[0020] FIG. 16 is a section view through one of the pockets of the dumpster of FIG. 15 .
[0021] FIG. 17 is a perspective view of a dumpster according to a fifth embodiment.
[0022] FIG. 18 shows the dumpster of FIG. 17 with the lids removed.
[0023] FIG. 19 is a bottom perspective view of the dumpster of FIG. 18 .
[0024] FIG. 20 shows the dumpster of FIG. 18 with the sleeves removed.
[0025] FIG. 21 is a top view of the dumpster of FIG. 20 .
[0026] FIG. 22 is a section view taken along line 22 - 22 of FIG. 21 .
[0027] FIG. 23 is a section view taken along line 23 - 23 of FIG. 21 .
[0028] FIG. 24 is a perspective view of one of the sleeves of the dumpster of FIG. 17 .
[0029] FIG. 25 is a rear view of the sleeve of FIG. 24 .
[0030] FIG. 26 is a horizontal section view through the sleeve of FIG. 24 .
[0031] FIG. 27 is a vertical section view through the sleeve of FIG. 24 .
[0032] FIG. 28 is a section view through one set of supports and one sleeve of the dumpster of FIG. 17 .
[0033] FIG. 29 is a side view of the dumpster of FIG. 17 with a similar dumpster nested therein.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0034] A dumpster 10 according to a first embodiment of the present invention is shown in FIG. 1 . The dumpster 10 includes a base wall 12 , front wall 14 , side walls 16 and a rear wall 46 ( FIGS. 3 and 4 ) defining an interior of the dumpster 10 . Between the front wall 14 and side walls 16 are front bevel walls 18 . Between the rear wall 46 and side walls 16 are rear bevel walls 19 .
[0035] The dumpster 10 includes pockets 20 adjacent each side wall 16 . An upper gusset 22 above the pocket and a lower gusset 24 below the pocket 20 are integral with the rear bevel wall 19 . An upper gusset 28 above the pocket and a lower gusset 30 below the pocket 20 are integral with the front bevel wall 18 . The gussets 22 , 24 , 28 , 30 support and reinforce the pockets 20 . The pockets 20 include openings 32 for receiving the fork of a truck for lifting and dumping the dumpster 10 .
[0036] By virtue of the connected perpendicular walls, the joints between the side walls and the front or rear wall of a container (usually the “corners,” and here including the bevel walls) are inherently stronger and more rigid than the walls themselves. By positioning the gussets 22 , 24 , 28 , 30 in the corners (i.e. the bevel walls 18 , 19 ) in the dumpster 10 , the connection of the pockets 20 to the dumpster 20 is stronger and more rigid.
[0037] The dumpster 10 may include optional casters 36 on the base 12 .
[0038] As shown, the upper edges of the side walls 16 are angled downwardly toward the front wall 14 . The upper edges of the walls 14 , 16 , 46 include a lip 38 that reinforces the walls and accommodates a hinge 42 connecting a pair of lids 40 to the rear wall 46 .
[0039] FIG. 2 is a front view of the dumpster 10 . FIG. 3 is a side view of the dumpster 10 , showing the gussets 22 , 24 , 28 , 30 connected only to the bevel walls 18 , 19 .
[0040] FIG. 4 is a perspective interior view of the dumpster 10 , partially broken away. The base 12 may include convex portions 13 for reinforcement. The lip 38 is hollow, as shown. A center wall 48 extends outwardly from the rear bevel wall 19 to the pocket 20 . The gussets 22 , 24 on the rear bevel wall 19 are open to the interior of the dumpster 10 . The upper gusset 22 includes a first wall 50 extending from the rear bevel wall 19 to the center wall 48 , a second wall 52 adjacent the first wall 50 and extending from the rear bevel wall 19 to an area proximate the outer edge of the pocket 20 and a third wall 54 adjacent the second wall 52 and extending from the bevel wall 19 across a portion of the pocket 20 .
[0041] Similarly, the lower gusset 24 includes a first wall 56 extending upwardly from the rear bevel wall 19 to the center wall 48 , a second wall 58 adjacent the first wall 56 and extending from the rear bevel wall 19 to an area proximate the outer edge of the pocket 20 and a third wall 60 adjacent the second wall 58 and extending from the bevel wall 19 across a portion of the pocket 20 .
[0042] As can be seen in FIG. 4 , apertures 73 are formed through the side wall 16 above and below the pocket 20 .
[0043] The apertures 73 are also shown in FIG. 5 , which illustrates a portion of the pocket 20 , sectioned laterally and longitudinally. The pocket 20 includes an upper wall 68 , a lower wall 64 and an outer wall 66 . The upper wall 68 includes alternating single wall sections 76 and box beam sections 80 , thereby defining alternating channels 78 above the single wall sections 76 between the box beam sections 80 . The box beam sections 80 define apertures 73 that open to the interior of the dumpster 10 ( FIG. 3 ). The lower wall 64 includes alternating single wall sections 70 and box beam sections 72 , thereby defining alternating channels 74 above the single wall sections 70 between the box beam sections 72 . The box beam sections 72 define apertures 73 that open to the interior of the dumpster 10 ( FIG. 3 ).
[0044] FIGS. 6-9 are front, rear, top and bottom views of the dumpster 10 , without the lids 40 or casters 36 .
[0045] FIG. 10 is a perspective view of a dumpster 110 according to a second embodiment. The dumpster 110 includes a base wall 112 , front wall 114 , side walls 116 and a rear wall 146 defining an interior of the dumpster 110 . The dumpster 110 includes pockets 120 adjacent each side wall 116 . The pockets 120 define openings 132 for receiving a fork of a truck. A lip 138 is defined around the upper edges of the walls. Lids 140 may be connected via a hinge 142 .
[0046] Each pocket 120 is supported by the front wall 114 and rear wall 146 which extends outward continuously to circumscribe the opening 132 of the pocket 120 .
[0047] FIG. 11 illustrates one of the pockets 120 in more detail in section. The pocket 120 includes a lower wall 164 , outer wall 166 , inner wall 167 and upper wall 168 that define the opening 132 through the pocket 120 . The lower wall 164 is formed similarly to that of the embodiment of FIGS. 1-9 , having box beam sections 172 having openings 173 into the interior of the dumpster 110 . Over the side walls 116 , the lip 138 includes an upper wall 180 having an inner flange 182 extending downward from an inner edge thereof. A corrugated wall 184 extends downward from the outer edge of the upper wall 180 down to the upper wall 168 of the pocket 120 . The corrugations increase the rigidity and strength of the corrugated wall 184 to further support the pocket 120 , although most of the support for the pocket 120 comes from the front wall 114 and rear wall 146 . When the dumpster 110 is lifted by the fork, most of the weight of the dumpster 110 and its contents is transferred directly to the front wall 114 and rear wall 146 .
[0048] FIGS. 12-14 illustrate a dumpster 210 according to a third embodiment. The dumpster 210 includes a base wall 212 , front wall 214 , side walls 216 and rear wall 246 . Pockets 220 are adjacent side walls 214 and are reinforced by rear gussets 222 , 224 and front gussets 228 , 230 .
[0049] Referring to FIG. 13 , the upper rear gusset 222 includes a first wall 250 , second wall 252 and third wall 254 all supporting the pocket 220 . The third wall 254 is generally parallel to the rear wall 246 of the dumpster 210 so that weight is transferred directly to the side wall 216 , while the first wall 250 is generally a continuous extension of the outer wall of the lip 238 . Similarly, the lower rear gusset 224 includes a first wall 256 , second wall 258 and third wall 260 , with the third wall 260 being generally parallel to the rear wall 246 of the dumpster 210 and connected to the side wall 216 .
[0050] The front gussets 228 , 230 each have three walls extending to the pocket 220 in a similar manner, such that the innermost walls of the gussets 228 , 230 are generally continuous extensions of the front wall 214 . Additionally, the outermost wall of the upper gusset 228 is generally a continuous extension of the outer wall of the lip 238 .
[0051] Referring to FIG. 14 , the pocket 220 has walls that are generally formed with alternating single wall sections and box beam sections, as described above with respect to the embodiment of FIGS. 1-9 .
[0052] FIGS. 15 and 16 illustrate a dumpster 310 according to a fourth embodiment. The dumpster 310 includes a base wall 312 , front wall 314 , side walls 316 and rear wall 346 . The pockets 320 are each formed by a sleeve 390 inserted (or, alternatively, insert-molded) into a front support 392 and a rear support 394 .
[0053] The supports 392 , 394 are reinforced by gussets 328 , 322 . Additional gussets below the supports 392 , 394 could optionally be used. Referring to FIG. 16 , the upper front gusset 328 includes a wall 329 extending perpendicularly to the side wall 316 and to the pocket 320 .
[0054] The sleeves 390 could be formed of a material different from that of the rest of the dumpster 310 . For example, the sleeves 390 could be metal, or the sleeves 390 could be a higher-density polymer. If plastic, the sleeves 390 could be injection molded or extruded. The sleeves 390 could be removable, such that damaged sleeves 390 could be replaced.
[0055] A dumpster 410 according to a fifth embodiment is shown in FIGS. 17-21 . Referring to FIG. 17 , the dumpster 410 includes a base wall 412 , front wall 414 , side walls 416 and rear wall 446 ( FIG. 18 ). A hollow lip 438 extends around the upper edge of the periphery of the dumpster 410 . Lids 440 are hingeably mounted on the dumpster 410 . Pockets 420 are each formed by a sleeve 490 inserted (or, alternatively, insert-molded) into a front support 492 and a rear support 494 .
[0056] The supports 492 , 494 are reinforced by upper gussets 428 , 422 . Stacking posts 506 are formed below the supports 492 , 494 . The sleeves 490 could be formed of a material different from that of the rest of the dumpster 410 . For example, the sleeves 490 could be metal, or the sleeves 490 could be a higher-density polymer. The sleeves 490 could be removable, such that damaged sleeves 490 could be replaced. The sleeves 490 each include a front flange 496 , including a large inner flange portion 498 .
[0057] FIG. 18 shows the dumpster 410 with the lids removed to show the interior. The upper gusset 422 includes an outer wall 422 a extending at an angle from the lip 438 to an inner wall 494 a of the support 494 . The upper gusset 422 also includes generally triangular side walls 422 b extending between the side walls 416 of the dumpster 410 to the inner wall 494 a of the support 494 . The upper edge of the lip 438 includes stacking recesses 508 aligned with the stacking posts 506 .
[0058] FIG. 19 is a bottom perspective view of the dumpster 410 of FIG. 18 . The base wall 412 includes a plurality of recesses 510 for receiving plates of casters (e.g. casters 36 of FIG. 1 ).
[0059] FIG. 20 shows the dumpster 410 without the lids 440 or sleeves 490 . In the illustrated embodiment, what is shown in FIG. 20 is rotomolded as a single piece. The lids 440 and sleeves 490 are subsequently attached.
[0060] FIG. 21 is a top view of the dumpster 410 of FIG. 20 . FIG. 22 is a section view taken along line 22 - 22 of FIG. 21 . FIG. 23 is a section view taken along line 23 - 23 of FIG. 21 . As shown, each pocket support 494 includes an inner wall 494 a spaced inwardly of the pocket support 494 .
[0061] The sleeve 490 is shown in more detail in FIGS. 24-27 . The sleeve 490 includes the front flange 496 around the periphery of the front opening of the sleeve 490 . The inner flange portion 498 is larger than the remainder of the front flange 496 and includes a convex outer surface 500 protruding outwardly. The convex outer surface 500 protects the outer surface of the front wall 414 of the dumpster 410 from the fork and helps redirect the fork into the sleeve 490 . The sleeve 490 further includes an elongated hollow body portion 502 , which in the example shown is tapered toward the rear of the sleeve 490 . At least one, and optionally several, protruding retainers 504 are integrally formed in the body portion 502 of the sleeve 490 . One is shown formed in the front surface of the sleeve 490 , and a second retainer 504 is formed one the rear surface of the example sleeve 490 (as can be seen in FIG. 25 ), but the upper and lower surfaces could also be used. The retainers 504 are sized and positioned to snap-fit past the front supports 492 to retain the sleeves 490 in the supports 492 , 494 , as shown in FIG. 28 . Alternatively, recesses could be formed in the sleeves 490 , with corresponding protrusions formed in the supports 492 , 494 . Additional, or alternate, fasteners (e.g. screws, rivets, etc) could also fasten the sleeves 490 to the dumpster 410 .
[0062] Referring to FIG. 28 , the retainers 504 and the sleeve 490 deform as the sleeve 490 is inserted through the front support 492 and then the retainers 504 snap behind the support 492 to prevent the unintended removal of the sleeve 490 forwardly from the support 492 . Meanwhile, the front flange 496 and the taper of the body portion 502 prevent the sleeve 490 from sliding rearwardly in the supports 492 , 494 .
[0063] During use, the sleeves 490 will be subject to impact from the forks of the truck, but can be replaced by releasing the sleeve 490 by depressing the retainers 504 and sliding the sleeve 490 forwardly.
[0064] FIG. 29 illustrates the dumpster 410 (without lids 440 ) with a similar dumpster 410 ′ nested therein, such as for shipping or for storage. The stacking posts 506 ′ of the upper dumpster 410 ′ are received in the stacking recesses 508 of the lower dumpster 410 for more stable stacking and better transfer of the weight of the upper dumpster 410 ′ to the lower dumpster 410 .
[0065] The dumpsters 10 , 110 , 210 , 310 , 410 disclosed herein can be rotomolded plastic dumpsters; however, other manufacturing techniques could conceivably be used instead or in addition to rotomolding. The dumpsters 10 , 110 , 210 are disclosed as having integrally molded pockets, but alternatively the pockets could be formed separately and subsequently attached.
[0066] In accordance with the provisions of the patent statutes and jurisprudence, exemplary configurations described above are considered to represent a preferred embodiment of the invention. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope. Alphanumeric identifiers on method steps are for convenient reference in dependent claims and do not signify a required sequence of performance unless otherwise indicated in the claims.
|
Several embodiments of plastic dumpsters with improved strength and durability are disclosed. In one embodiment, gussets connect pockets to bevel walls, connecting the side walls to front and rear walls of the dumpster. The bevel walls are stronger than the side walls of the dumpster. Other embodiments disclose gussets integral with front and rear walls of the dumpster for improved strength. Other embodiments disclose removable, separately formed sleeves that are secured to the sides of the dumpster to form pockets for receiving the forks of a truck.
| 8
|
TECHNICAL FIELD
[0001] The invention relates to a method of bonding by eutectic bonding of two semiconductor substrates and a MEMS device formed by the same.
BACKGROUND ART
[0002] As a bonding method of these kinds of semiconductor substrates, a method has been known in which a silicon wafer formed with a MEMS structure has a germanium layer and a silicon wafer formed with integrated circuits has an aluminum containing layer, the germanium layer and the aluminum containing layer are faced to each other to be pressurized and heated, and an eutectic alloy made of the germanium and aluminum fixed to each other is formed (Patent Document 1).
[Patent Document 1] U.S. Pat. No. 7,442,570
DISCLOSURE OF THE INVENTION
Problems that the Invention is to Solve
[0004] In such a bonding method, in a case that the germanium layer and the aluminum containing layer are film-formed on a whole bonding surface of the semiconductor substrates, the eutectic alloy made of the germanium and the aluminum might be formed to be pressed out from the bonding surface by the pressurization. In other words, in this case, the eutectic alloy formed to be pressed out might be conducted to an electrode formed around the bonding surface of the semiconductor substrate, and there arises a problem such that a device is defective, making productivity lower.
[0005] In view of the foregoing problem, it is an object of the invention to provide a method of bonding a semiconductor substrate without letting an eutectic alloy press out from a bonding surface in eutectic bonding and to provide a MEMS device formed by the same.
Means for Solving the Problems
[0006] According to one aspect of the invention, there is provided a method of bonding a semiconductor substrate in which a first semiconductor substrate is bonded with a second semiconductor substrate by eutectic bonding with pressurization and heating, an aluminum containing layer primarily made of aluminum and a germanium layer in a polymer state being interposed between a bonding surface of the first semiconductor substrate and a bonding surface of the second semiconductor substrate. The method has a step of receding an outer end of the germanium layer inward with respect to an outer end of the aluminum containing layer as to the aluminum containing layer and the germanium layer in the polymer state.
[0007] According to the structure above, since the outer end of the germanium layer is receded inward with respect to the outer end of the aluminum containing layer, a formed eutectic alloy does not protrude from the bonding surface even if the eutectic alloy in a melting state by the pressurization spreads to an outside. Therefore, undesirable conduction to an electrode can be avoided and productivity of the device can be improved. The length from the outer end of the aluminum containing layer to the receded outer end of the germanium layer is preferably equal to or less than 20 μm. Further, the aluminum containing layer and the germanium layer may be film-formed on either the first semiconductor substrate or the second semiconductor substrate. Still further, the aluminum containing layer and the germanium layer may be film-formed on a bonding surface of a same semiconductor substrate or on bonding surfaces of different semiconductor substrates.
[0008] In this case, it is preferable that heating temperature and heating time of the pressurization and heating be controlled for alloying the germanium layer and the aluminum containing layer by eutectic bonding except an outer end portion of the aluminum containing layer.
[0009] According to the structure above, it is possible to control an area where the eutectic alloy is formed accurately, and to efficiently avoid that the formed eutectic alloy protrudes from the substrates.
[0010] In these cases, it is preferable that the aluminum containing layer and the germanium layer be film-formed on either the first semiconductor substrate or the second semiconductor substrate.
[0011] According to the structure above, since a metal film does not need to be film-formed on the other semiconductor substrate, a film formation process before bonding the semiconductor substrate can be omitted, thereby a bonding process can be simplified.
[0012] In this case, it is preferable that the aluminum containing layer be film-formed in a ring shape in planar view as having predetermined width, and the germanium layer have one or more strip layer sections film-formed in a ring shape in planar view on the aluminum containing layer.
[0013] According to the structure above, since the eutectic alloy is formed consecutively in a direction orthogonal to an inner/outer direction of the semiconductor substrate, it is possible to bond the semiconductor substrate with high sealing characteristics.
[0014] Further in this case, it is preferable that the aluminum containing layer be film-formed in a ring shape in planar view as having predetermined width, and the germanium layer have a strip layer section film-formed in a ring shape in planar view and a plurality of branch layer sections branched from the strip layer section on the aluminum containing layer.
[0015] According to the structure above, since a total extension of a contact end of the germanium layer to the aluminum containing layer can be longer, the eutectic alloy formed by the heating and pressurization tends to fix on the first semiconductor substrate and bonding with high bonding strength can be performed.
[0016] In these cases, it is preferable that the aluminum containing layer and the germanium layer be film-formed on the second semiconductor substrate and a pit be formed on the bonding surface of the first semiconductor substrate, in which a eutectic alloy generated by the pressurization and heating fills.
[0017] According to the structure above, the eutectic alloy in the melting state formed in a vacuum by the heating and the pressurization fills in the pit by capillary phenomenon. This leads the eutectic alloy to spread in the pit thoroughly, thereby, since the eutectic alloy layer is formed to bite in the first semiconductor substrate, bonding strength of the bonding section can be increased. The pit formed in the first semiconductor substrate may be a plurality of apertures formed intermittently or a slit-like groove formed consecutively.
[0018] According to the other aspect of the invention, there is provided a MEMS device bonded by the above bonding method of the semiconductor substrate. The first semiconductor substrate has a MEMS structure formed to be engraved at the bonding surface side thereof, and the second semiconductor substrate has an integrated circuit formed at the bonding surface side to control the MEMS structure.
[0019] According to the structure, the substrates are bonded to avoid conduction to an undesired electrode, electric conducts of the MEMS structure, the integrated circuit and an outer circuit are maintained, and the MEMS structure and the integrated circuit are packaged integrally to protect against an outer environment such as moisture, temperature, dust and the like. Therefore, it is possible to provide a MEMS device having high precision.
[0020] Further in this case, it is preferable that the MEMS sensor above is either one of an acceleration sensor, an angular velocity sensor, an infrared ray sensor, a pressure sensor, a magnetic sensor and a sonic sensor.
[0021] According to the structure above, with the efficient package, it is possible to provide the acceleration sensor, the angular velocity sensor, the infrared ray sensor, the pressure sensor, the magnetic sensor and the sonic sensor having high precision.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIGS. 1A and 1B are schematic appearance perspective views of a MEMS chip and a CMOS chip according to an embodiment.
[0023] FIG. 2 is a schematic perspective view of a MEMS device according to the embodiment.
[0024] FIGS. 3A and 3B are cross sectional views illustrating film formation arrangement of an aluminum containing layer and a germanium layer according to the embodiment.
[0025] FIG. 4 is a table describing film thickness of the aluminum containing layer and the germanium layer, a weight ratio of the germanium layer to the aluminum containing layer, and numeric values of a sealing ratio and share strength (bonding strength) of a bonding section.
[0026] FIGS. 5A and 5B are graphs illustrating relationships among a weight ratio of the germanium layer to the aluminum layer, the sealing ratio and the share strength of the bonding section after eutectic bonding.
[0027] FIG. 6A is an elevation view and FIG. 6B is a cross sectional view illustrating film formation arrangement of the aluminum containing layer and the germanium layer according to a first modification of the embodiment.
[0028] FIG. 7A is an elevation view and FIG. 7B is a cross sectional view illustrating film formation arrangement of the aluminum containing layer and the germanium layer according to a second modification of the embodiment.
[0029] FIG. 8A is an elevation view and FIG. 8B is a cross sectional view illustrating film formation arrangement of the aluminum containing layer and the germanium layer according to a third modification of the embodiment.
[0030] FIG. 9A is an elevation view and FIGS. 9B and 9C are cross sectional views illustrating film formation arrangement of the aluminum containing layer and the germanium layer according to the other embodiment.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0031] Referring to the accompanying drawings, a method of bonding a semiconductor and a MEMS device according to one embodiment of the invention will be explained. In the method of bonding a semiconductor substrate according to the embodiment, a MEMS wafer having a number of sensing sections is faced to a CMOS wafer having a number of integrated circuits each of which controls each sensing section to bond by eutectic bonding via metal. In other words, in the invention, the formed MEMS sensor and the integrated circuits are formed in separate processes to face each other and are bonded by eutectic bonding. In the eutectic bonding, a wafer level package technology (WLP technology) is used, by which wafers are sealed collectively as they are, and then are cut off into each chip.
[0032] A MEMS device according to the embodiment is fabricated by such eutectic bonding, and, for example, may be conceived as an acceleration sensor, an angular velocity sensor, an infrared ray sensor, a pressure sensor, a magnetic sensor and a sonic sensor.
[0033] FIG. 1A illustrates a piece in close-up of MEMS wafers (not illustrated) in which a plurality of sensing sections 12 are formed in a matrix shape. Hereinafter, a MEMS chip 10 as the piece will be explained for convenience.
[0034] As illustrated, the MEMS chip 10 has a substrate 11 made of Silicon (Si) and a sensing section 12 formed at a center of the substrate 11 by micro fabrication technology. The sensing section 12 is formed to be engraved at the center of the substrate 11 and is composed of elements of an acceleration sensor, an angular velocity sensor, an infrared ray sensor, a pressure sensor, a magnetic sensor, a sonic sensor or the like. Further, the substrate 11 has a ring-shaped bonding section 30 a in a planar view which surrounds the sensing section 12 . In the MEMS chip 10 in the embodiment, the sensing section 12 and the bonding section 30 a are turned over to be upside down to face the CMOS chip 20 described later and the MEMS chip 10 is bonded with the CMOS chip 20 . Then, the bonding section 30 a of the MEMS chip 10 is confronted with a bonding section 30 b formed in the CMOS chip 20 , and both are bonded by eutectic bonding via a metal layer film-formed on the bonding section 30 b . The substrate 11 corresponds to a first semiconductor substrate and the sensing section 12 corresponds to a MEMS structure in claims.
[0035] FIG. 1B illustrates apiece in close-up from a CMOS wafer (not illustrated) in which a plurality of integrated circuits 22 are formed in a matrix shape. The CMOS chip 20 as the piece, similar to the MEMS chip 10 , will be explained. The CMOS chip 20 has a substrate 21 made of silicon and the integrated circuit formed by micro fabrication technology (semiconductor fabrication technology) on the substrate 21 . Further, the ring-shaped bonding section 30 b in a planar view is disposed to surround a circuit central section 23 of the integrated circuit 22 facing the sensing section 12 of the MEMS chip 10 at the time of eutectic bonding. The integrated circuit 22 controls the sensing section 12 of the MEMS chip 10 and is connected to input/output signal lines from an outside.
[0036] Further, the integrated circuit 22 has aluminum wirings, and an aluminum containing layer 31 film-formed at the time of aluminum wiring formation becomes a part of an eutectic alloy at the bonding. In other words, the bonding section 30 b of the CMOS chip 20 is formed in a same shape approximately in a planar view with the bonding section 30 a of the MEMS chip 10 . At the bonding section 30 b of the CMOS chip 20 , the aluminum containing layer 31 as the eutectic alloy is film-formed on the substrate 11 and a germanium layer 32 as the eutectic alloy is film-formed on the aluminum containing layer 31 (for example, film formation by sputtering or vapor deposition technology). The substrate 21 corresponds to a second semiconductor substrate and the bonding section 30 b corresponds to a bonding section of the second semiconductor substrate.
[0037] FIG. 2 illustrates a MEMS device 1 formed by dicing or breaking the MEMS wafer and the CMOS wafer after the bonding (lamination bonding). As illustrated, the MEMS device 1 is made up of the bonded MEMS chip 10 and the CMOS chip 20 such that the sensing section 12 faces the circuit central section 23 .
[0038] At the time of bonding, the MEMS chip 10 (MEMS wafer) and the CMOS chip 20 (CMOS wafer) are confronted, are heated from both sides, that is, from the MEMS chip 10 side and the CMOS chip 20 side under vacuum environment and are pressurized from the MEMS chip 10 side. Thus, the germanium layer film-formed at the bonding section 30 b of the CMOS chip 20 develops eutectic reaction at a boundary surface with the aluminum containing layer 31 , and an aluminum-germanium alloy (hereinafter, refereed as eutectic alloy) is formed. Especially, the eutectic alloy in a melting state is pressed against a silicon surface of the bonding section 30 a to be welded by the pressurization from the MEMS chip 10 side, and then, is fixed to be bonded solidly. Further, the eutectic bonding achieves electrical conduction between the substrates 11 and 21 and high sealing characteristics. Heating temperature at the time of bonding is preferably around 450° C. in consideration of heating damage to the sensing section 12 and the integrated circuit 22 . Further, the pressurization at the time of bonding may be performed from CMOS chip 20 side or from both the MEMS chip 10 side and the CMOS chip 20 side. Then, after the bonding, an individual MEMS device 1 is fabricated through separation process from a wafer to each chip.
[0039] Referring to FIGS. 3A and 3B , a film formation arrangement (film formation pattern) of the aluminum containing layer 31 and the germanium layer 32 will be explained. FIGS. 3A and 3B are enlarged views of the A-A line cross section in FIG. 2 . As illustrated in FIG. 3A , the aluminum containing layer 31 is evenly film-formed on the bonding section 30 b of the CMOS chip 20 in a state before the eutectic bonding. Further, the germanium layer 32 on the aluminum containing layer 31 is film-formed such that an outer end 32 a of the germanium layer 32 is receded inward with respect to an outer end 31 a of the aluminum containing layer 31 . While, any metal layer is not film-formed at all on the bonding section 30 a of the MEMS chip 10 and a silicon surface of the substrate 11 is barely formed. From this state, an eutectic alloy layer 33 is formed between the substrates 11 and 21 by the bonding method described above as illustrated in FIG. 3B , and the MEMS chip 10 and the CMOS chip 20 are bonded by eutectic bonding. In the eutectic bonding of the embodiment, the pressurization and the heating is controlled appropriately, and a portion of the aluminum containing layer 31 which is not in contact with the germanium layer 32 remains without eutectic action (residual portion 34 ). In this case, the germanium layer 32 is preferably film-formed thinner than the aluminum containing layer 31 for the purpose of effective eutectic reaction.
[0040] Thus, in a case that a metal layer is not film-formed at the MEMS chip 10 side before the bonding, a film formation process can be simplified after forming the sensing section 12 and undesired effect such as deformation, adhesion and breakage by film formation on a movable structure of the sensing section 12 as a thin film can be avoided. Further, since the aluminum containing layer 31 utilizes aluminum wirings of the integrated circuit 22 , metal film formation needed for actual bonding is only the germanium film formation on the bonding section 30 b of the CMOS chip 20 , thereby bonding process can be simplified. Still further, since the bonding section 30 is disposed to surround the sensing section 12 and the circuit central section 23 and the eutectic alloy layer 33 is formed in such away as to be orthogonal in an inner/outer direction of the facing MEMS chip 10 and the CMOS chip 20 , the MEMS chip 10 and the CMOS chip 20 can be bonded with high sealing characteristics and bonding strength. The aluminum containing layer 31 and the germanium layer 32 may be film formed on either bonding section of the MEMS chip 10 or of the CMOS chip 20 , and they may be film-formed on a bonding section of a same substrate or on bonding sections of different substrates.
[0041] Further, since the germanium layer 32 is film-formed such that the outer end 32 a of the germanium layer 32 is receded inward with respect to the outer end 31 a of the aluminum containing layer 31 , the formed eutectic alloy is formed without being pressed out from the bonding section 30 even if the eutectic alloy in the melting state expands to an outer side by pressurization at the time of bonding, thereby undesired conduction to an electrode can be avoided and productivity (an yield rate) of a device can be enhanced. Length from the outer end 31 a of the aluminum containing layer 31 to the outer end 32 a of the receded germanium layer 32 is preferably equal to or less than 20 μm.
[0042] Referring to FIGS. 4 to 5B , a weight ratio of the germanium layer 32 to the aluminum containing layer 31 at the time of bonding will be explained. In the bonding method of the embodiment, heating temperature and heating time as well as heating pressure is controlled for eutectic reaction between the whole germanium layer 32 and a part of the aluminum containing layer 31 in mutual bonding surfaces (see FIG. 3B ). In practice, the weight ratio of the germanium layer 32 to the aluminum containing layer 31 is controlled by mainly a film thickness ratio of the germanium layer 32 to the aluminum containing layer 31 . Therefore, the germanium layer 32 and the portion of the aluminum containing layer 31 in contact therewith directly react by eutectic reaction, and the residual portion of the aluminum containing layer 31 remains as it is (see FIG. 3B ).
[0043] FIGS. 4 to 5B illustrates a test result of eutectic bonding in which film thickness of the germanium layer 32 is changed arbitrary while film thickness of the aluminum containing layer 31 is set fixedly (800 nm). FIG. 4 illustrates relationships among film thickness of the aluminum containing layer 31 and the germanium layer 32 film-formed before the eutectic bonding, a weight ratio of the germanium layer 32 to the aluminum containing layer 31 , and a sealing ratio and share strength (bonding strength) of the bonding section after the eutectic bonding. While, FIG. 5A is a graph of the weight ratio of the germanium layer 32 to the aluminum containing layer 31 versus the sealing ratio of the bonding section after the eutectic bonding, and FIG. 5B is a graph of the weight ratio of the germanium layer 32 to the aluminum containing layer 31 versus the share strength (bonding strength) of the bonding section after the eutectic bonding.
[0044] As illustrated in FIG. 5A , when the weight ratio of the germanium layer 32 to the aluminum containing layer 31 is between 27 wt % and 57 wt %, the sealing ratio of the bonding section after the eutectic bonding is equal to or more than about 50%. Further, FIG. 5B illustrates that the bonding strength (share strength) of the bonding section after the eutectic bonding is equal to or more than about 30 N when the weight ratio of the germanium layer 32 is between 27 wt % and 52 wt %. Still further, when the weight ratio of the germanium layer 32 is between 33 wt % and 42 wt %, the sealing ratio is 100% and the share strength (bonding strength) is between 41.6 N and 56.3 N (see FIG. 4 ). In short, it becomes apparent by the test result that the bonding is performed with the highest sealing ratio and highest bonding strength when the eutectic bonding is performed by the method above with the weight ratio of the germanium layer 32 to the aluminum containing layer 31 as having 33 wt % to 42 wt %. This also indicates that good eutectic bonding can be obtained when the germanium layer 32 in the embodiment (film thickness of the aluminum containing layer 31 =800 nm) is film-formed between 200 nm and 300 nm thickness (see FIG. 4 ).
[0045] Referring to FIGS. 6A to 8B , a modification of the film formation arrangement of the aluminum containing layer 31 and the germanium layer 32 according to the embodiment will be explained. FIG. 6A illustrates a portion of the bonding section 30 b of the CMOS chip 20 before the eutectic bonding, and FIG. 6B illustrates a cross section of the bonding section 30 before the eutectic bonding (a first modification). As illustrated, the aluminum containing layer 31 is evenly film-formed on the bonding section 30 b of the CMOS chip 20 and the germanium layer 32 is film-formed on the aluminum containing layer 31 in a plurality of strips shape. In short, the germanium layer 32 is made up of a plurality of concentric strip layer sections 35 which have an identical shape.
[0046] In this kind of eutectic bonding, it has been known that the bonding strength is high at the end portion of the germanium layer 32 . Therefore, as the modification above, a total area of the end portion in the germanium layer 32 (strip layer sections 35 ) can be increased by film-forming the germanium layer 32 as the strip layer sections 35 , and strong eutectic bonding can be achieved without increasing an area of the bonding section 30 . Further, since the plurality of strip-shaped germanium layers 32 are disposed to be orthogonal in the inner/outer direction of the bonding section 30 , the MEMS chip 10 and the CMOS chip 20 can be bonded as having higher sealing characteristics and bonding strength.
[0047] FIGS. 7A and 7B illustrate a second modification of the film formation arrangement of the aluminum containing layer 31 and the germanium layer 32 according to the embodiment. As illustrated, in the film formation arrangement of the second modification, as the first modification, the aluminum containing layer 31 is evenly film-formed on the bonding section 30 of the CMOS chip 20 , and the germanium layer 32 film-formed on the aluminum containing layer 31 is integrally formed with a single strip layer section 35 and a plurality of branch layer sections 36 . The strip layer section 35 is formed in a square ring-shape along the aluminum containing layer 31 at a center of the aluminum containing layer 31 in a width direction. While, the plurality of branch layer sections 36 are film-formed so as to branch from each section of the strip layer section 35 to both sides at aright angle. Thus, a total area of the end portion of the germanium layer 32 (strip layer section 35 and branch layer sections 36 ) can be increased by forming the plurality of branch layer sections 36 (germanium layer 32 ) in a branch shape (fish's bone shape), thereby strong eutectic bonding can be achieved.
[0048] FIGS. 8A and 8B illustrate a third modification of the film formation arrangement of the aluminum containing layer 31 and the germanium layer 32 . As illustrated, the film formation arrangement of the third modification has a configuration in which the first modification is combined with the second modification. In other words, in the third modification, the aluminum containing layer 31 is evenly film-formed on the bonding section 30 b of the CMOS chip 20 , and the germanium layer 32 film-formed on the aluminum containing layer 31 is made up of a plurality of strip layer sections 35 and a plurality of branch layer sections 36 . More specifically, the germanium layer 32 is made up of concentric three strip layer sections 35 having an identical shape and the plurality of branch layer sections 36 which branch from each section of a centrally positioned strip layer section 35 to both side at a right angle. Thus, the MEMS chip 10 and the CMOS chip 20 can be bonded with higher sealing characteristics and bonding strength.
[0049] Referring to FIGS. 9A to 9C , the other embodiment (second embodiment) of the invention will be explained. Portions different from those of the above embodiment will be mainly explained and same numerals are labeled for similar elements. As illustrated in FIGS. 9A and 9B , the aluminum containing layer 31 film-formed on the bonding section 30 b of the CMOS chip 20 is made up of a plurality of aluminum ring-shaped layer sections 37 . The plurality of aluminum ring-shaped layer sections 37 are formed in a ring shape in a plan view concentrically with the bonding section 30 b , and are disposed to be orthogonal in the inner/outer direction of the bonding section 30 b . Further, a plurality of ring-shaped germanium layers 32 (germanium ring-shaped layer sections 38 ) are film-formed so as to fill in space of these aluminum ring-shaped layer sections 37 . In this case, the plurality of germanium ring-shaped layer sections 38 are film-formed to contact contact-ends of the plurality of aluminum ring-shaped layer sections 37 in a vertical direction and to slightly overlap thereon (overlap layer sections 40 ) in a horizontal direction.
[0050] While, as illustrated in FIG. 9B , a plurality of engraved pits 41 are formed on the bonding section 30 a of the substrate 11 . The plurality of pits 41 are formed to correspond to positions (the overlap layer sections 40 ) where the plurality of germanium ring-shaped layer sections 38 overlap on the plurality of aluminum ring-shaped layer sections 38 , and an alloy in a melting state after being heated and pressurized gets into the plurality of pits 41 . The plurality of pits 41 may be newly formed on the substrate 11 after the sensing section 12 has been formed, or engraved portions formed in the formation process of the sensing section 12 may be used. Further, the pits 41 may have intermittent aperture shape or consecutive groove shape.
[0051] FIG. 9C illustrates the bonding section after eutectic bonding. A eutectic alloy in a melting state formed by heating spreads into the plurality of pits 41 thoroughly by capillary action in vacuum by pressurization. Then, the fixed eutectic alloy layer 33 is formed to bite into the bonding section 30 (substrate 11 ) of the MEMS chip 10 . In other words, as illustrated, since the eutectic alloy layer 33 is formed vertically with respect to a surface direction of the bonding section, bonding with higher bonding strength can be achieved.
[0052] According to the structures, a semiconductor substrate can be bonded with high bonding strength and sealing characteristics at appropriate portions while adverse effect on the sensing section 12 is restrained. Further, such effective bonding enables the sensing section 12 , the integrated circuit 22 and the external circuit to conduct electrically, and high precision MEMS devices in which the sensing section 12 and the circuit central section 23 are integrally packaged can be provided while an external atmosphere such as moisture, temperature, dust and the like is avoided.
[0053] In the embodiment, the silicon wafers formed with the sensing section 12 and the integrated circuit 22 controlling the sensing section is used, but structures formed in the silicon wafer may be any circuits, not being limited thereto. Still further, a semiconductor substrate (composite semiconductor) having other base material instead of silicon wafer formed by silicon may be used. It is preferable that either one of the bonded semiconductor substrates have aluminum wirings.
REFERENCE NUMERALS
[0054] 1 MEMS device 10 MEMS chip 12 sensing section 11 , 12 substrate 20 CMOS chip 22 integrated circuit 31 aluminum containing layer 31 a , 32 a outer end 32 germanium layer 35 strip layer section 36 branch layer section 41 pit
|
Disclosed is a method for bonding semiconductor substrates, wherein an eutectic alloy does run off the bonding surfaces during the eutectic bonding. Also disclosed is an MEMS device which is obtained by bonding semiconductor substrates by this method. Specifically, a substrate ( 11 ) and a substrate ( 21 ) are eutectically bonded with each other by pressing and heating the substrate ( 11 ) and the substrate ( 21 ), while interposing an aluminum-containing layer ( 31 ) and a germanium layer ( 32 ) between a bonding part ( 30 a ) of the substrate ( 11 ) and a bonding part ( 30 b ) of the substrate ( 21 ) in such a manner that the aluminum-containing layer ( 31 ) and the germanium layer ( 32 ) overlap each other, with an outer edge ( 32 a ) of the germanium layer ( 32 ) being inwardly set back from the an outer edge ( 31 a ) of the aluminum-containing layer ( 31 ).
| 1
|
FIELD OF THE INVENTION
The present invention relates to light weight easily assembled and portable scaffolding.
BACKGROUND OF THE INVENTION
In building structures or repairing buildings, scaffolding is used as a work platform in order that workers can access raised portions that are not accessible from the ground. Some typical uses of scaffolding are in painting buildings, hanging rain gutter on steep roofs, laying of bricks or masonry and any other work which requires a worker to be off the ground to complete the task.
The most common scaffold is probably two saw-horses with a plank between them, however, this does not allow for work at extended heights. Another extremely common scaffold is the build as you go which must be torn down to move when that portion of the building or work area is complete. It also requires that the work station be torn down each time as elevation change is necessary.
There are also some mobile scaffolding which utilize a vertical tower structure in which the work platform is mounted on the tower and is driven up and down by motor. The device does not require a tear down to change elevation of the work station as the platform merely moves up and down the tower. Such devices are not easily utilized except on relatively flat terrain without obstacles.
Although the mobile scaffold is an improvement to the typical fixed scaffold, it lacks versatility to used where there are various obstacles such as fences and uneven terrain. In U.S. Pat. No. 5,067,587, Mims, Jr. et al, discloses a mobile scaffold, however it is a very bulky unit designed to be moved around by a vehicle and is not capable of accommodating obstacles and rough terrain.
In U.S. Pat. No. 4,194,591, Fisher discloses a pedestal scaffold which can be rolled around by a single person, however the device is bulky, not easily transported and is not beneficial for use on rough terrain or where there are various obstacles such as fences and the like.
Ream et al, U.S. Pat. No. 4,397,373 discloses a mobile pedestal scaffold having similar disadvantages as Fisher above. It is bulky, not easily transported and is basically unusable on rough terrain.
Novarini, U.S. Pat. No. 4,569,418 discloses a system which may be used as a fire escape for tall buildings however would be impractical for use as a scaffold and has all the disadvantages previously described as well as it is incapable of being easily transported by an individual.
Although Beeche, U.S. Pat. No. 4,234,055 shows a unique movable roof mounted suspension scaffold system it is quite cumbersome with extensive time required for tear down or erection and could not be managed by a single individual or easily transported.
As can be seen by the prior art there are no scaffold devices currently available which provide the benefits of being light weight, easily transported by a single individual such as in the back of a pickup truck, has minimum time required to set up or tear down and is readily adaptable to rough terrain and obstacles.
Additionally, one of the major difficulties with the use of scaffolding is the additional time required for the assemble and disassembly of the scaffolding. Even with the so called mobile scaffolding described hereinabove, there is substantial amounts of time required to get the equipment ready so that the actual work intended to be performed can be started. Additionally, the small contractor generally does not have the financial where with all to purchase these types of equipment even if they could do the job which they will not. Instead, many times a plank is run been two ladders or some other make shift device is utilized.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a light weight, portable, easily assembled electric lift which can be utilized on rough terrain and around obstacles such as fences and the like.
The portable scaffolding unit of the present invention includes a mast, a drive unit for raising and lowering the work platform, a base having outriggers with feet adjustable to rough terrain. The base is removable from the mast and the outriggers on the base fold up after the feet are removed from the outrigger for ease of being transported by a single individual. The mast which is sectioned for ease of transporting and use may be used with the sections together or individually when the full height of the device is not required. The mast has a rack mounted on it which is part of the drive means for raising and lowering the work platform. The drive unit has an electric motor with a 90 degree gear box and a pinion gear for interacting with the rack for raising and lowering the work platform.
If the portable scaffolding is to be used on flat surfaces, locking castors may be attached to the feet for further ease of movement of the scaffold.
It is another object of the present invention to provide a simple light weight, portable easily assembled electric lift which can be used singlely or in conjunction with another light weight portable easily assembled electric lift. The single unit would have a single basket work platform. When the present invention was used with another unit, it may be interconnected electrically so that the work platform on both units are raised and lowered in concert allowing a single individual to operate the device, however, where desired, each unit may be operated independently of each other where two individuals are utilizing the devices and need to have slightly different heights. When two units are utilized, a platform is extended between them forming a large work station on a single scaffolding.
As a further object of the invention it is the intention to provide a unit that is quickly assembled and disassembled and is easily transported without the need for a special vehicle thus reducing the time required to perform the intended task. Job site time is thus reduced making the job more profitable for contractor and less expensive for the building owner.
The present invention can be quickly assembled or disassembled and transported in the back of a pickup which is the vehicle utilized by many small contractors.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG 1 is a perspective view of the portable scaffolding unit of the present invention, in accordance with a preferred embodiment.
FIG. 2 is a side view of the mast sections.
FIG. 3 perspective view of the top cap of the mast.
FIG. 4 is a close up partial cross-sectional of the drive unit and work station support.
FIG. 5 is a partial top cross-sectional view of the drive unit of FIG. 4 taken along the lines 5--5.
FIG. 6 is partial sectional view of the base unit.
FIG. 7 is a top cross-sectional view of the base unit of FIG. 6 taken along the lines 7--7.
FIG. 8 is a cross-sectional of the base in FIG. 7 taken along the lines 8--8.
FIG. 9 is a cross-sectional of the drive unit of FIG. 5 taken along the lines 9--9.
FIG. 10 a perspective view of another embodiment of the present invention.
FIG. 11 is a top cross-sectional view of the drive unit of FIG. 10 taken along the lines 11--11.
FIG. 12 is a cross-sectional view of the worm drive of the drive unit of FIG. 11 taken along the lines 12--12.
FIG. 13 is a perspective view of two of the devices of the present invention used in conjunction with each other in accordance with a preferred embodiment.
FIG. 14 is a perspective view of a single unit of the present invention, in accordance with a preferred embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1 there is shown a perspective view of the portable scaffolding unit 10 of the present invention, in accordance with a preferred embodiment. The portable scaffolding unit 10 is generally used by setting it up adjacent to the wall or area of a building or structure to be worked on. The portable scaffolding unit 10 provides the worker a single basket platform 76 which moves up and down along the work area. The portable scaffolding unit 10 includes mast 30 and extension mast 32, drive unit 20, base 40, a plurality of outrigger 50, and a plurality of adjustable feet 56. The mast 30 and extension mast 32 are made of a strong light weight material such as aluminum and has a rack 34 affixed to one side as shown in FIG. 2. When mast 30 and extension mast 32 are used together, the worker can reach a height of approximately 30 feet. Mast 30 and extension mast 32 are joined together in a manner that the rack 34 of mast 30 and the rack 34 of extension mast 32 meet so as to provide a single continuous rack and the drive unit 20 will continue moving up extension mast 32 from mast 30 without interruption.
When the portable scaffold 10 is being setup after being transported a clevis pin 44 is inserted into each channel aperture 43 and outrigger aperture 45 after each outrigger 50 is unfolded by pivoting outrigger 50 on pivot 46 as shown in FIG. 6. In order to make base 40 easier to move, pivot 46 may be removed allowing each outrigger 50 to be completely removed for transportation. The adjustable foot 56 is then secured in foot receiver 52 for each outrigger 50 at the height necessary to adjust for the terrain with a clevis 54 being inserted through each aperture 51 and aperture 53 for each adjustable foot 56.
Drive unit 20 is adjusted on mast 30 so as to engage rack 34 with pinion gear 36 by adjusting both the upper and lower adjustment screw 27 forcing rack 34 against pinion gear 36. Drive unit 20 has guide 26, adjustment guide 28 and spacer 29 to allow drive unit 20 to move up and down mast 30 without slippage or galling. Spacer 29 generally extends the full distance on the rack side of the drive unit 20. Guide 26 and adjustment guide 28 and spacer 29 are made of materials which provide excellent wear and tensile strength such as a material known as UHMWPE (Ultra High Molecular Weight Polyethylene). In operation, drive unit 20 is adjusted within adjustment slot 47 by untightning each adjustment nut 25 and advancing or retracting adjustment screw 27 so that the rack 34 and pinion gear 36 mesh without excessive pressure or slop and then each adjustment nut 25 is tightened securing drive unit 20 in place on mast 30 for proper operation as shown in FIGS. 4 and 5. Drive unit 20 has motor 22 engaged to a 90 degree gear box 24 which drives shaft 38 and pinion gear 36 and provides an automatic brake when drive unit 20 is not operating up or down as shown in FIGS. 4 and 9. Drive unit 20 is connected to a typical 110 outlet by power cord 80 as seen in FIGS. 1, 10, 13, and 14.
The rack 34 and pinion gear 36 system may be replaced by the rack 90 and worm gear 92 as shown in FIGS. 11 and 12. When the rack 90 and worm gear 92 are used, the 90 degree gear box 24 is eliminated as the rack 90 and worm gear 92 provide an automatic brake.
In order to provide additional stability due to the torque from the work platform 72 or single basket platform 76, adjustable guy wires 62 are affixed to the guy angle 64 of the top cap 60 and to two of the outrigger 50 adjacent to the foot receiver 52 and on the opposite side as the work platform 72 or single basket platform 76 as shown in FIGS. 1, 3, 6, 10, 13, and 14. Further support may be added for heavier loads by inserting center support 49 which is slightly smaller than the inside dimensions of the mast 30 and securing it in place by mast clevis 42 as shown in FIG. 1.
When a worker desires to move the work platform 72 or single basket platform 76 up or down, he merely presses the up or down button (not shown) on the drive unit control 21. When two portable scaffold 10 are used by a single individual, the drive unit 20 are interconnected by dual drive interconnect cable 23 and operated by drive unit control 21 as shown in FIGS. 1, 10, 13, and 14.
When portable scaffold 10 is used on rough terrain, each adjustable foot 56 and center support 49 may utilize the swivel foot pad 59 which allows all of the weight on the adjustable foot 56 to be distributed a little more evenly as shown in FIG. 6.
In setting up the portable scaffold 10 for use by a single individual single basket platform 76 is affixed to the platform carrier 70. When two portable scaffold 10 are to be used in conjunction with each other, platform 72 is extended between platform carrier 70 on each portable scaffold 10. Single basket platform 76 and platform 72 have stage hand rails 74 and 78 respectively as shown in FIGS. 1, 13, and 14.
Although it is understood that many substitutions may be made as to materials such as molding the mast 30 and rack 34 as a single unit out of materials such as polycarbonate or other polymeric material having high strength and wear capabilities.
In the drawings and specification there has been set forth the best mode, presently contemplated, for the practice of the present invention, and although specific terms are employed, they are used in a generic and descriptive sense only and are not for purposes of limitation. Several modifications of the specific design features illustrated herein are permissible while still retaining the essential features of the tool of this invention without departing from the scope of the applicants invention.
|
A light weight, easily assembled, readily portable by a single individual, adjustable to most any terrain electric scaffold having a base with a plurality of outrigger members with adjustable feet to accommodate differential terrain wherein the base is affixed to a mast having a drive unit thereon capable of raising and lowering the work platform affixed thereto. The drive unit is plugged into any 110 outlet providing the required power for raising and lowering the work platform.
| 4
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to composite structures and their methods of manufacture, more particularly to structures used in composite aircraft construction.
2. Description of Related Art
Apparatus for the manufacture of structures from layers of composite material are well known. However, for some applications the existing apparatus has certain drawbacks.
Automated Tape Layer (ATL) apparatus places single layers of uncured composite pre-impregnated material on flat or contoured surfaces, but the apparatus is extremely complex and very expensive. The tape dispensed is unidirectional, so when making long, narrow parts where an angled ply or cross ply is needed, the tape laying head must traverse the part once for each width of tape, which makes the process extremely slow.
Another method of manufacturing composite parts is by use of Automated Fiber Placement (AFP) equipment. This is similar in nature to the ATL process discussed above, except that the material used is a thin ribbon or yarn, often referred to as a tow, of pre-impregnated composite material.
U.S. Pat. No. 5,954,917, assigned to the assignee of the present invention, and herein incorporated by reference, comprises a first station having at least one dispensing module, a second station where tape layers that have been deposited on the tool are vacuum treated in order to remove air entrapped between layers of the tape, and a track system which enables movement of the tool between the first and second stations as well as a tool storage station. In the apparatus of this patent and similar apparatus there are two established methods of obtaining the peripheral shape of the part in the form desired. In one method, each layer of composite material is pre-cut to its final dimensions at another station and then is kitted on spools for the final lay-up step. In another method the lay-up is performed with over-sized material, all compaction is performed and the part is either trimmed to shape at that point or cured to it's final condition and then trimmed. When a number of layers of composite material are trimmed, the ultrasonic knives that are customarily used, must travel very slowly.
Another method of manufacturing multiple layer composite parts is hand lay-up of the layers. In this method, the layers are usually trimmed to the proper shape and kitted at one station and then manually aligned with one another to build the lay-up desired. Correct positioning is handled either through physical templates or through projected light templates, usually using a projected laser system. While this method works, it is relatively slow, subject to human error, and not well suited to the production rates found in the manufacture of commercial aircraft.
Thus there is a need for a more efficient means of manufacturing multiple layer composite parts.
BRIEF SUMMARY OF THE INVENTION
According to a number of embodiments, the present invention is a novel system for lay-up of multiple layer composite parts in which executes the operations of dispensing the material, cutting each layer to its proper dimensions, and positioning the layers properly with respect to one another are combined in a single continuous operation.
According to other embodiments the present invention is a novel system of dispensing, feeding, trimming and lay-up of composite material to form a multiple layer composite part where the composite material passes through a trimming system with at least one cutting device capable of being moved in multiple axes such that it can trim the periphery of the composite material to the desired shape without the material changing speed.
Other embodiments disclose a novel method of manufacturing a multiple layer composite part by dispensing layers of composite material, trimming each layer to its final shape as it is being dispensed, and positioning it properly with respect to prior layers in the part lay-up.
According to other embodiments the present invention is a method for manufacturing an airplane fuselage by dispensing layers of composite material; trimming each layer to it's final shape as it is being dispensed; positioning it properly with respect to prior layers in the part lay-up, further processing the lay-up to form a final multiple layer composite part, and joining a plurality of such parts with other parts to form a composite fuselage.
According to other embodiments the present invention is a method for manufacturing an airplane by dispensing layers of composite material; trimming each layer to it's final shape as it is being dispensed; positioning it properly with respect to prior layers in the part lay-up; further processing the lay-up to form a final multiple layer composite part; and joining a plurality of such parts with other parts to form an airplane.
In many embodiments of this invention the technical advance lies in cutting the material while it is in motion and in the form of a single layer. This allows very rapid cutting and an increase in production rate over many of the earlier methods used.
While producing substantial increases in production rate over previous designs, many embodiments of this invention are substantially less complex and require correspondingly less capital investment than methods such as Automatic Tape Laying or Automated Fiber Placement.
While many of the embodiments of the present invention create structures that are discernable from those of many of the previous methods due to the manner in which the layers are assembled and cut, the same degree of compaction, strength to weight ratios, and strength to volume ratios are obtainable.
Other features and advantages of the present invention will become apparent to those skilled in the art from a consideration of the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is an isometric view of one embodiment of the invention;
FIG. 2 is a second isometric view of the embodiment of FIG. 1 ;
FIG. 3 is a partial isometric view of the embodiment of FIG. 1 , illustrating the arrangement of the feed and trim system;
FIG. 4 is a schematic diagram of a composite trim and lay-up system;
FIG. 4 a is a schematic illustration of a typical part on the lay-up table;
FIG. 5 is a partial isometric view of an aircraft fuselage panel containing parts made in accordance with an embodiment of the invention;
FIG. 6 is an illustration of a representative airplane made in accordance with an embodiment of the invention;
FIG. 7 is a flow chart illustrating an embodiment of the method of the present invention;
FIG. 8 is a flow chart illustrating one method of generating a part program from the part definition in a Computer Aided Design file.
DETAILED DESCRIPTION OF THE INVENTION
Referring particularly to FIGS. 1 and 2 of the drawings, a preferred embodiment of a composite trim and lay-up system is shown at 1 . The composite trim and lay-up system 1 may include a frame 2 , a material supply system 5 , a feed and trim system 3 , a lay-up table 4 , and a backing material take-up reel 6 .
In a number of embodiments, the material supply system 5 may include a supply system pivot 50 with two axles 55 and 56 mounted thereon for removably placing composite material supply reels 51 and 52 . The supply system pivot 50 may advantageously have a supply system pivot latch 53 and a supply system pivot lever 54 . The system may in some embodiments be configured with a single supply reel, or may have more than two supply reels by arranging them in a carousel or any of a number of other known mechanisms to bring them into the feed position as desired.
As best shown in FIG. 4 , a layer of composite material 11 may be attached to a backing material 12 , which may be a paper or a plastic film which acts to keep the composite material from adhering to itself when rolled on the composite material supply reels 51 and 52 . The composite material may advantageously consist of a ply or plies of fibers or fabric preimpregnated with a plastic resin and supplied in a variety of forms. The combined composite material with backing material is denoted 10 on FIG. 4 and for purposes of this application will be referred to as prepreg. Dry composite material may also be used and filled with resin at a later stage of the process.
Referring now to FIG. 3 , the feed and trim system 3 may include a trim table 35 , and may include two trim cutter mechanisms 31 and 32 . The trim cutter mechanisms 31 and 32 may comprise linear control axes 310 and 320 in the X direction, 311 and 321 in the Y direction, and 33 and 34 in the Z direction as shown in coordinate system 8 . The X axis is in the direction of motion of the material on the trim table 35 , the Y axis is transverse to the direction of motion and in the plane of the trim table 35 , and the Z axis is normal to the surface of the trim table 35 . The feed and trim system may also comprise a rotational axis B about the Z axis. The cutter trim mechanisms 32 and 33 control the positions and rotations of cutters 37 and 38 in FIG. 4 , which may be ultrasonic knives.
The Z-axis actuators 33 and 34 are mounted to the Y-axis actuators 311 and 321 . The Y-axis actuators 311 and 321 allow movement across the prepreg 10 as it is moving across the trim table 35 .
The Y-axis actuators 311 and 321 are coupled to the X-axis actuators 310 and 320 , which allow movement of the cutters in the X axis.
The speeds of the X-axis actuators 310 and 320 and of the Y-axis actuators 311 and 321 are controllable and the maximum speed is such that all desired trim cuts can be made within the range of motion of the X-axis actuators 310 and 320 without changing the speed of the prepreg 10 as it is being dispensed. While the embodiment shown utilizes two sets of cutters, if sufficiently complex cuts or a higher speed were required the trim table could be lengthened and additional cutting systems ganged together. Also, it is possible to cut both sides of the composite material 11 with a single cutting system, if the speed of the prepreg 10 is sufficiently low.
As shown in FIG. 4 , the feed and trim system 3 may also comprise a drive system which may comprise powered nip rollers 14 and 15 . Vacuum system 36 , illustrated in FIG. 3 , pulls the prepreg 10 down and creates a frictional force which causes the prepreg 10 and the backing material 12 to be under tension between vacuum system 36 and powered nip rollers 14 and 15 .
As best shown in FIG. 2 , the composite trim and lay-up system 1 may also comprise a backing material take-up reel 6 which may be powered through a slip clutch to maintain tension on the backing material between the take-up reel 6 and the powered nip rollers 14 and 15 .
The composite material trim and lay-up system 1 may also comprise a lay-up table 4 , having a lay-up surface 40 . The lay-up table 4 may ride on a rail 7 and may be driven by a lay-up table driver 41 . For some parts it is possible to mount the mold directly to the rail 7 in place of or attached to the lay-up table 4 .
As illustrated in FIG. 4 a , both the composite material that will become a layer of the final part 44 and that which is scrap 43 may be deposited on the lay-up surface 40 . Alternatively, means may be provided to remove the scrap as it comes off the trim table 35 . The scrap 43 may be removed from around the part 44 when it is on the lay-up surface 40 either by hand or by any conventional material pick-up machine, such as a vacuum device on a controllable arm. Note that the longitudinal dimension of the part 44 has been compressed in FIG. 4 a for ease of illustration and to allow illustration of typical features such as reverse cut 47 and bat ears 48 .
It is known in the art of composite structure manufacturing, that the layers of composite material 11 must be compacted together periodically to achieve the desired strength of the final part with minimum weight. This may either be achieved by compaction of each layer as it is deposited or by periodic compaction of a number of layers together. The particular method used depends on a number of factors in the design of the particular part being manufactured, but is commonly accomplished by sealing the part under a bag and drawing a vacuum on the bag to remove air and allow atmospheric pressure to provide the compaction force. As illustrated in FIG. 4 , the lay-up table 4 may be moved from a part lay-up station 20 to a part compaction station 21 , where it is shown in phantom as 4 ′, for periodic compaction of the composite layers. This station may also advantageously be utilized to unload the part or transfer it to a mold for further processing.
Turning now to FIG. 5 , there is illustrated a portion of an aircraft fuselage 500 , constructed using an embodiment of the invention. Fuselage stringers 530 a , 530 b , 530 c and 530 d are formed of multiple layers of composite material in which the material is dispensed from a material supply system, such as material supply system 5 , trimmed to shape with a trim and feed system such as trim and feed system 3 , and deposited in the proper position with respect to previous layers on a lay-up table or forming die such as lay-up table 4 . When all layers are assembled, the completed composite lay-up may be formed and cured or may be formed and partially cured and attached to fuselage skin 510 . The attachment of the fuselage stringers 530 a through 530 d to the fuselage skin 510 may be through co-curing, adhesive bonding, mechanical fastening, or any other known means of attachment.
Fuselage frames as illustrated by 520 a and 520 b , may be added after the stringers 530 a through 530 d are joined to skin 510 or they may all be assembled concurrently.
Of course, the composite trim and lay-up system 1 may be used to make many other parts, such as wing stringers, fuselage frames 520 a and 520 b , and any number of other parts both inside and outside the aerospace industry.
FIG. 6 illustrates an aircraft including a fuselage which may be constructed using an embodiment of the present invention. In particular one or more of fuselage sections 610 , cab 620 , empennage 615 or wings 630 may advantageously be constructed using the methods discussed for the construction of fuselage section 500 of FIG. 5 . The fuselage sections 610 are joined at joints 612 to form the major portion of the fuselage. The cab section 620 , the wings 630 , empennage 615 , engines 640 and landing gear, not shown, are attached, as well as interior systems and components too numerous to name, but well known in the art; to form a complete airplane. If it is desired that the airplane be used to carry passengers, certain other amenities may be added, such as seats 606 .
We will now describe the operation of the exemplary composite trim and lay-up system 1 utilizing FIG. 7 .
In step 710 a first layer of composite material may be dispensed from material supply reel 51 or 52 . The two supply reels may each have the same type of prepreg 10 on them, or they may have different forms of prepreg 10 . That is one of the material supply reels 51 and 52 may contain composite material 11 with a 0° fiber orientation and the other may contain composite material 11 with a +/−45° fiber orientation. Of course these are only two of many different material configurations that may be stored on the supply reels and other embodiments of the invention may incorporate more supply reels as discussed above. The two material supply reels 51 and 52 may also have a different backing material 12 attached to the same or different composite materials 11 .
When the type of material is desired to be changed, or when one of the material supply reel 51 , 52 is empty, they may be switched by moving the supply system pivot lever 54 to disengage the supply system pivot latch 53 and rotating the supply system reels 51 , 52 about the supply system pivot 50 to place the other reel in position as the active feed reel. Supply system reel axles 55 & 56 may contain a quick release mechanism to allow rapid change of the idle material supply reel 51 or 52 .
In step 715 the feed and trim system 3 is used to trim the first layer of composite material 11 as it moves from the material supply reel 51 or 52 to the part lay-up station 20 . The trim system 31 may trim one side of the material as it passes over the trim table 35 and the trim system 32 may be used to trim the other side of the composite material 11 . The X-axis actuators 310 and 320 control the motion of the cutters 37 and 38 in relation to the speed of the prepreg 10 as it moves across the trim table 35 . The relative speeds of the X-axes 310 and 320 and the prepreg 10 are determined in the conversion of the Computer Aided Drawing (CAD) to the part program as discussed later in this application and shown in FIG. 8 . The speed of the Y-axis actuators 311 and 321 are controlled in relation to the speeds of their respective X-axis actuators 310 and 311 to achieve the desired form of the layer being cut. The Z-axis actuators 33 and 34 may primarily be two position actuators, though it is preferable that the end positions be adjustable which may be accomplished through a micro-mechanical adjustment. It is necessary that in the cutting position the cutters 37 and 38 cut completely through the composite material 11 without significantly scoring and weakening the backing material 12 . To accomplish this, the prepreg 10 may be held snugly against the trim table 35 by the tension created between the vacuum system 36 and the powered nip rollers 14 and 15 . B-axis controls may be provided to produce a rotation of the cutters 37 and 38 to align them with their paths of motion with respect to the composite material 11 .
In step 720 the backing material is removed from the first layer of composite material. The composite material 11 is relatively stiff when compared with the backing material 12 , so when the backing material 12 wraps around the nose of the trim table 35 , the peel strength of the bond between the backing material 12 and the composite material 11 is exceeded and they separate from one another. The backing material 12 may be fed between the powered nip rollers which control the speed of the prepreg 10 . Tension may be maintained in the system by a drag brake on the material feed reels 51 and 52 and the backing material take-up reel 6 which may be powered through a slip clutch as described above.
In step 725 the first layer of composite material may be deposited on a lay-up surface 40 . The position of the lay-up table 4 is controlled by lay-up table drive 41 such that the speed of the lay-up surface 40 and the composite material 10 are the same when the material is being deposited. The start position of lay-up table 4 may be controlled by mechanical stops or may be included in the programming of the machine control system. At the end of depositing the first layer of composite material 11 , the feed and trim system 3 may be used to make a complete transverse cut of the composite material 11 to separate the first layer of the part. The lay-up table 4 may then be returned to its start position.
In step 730 , another layer of prepreg 10 is then dispensed, the composite material 11 may be trimmed 735 , and the backing material 12 may be removed 740 . These steps are essentially the same as steps 710 , 715 and 720 respectively.
In step 750 the layer may be positioned on the lay-up surface in the proper position with respect to the previous layer. The start position for the leading edge of the scrap 43 for this layer may be the same index location as on the first layer, with the position of the start of the part layer 44 controlled by the feed and trim system 3 . Alternatively, the position of the lay-up table 4 may be controlled to a different start position. For parts that require partial length plies, the latter method may result in a significant reduction in the amount of scrap 43 created.
In step 755 a decision is made whether compaction is necessary. If not, the process returns to the material dispensing step and another layer is added in the same fashion. If compaction is needed, in step 760 the lay-up table may be moved from the part lay-up station 20 to the part compaction station 21 , and in step 765 the layers may be compacted. Alternatively the system may be designed with the capability to compact the layers at the lay-up station 20 . The decision as to whether or not compaction is required may be made during the design of the part by referring to rules for the manufacture of composite parts. It may also be made during the development phase of the part production based on the results obtained with test parts, or it may be made during production of the part based on the results of some means of non-destructive inspection. Alternatively, the decision may be made by a combination of the above methods.
In step 770 when the layers have been compacted, if the final layer has been added, the process is complete, step 775 . If the final layer has not been added, the process returns to the material dispensing step 730 and another layer is added in the same fashion.
Turning now to FIG. 8 , the definition of the composite part may reside in a computer model 801 which defines the geometry of each layer of the part. For composite parts, this is a necessary condition to obtain the desired strength-to-weight ratios for aerospace applications; since the definition of each layer and each layer's relation to the overall part geometry are critical to the material properties of the part as a whole. In other applications, it is possible that only the overall part geometry would be stored; in which case it would be necessary to add a step of generating the individual layer geometries based on the overall part geometry.
In step 802 the geometry of the first layer is extracted from the overall part definition. This may require a change in the file format to a more convenient format for flat pattern work. Many engineering part definitions are now produced using three-dimensional drawing formats, even when the part is essentially two dimensional in nature. This is done for consistency of the overall electronic definition of the product.
In step 803 the cutter paths are generated from the part geometry. Since the prepreg 10 is moving, this must be done using the relative motions of the prepreg 10 , the X-axis actuators 310 and 320 , the Y-axis actuators 311 and 321 , the Z-axis actuators 33 and 34 , and the B-axis actuators.
In step 804 a ratio of cutter speed to material speed is chosen and in step 805 a simulation or other analysis may be conducted to determine the envelope of cutter travel in the X axis, and in step 806 this envelope is compared with a predetermined operating envelope. If the operating envelope is exceeded by the simulation or other analysis, a new ratio of cutter speed to material speed is chosen and the simulation or other analysis is repeated at that new ratio. This process is repeated until the cutters 37 and 38 remain in the operating envelope over the length of the layer. It is possible that some particularly complex parts may require breaking the layer down into smaller longitudinal segments with different ratios of cutter speed to material speed in different segments of the layer.
In step 807 the cutter paths generated in step 803 and the ratio of cutter speed to material speed determined in the previous step are used to generate machine code that will produce the desired cutter path and ratio of cutter speed to material speed. This step may also produce the code necessary to engage and retract the Z-axis actuators 33 and 34 , move the lay-up table 4 , cut off the ends of the layer, and miscellaneous other control functions necessary to operation of the composite material trim and lay-up system 1 .
In step 808 the machine code generated in step 807 is placed in storage.
In step 809 , it is determined whether or not the machine code for the final part layer has been generated. If it has not, the geometry for the next layer is extracted in step 810 and the process goes back to step 803 and proceeds to generate the machine code for that layer in the same manner as the previous layer.
When it has been determined in step 809 that the final machine code for the final layer has been generated, in step 811 the machine codes for each of the individual layers are merged into a total part program and the necessary auxiliary commands to start and end the part and transition between layers are inserted.
In step 812 the part program generated in step 811 is stored for later execution in step 813 .
While the invention is illustrated for the construction of fuselage components, it is adaptable to the construction of other components as well, such as wing components, empennage components, aircraft cab components, and many non-aircraft components.
Those skilled in the art will understand that the preceding embodiments of the present invention provide the foundation for numerous alternatives and modifications thereto. For example, the trim table need not be flat and the trim mechanisms may then move in more than three axes; other stations may be added to the apparatus to perform additional manufacturing or inspection steps; multiple trimming stations may operate in parallel feeding a single lay-up station; or multiple lay-up stations could be supplied by a single feed and trim system. These other modifications are also within the scope of the present invention. Accordingly, the present invention is not limited to that precisely as shown and described in the present invention.
|
Disclosed is a method and apparatus for manufacturing multiple layer composite structures and structures containing components made of multiple layer composite structures, comprising dispensing layers of composite material, trimming each layer to its final shape as it is being dispensed, and positioning it properly with respect to prior layers in the part lay-up.
| 8
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an information processing blade and an information processing apparatus using the same, and in particular, relates to an information processing blade in which temperature control of parts is easy.
2. Description of the Related Art
In an information processing apparatus, a water-cooling system is known as a method of cooling a semiconductor chip such as a CPU for information processing. The water-cooling system is achieved by fixing a water-cooling head inside the information processing apparatus with such a fixture as a screw, for the semiconductor chip fixed in advance in the information processing apparatus.
On the other hand, in the information processing apparatus, a computer of a blade structure is known in which components necessary for a computer are mounted on a single printed circuit board. The computer blade has an information processing function, and is provided with chips such as a microprocessor (CPU) and a memory and a hard disk unit. The blade computer is mainly inserted into one of slots for blades provided for a main body of the information processing apparatus. At this time, the main body of the information processing apparatus carries out power supply to the blade, operation control of the blade computer, and so on. A blade personal computer and a blade server are known as the information processing apparatus using blade computers.
The blade computers are inserted in and pulled out from the slots for blade computers according to need. Therefore, a water-cooling head of a cooling unit provided to the main body of the information processing apparatus cannot be fixed on a chip when the chip on the blade computer should be water-cooled. Thus, only air-cooling by a fan fixed on the blade computer is possible. The blade computer is restricted in its height and size. That is to say, cooling capacity is limited. Therefore, in case of the air-cooling by the fan, there is a possibility that kinds of chips provided for a blade computer are limited, and it is possibly difficult to configure a server having a larger number of blade computers.
In conjunction with the above description, Japanese Laid Open Patent Publication (JP-P2004-326343A) discloses a liquid-cooling device. The liquid-cooling device has a heating unit, a heat receiving unit, a heat radiation section, a circulation section, and an airflow generating section. The heating unit is housed in a main body. The heat receiving unit receives heat generated in the heating unit. The heat radiation section radiates the heat transferred from the heat receiving unit based on circulation of a heat transfer medium. The circulation section circulates the heat transfer medium by connecting the heat receiving unit and the heat radiation section. The airflow generating section generates an airflow that passes through a plurality of cooled sections including the heat radiation section.
Also, Japanese Laid Open Patent Publication (JP-A-Heisei 8-139481) discloses a cooling device for electronic devices. The cooling device for electronic devices is provided with a planar heat pipe, a cooling plate, and a tapered member. The planar heat pipe is mounted to a plurality of printed circuit boards arranged approximately in parallel and adjacently to cover each printed circuit board. The cooling plate is provided close to a heat radiation section of each heat pipe. The tapered member is provided movably between the cooling plates and is formed to have a less diameter gradually toward a moving direction. The tapered member is used to press and closely attach the radiation section of the heat pipe to the cooling plate, by moving the tapered member into the moving direction.
Also, Japanese Laid Open Patent Publication (JP-A-Heisei 11-121959) discloses a cooling device. This cooling device for cooling electronic parts has a housing unit, a heat conduction plate, a heat conduction mat, and a mat holding member. The housing unit houses an electronic part to be detachable from a front side. The heat conduction plate is fixed to a back board substrate or sidewall of the housing unit. At the same time, the heat conduction plate in which a heat pipe is buried is provided apart from the electronic part and opposes to the electronic part. The heat conduction mat is arranged on the surface of the heat conduction plate on the side of the electronic part being arranged. The mat holding member increases the thickness of the heat conduction mat to the direction of the electronic part being arranged, by pressing an end of the heat conduction mat.
SUMMARY OF THE INVENTION
Therefore, an object of the present invention is to provide an information processing blade computer and an information processing apparatus which can carry out temperature control of parts in a blade computer without being affected by replacement of the blade computer.
Another object of the present invention is to provide an information processing blade computer and an information processing apparatus which can use a water cooling method for cooling of a semiconductor chip in a blade computer without any influence of replacement of blade computers, in an information processing apparatus with a blade structure.
In an aspect of the present invention, an information processing blade computer includes a board having a blade structure such that the board is stored in a main body of an information processing apparatus; a part contained in a circuit which is mounted on the board to execute an process, wherein heat is generated during an operation of the part; and a holding mechanism provided to detachably hold a heat exchange section on the part for heat exchange with the part.
Here, the part may be a semiconductor chip for the process.
Also, the holding mechanism may include a holding section operated to separate the heat exchange section from the part and contact the heat exchange section with the part; and a hold control section configured to control the holding section.
In this case, the holding section may include a pushing section configured to push the heat exchange section on the part, and the hold control section controls the pushing section to push the forcing section on the part.
Also, the information processing blade computer may further include a control unit which permits supply of power to the circuit when the heat exchange section is held on the part.
Also, the information processing blade computer may further include a control unit permits supply of power to the circuit when the heat exchange section is held on the part.
Also, in another aspect of the present invention, an information processing apparatus includes an information processing blade computer; a main body configured to store the information processing blade computer; a heat exchange section through which a heat medium flows; a first pipe supported by the main body, and connected to the heat exchange section to supply the heat medium to the heat exchange section; and a second pipe supported by the main body, and connected to the heat exchange section to receive the heat medium from the heat exchange section. The information processing blade computer includes a board having a blade structure; a part contained in a circuit which is mounted on the board to execute an process, wherein heat is generated during an operation of the part; and a holding mechanism provided to detachably hold the heat exchange section on the part for heat exchange with the part. The first and second pipes are supported by the main body such that the heat exchange section comes to the part.
Also, the information processing apparatus may further include a radiating section connected with the first and second pipes and configured to irradiate heat of the heat medium and to supply to the heat exchange section the heat medium from which the heat is irradiated.
Also, the part is a semiconductor chip for the process.
Also, the holding mechanism includes a holding section operated to separate the heat exchange section from the part and contact the heat exchange section with the part; and a hold control section configured to control the holding section.
In this case, the holding section comprises a pushing section configured to push the heat exchange section on the part, and the hold control section controls the pushing section to push the forcing section on the part.
Also, the information processing apparatus may further include a guide section configured to guide the heat exchange section onto the part.
Also, the information processing apparatus may further include a control unit which permits supply of power to the circuit when the heat exchange section is held on the part.
Also, in another aspect of the present invention, a method of cooling a part of a circuit in an information processing blade computer, is achieved by supporting a heat exchange section by first and second pipes, wherein heat medium flows through the heat exchange section, the heat medium is supplied to the heat exchange section through the first pipe, and the heat medium is supplied from the heat exchange section through the second pipe; by storing the information processing blade computer in a main body; by guiding the heat exchange section on the part while the information processing blade computer is stored in the main body; and by holding the heat exchange section on the part for heat exchange with the part.
Also, the method may be achieved by further radiating heat of the heat medium; and supplying to the heat exchange section the heat medium from which the heat is irradiated.
Also, the method may be achieved by further permitting supply of power to the circuit when the heat exchange section is held on the part.
Also, the method may be achieved by further stopping the supply of power to the circuit when the heat exchange section is separated from the part.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view showing a structure of an embodiment of an information processing blade computer and an information processing apparatus of the present invention;
FIG. 2 is a perspective view showing the structure of the embodiment of the information processing blade computer and the information processing apparatus of the present invention;
FIG. 3 is a partial side view showing details of a water-cooling head fixing mechanism in FIG. 1 ;
FIG. 4 is a block diagram showing a structure of an information processing blade computer in FIG. 1 ;
FIG. 5 of the perspective view showing the structure of the embodiment of the information processing apparatus of the present invention;
FIG. 6 is a side view showing the structure of the embodiment of the information processing apparatus of the present invention;
FIGS. 7A to 7D are side views showing a method to insert the information processing blade computer into an information processing apparatus main body of the present invention; and
FIG. 8 is a flow chart showing an operation of the water-cooling head fixing mechanism.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, an information processing blade computer of the present invention will be described in detail with reference to the attached drawings.
FIG. 1 is a schematic view showing a structure of an information processing blade computer according to an embodiment of the present invention. FIG. 2 is a perspective view showing the structure of the information processing blade computer according to the embodiment of the present invention. An information processing blade computer 12 is provided with a blade 1 and a main body 11 .
The information processing blade 1 has a blade structure in which components necessary for a computer are mounted on a printed circuit board 1 b . The information processing blade 1 is provided with an information processing function, and has a front panel 1 a , a CPU 2 , a water-cooling head fixing mechanism 4 , a guide 5 , and a connector 6 in addition to the printed circuit board 1 b . The printed circuit board 1 b is provided with a circuit (not shown) to realize the information processing function of the information processing blade 1 . The circuit has components necessary for a computer that includes the CPU 2 and the connector 6 . The printed circuit board 1 b is also provided with the front panel 1 a , the water-cooling head fixing mechanism 4 , and the guide 5 . The front panel 1 a is connected approximately vertically to one side of the printed circuit board 1 b . The front panel 1 a is the front when the information processing blade 1 is inserted into a slot for the blade computer 12 in the information processing apparatus main body 11 . The front panel 1 a has an indicator lamp, a button, and a switch (they are not shown) relevant to the information processing function of the information processing blade 1 . The CPU 2 is a semiconductor chip for information processing in the information processing blade 1 .
The CPU 2 is a semiconductor chip for information processing in the information processing blade 1 . The CPU 2 is included in the circuit provided on the printed circuit board 1 b . The CPU 2 generates heat through performing the information processing function. Therefore, the CPU 2 is cooled by a water-cooling head 3 to be mentioned later. The water-cooling head fixing mechanism 4 can hold the water-cooling head 3 on the CPU 2 that is cooled by the water-cooling head 3 . When holding the water-cooling head 3 on the CPU 2 , the water-cooling head fixing mechanism 4 supplies power to the information processing blade 1 or the CPU 2 . When the water-cooling head fixing mechanism 4 does not hold the water-cooling head 3 on the CPU 2 , the water-cooling head fixing mechanism 4 stops the supply of power. The water-cooling head fixing mechanism 4 is provided with an operation switch 41 , a control section 42 , a fixing terminal driving section 44 , and fixing terminals 45 .
The fixing terminals 45 push the CPU 2 against the printed circuit board 1 b at all times. At the same time, the fixing terminals 45 take either a first state or a second state. The fixing terminals 45 push the water-cooling head 3 to be closely fixed to the CPU 2 in the first state, and the fixing terminals 45 are detached from the water-cooling head 3 such that the water-cooling head 3 is movable in the second state. The fixing terminal driving section 44 drives the fixing terminals 45 to take either the first state or the second state. The control section 42 controls the fixing terminal driving section 44 such that the fixing terminals 45 takes either the first state or the second state, based on an operation of the operation switch 41 . At the same time, the control section 42 supplies power to the information processing blade 1 or the CPU 2 in the first state. In the second state, the control section 42 stops the supply of power to the information processing blade 1 or the CPU 2 . Thus, the operation switch 41 outputs either the first state or the second state, as a selected state of the fixing terminals 45 , based on an operation by a user. Four fixing terminals 45 a , 45 b , 45 c , and 45 d are provided, as shown in FIG. 2 .
The guide 5 is fixed on the connector 6 , and extends from the connector 6 to the vicinity of the CPU 2 . The guide 5 guides the water-cooling head 3 such that the head 3 slides and reaches the CPU 2 . It is possible to easily move the water-cooling head 3 onto the CPU 2 without being interfered by other members or components on the printed circuit board 1 b , by sliding the water-cooling head 3 through a region between the guide 5 . The guide 5 may be better understood when described as an upper guide 5 b and a lower guide 5 a , as shown in FIG. 2 . In FIGS. 1 and 2 , lateral guides are not shown in the region between the upper guide 5 b and the lower guide 5 a . However, the lateral guides may be provided. In that case, the water-cooling head 3 can be guided onto the CPU 2 more accurately. The connector 6 is used for connection between the circuit on the printed circuit board 1 b and an external circuit. The connector 6 is connected with a connector 7 that is mentioned later.
The main body 11 has at least one slot (not shown) for housing the information processing blade 1 . The main body 11 is provided with the water-cooling head 3 , a water passage 10 ( 10 a and 10 b ), a back panel 8 , and a water-cooling system 9 . Water as a heat medium flows through the water-cooling head 3 . The water-cooling head 3 , when closely fixed to the CPU 2 by the fixing terminals 45 , takes out heat from the CPU 2 by using the flowing water to decrease the temperature of the CPU 2 . The water-cooling head 3 has the same structure as a cooling head in which heat exchange is easy in a well-known cooling system.
The water passage 10 includes water passages 10 a and 10 b . The water passage 10 a is held by the information processing apparatus main body 11 (not shown), and one end of the water passage 10 a is connected to the water-cooling head 3 and the other end thereof is connected to the water-cooling system 9 . The water passage 10 a receives cooled water from the water-cooling system 9 , and supplies the received water to the water-cooling head 3 . The water passage 10 b is held by the information processing apparatus main body 11 (not shown), and one end of the water passage 10 b is connected to the water-cooling head 3 and the other end thereof is connected to the water-cooling system 9 . The water passage 10 b receives warmed water from the water-cooling head 3 , and sends the received water to the water-cooling system 9 . The water passage 10 has given stiffness since the water passage 10 is provided with a function to support the water-cooling head 3 . On the other hand, the water passage 10 also has flexibility for some degree of deformation such that the water-cooling head 3 can be closely attached to an upper surface of the CPU 2 by being pushed by the fixing terminals 45 even when a lower surface of the water-cooling head 3 is not parallel to the upper surface of the CPU 2 . The water passage 10 is formed from a copper pipe and a resin pipe. The water-cooling system 9 receives water warmed from the water-cooling head 3 through the water passage 10 b , cools the received water, and sends the cooled water back to the water-cooling head 3 through the water passage 10 a . The water-cooling system 9 is a well-known cooling system having a pump for circulating cooling water, a radiator for cooling the cooling water, a tank for storing the cooling water, and so on. The water-cooling system 9 , the water passage 10 connected thereto, and the water-cooling head 3 , are independent, and are completely separated off from the information processing blade computer 1 . Consequently, it is possible to fix the water-cooling head 3 after the information processing blade 1 is mounted to the information processing blade computer 12 , and detach the water-cooling head 3 from the CPU 2 before the information processing blade 1 is taken out from the information processing blade computer 12 . Therefore, there is no need to provide a cooling device to the information processing blade 1 .
The back panel 8 is provided with a circuit having a function to perform power supply to the information processing blade 1 of the information processing blade computer 12 through the connector 7 , a function to control an operation of the information processing blade 1 , and so on.
FIG. 3 is a partial side view showing details of the water-cooling head fixing mechanism 4 of the present invention shown in FIG. 1 . The fixing terminals 45 push the CPU 2 against the printed circuit board 1 b , and push or release the water-cooling head 3 . The fixing terminals 45 have upper holding members 46 , supporting members 47 , and lower holding members 48 and 49 .
The supporting members 47 are connected to the fixing terminal driving section 44 with connection sections 40 through the printed circuit board 1 b . The supporting members 47 are provided to multiple positions around the periphery of the CPU 2 to be cooled, approximately vertically to the printed circuit board 1 b . Here, supporting members 47 are provided in correspondence to the four fixing terminals 45 , represented as fixing terminals 45 a , 45 b , 45 c , and 45 d in FIG. 2 . The supporting members 47 hold the lower holding members 49 fixedly, and the lower holding member 48 and the upper holding member 46 movably. The lower holding members 48 extend from the supporting members 47 approximately vertically toward the upper surface of the CPU 2 , and further extend in parallel to the upper surface of the CPU 2 . The lower holding members 48 have elasticity, and float the water-cooling head 3 such that the water-cooling head 3 does not rub the CPU 2 when the information processing blade 1 is taken out. At this time, the lower holding members 48 may be connected to a driving mechanism (not shown) of the fixing terminal driving section 44 . In that case, the lower holding members 48 take either a first state or a second state by the driving mechanism. The lower holding member 48 moves downward to be closely attached to the CPU 2 in the first state, and the lower holding member 48 , when the information processing blade 1 is taken out, moves upward to float the water-cooling head 3 in the second state. The lower holding members 48 is made of metal used for spring. Here, lower holding members 48 are provided in correspondence to the four supporting members 47 which correspond to the four fixing terminals 45 a , 45 b , 45 c , and 45 d shown in FIG. 2 . Movements of the four lower holding members 48 are linked.
The lower holding members 49 extend toward the direction of the guide 5 from the supporting member 47 . When the water-cooling head 3 moves from the guide 5 toward the upper surface of the CPU 2 , or when the water-cooling head 3 moves from the upper surface of the CPU 2 toward the guide 5 , the lower holding member 49 supports the lower surface of the water-cooling head 3 between the guide 5 and the CPU 2 . The lower holding member 49 is made of metal used for a spring. Here, the lower holding members 48 are provided in correspondence to the supporting members 47 on the side of the guide 5 . The upper holding members 46 pass through the supporting members 47 and extend upward from the upper portion of the supporting members 47 . The upper holding members 46 then extend toward the upper surface of the CPU 2 and extend in parallel to the upper surface of the CPU 2 . The upper holding members 46 are connected to the driving mechanism (not shown) of the fixing terminal driving section 44 with the connection section 40 . By the driving mechanism, the upper holding members 46 take either a first state or a second state. The upper holding members 46 move downward to push and closely fix the water-cooling head 3 in the first state, and the upper holding members 46 move upward and separate from the water-cooling head 3 to be movable in the second state. The upper holding members 46 are made of metal used for the spring. Here, upper holding members 46 are provided in correspondence to the supporting members 47 on the side of the guide 5 . Movements of the four upper holding members 46 are linked.
The fixing terminal driving section 44 is combined to a back side of the printed circuit board 1 b , and is also combined to the fixing terminals 45 (e.g. 45 a , 45 b , 45 c , and 45 d as shown in FIG. 2 ) with the connection sections 40 through the printed circuit board 1 b . The fixing terminal driving section 44 has a driving mechanism (not shown). Based on the control of the control section 42 , the driving mechanism drives the upper holding members 46 and the lower holding members 48 of the fixing terminals 45 ( 45 a to 45 d ) to link the movements of the upper holding members 46 and the lower holding members 48 , such that the upper holding member 46 and the lower holding members 48 take either the first state or the second state. The driving mechanism is exemplified by a mechanical mechanism that makes the upper holding members 46 and the lower holding members 48 move in correspondence to each other, to raise and lower the upper holding members 46 and the lower holding members 48 based on a control signal from the control section 42 (mentioned later), for example.
The control section 42 is combined onto the printed circuit board 1 b , and is also combined to the fixing terminal driving section 44 with a connection section 40 e through the printed circuit board 1 b by a combining member 43 . An electric interconnection between the control section 42 and the fixing terminal driving section 44 is provided in the combining member 43 . Based on an operation of the operation switch 41 , the control section 42 controls the driving mechanism of the fixing terminal driving section 44 through the interconnection by using a control signal, such that the fixing terminals 45 take either the first state or the second state. The control section 42 has a key mechanism and a slide mechanism, for example, selects the first state and the second state when being turned to a LOCK side and a FREE side, respectively.
The operation switch 41 takes either an A state where the first state is selected, or a B state where the second state is selected, based on a user's operation. In the A state, an operation to fix the fixing terminal 45 is selected. In the B state, an operation to detach the fixing terminal 45 is selected.
FIG. 4 is a block diagram showing the circuit configuration of the information processing blade 1 in FIG. 1 . The control section 42 outputs a signal 63 to the fixing terminal driving section 44 , and the signal 63 indicates either the A state or the B state based on the state of the operation switch 41 . When the signal 63 indicates the A state, the fixing terminal driving section 44 lowers the fixing terminals 45 . When the signal 63 indicates the B state, the fixing terminal driving section 44 raises the fixing terminals 45 . Also, the control section 42 outputs a signal 61 to a power supply switch 71 , and the signal 61 indicates either the A state or the B state based on the state of the operation switch 41 . When the signal 61 indicates the A state, the power supply switch 71 is ON, power 62 is supplied from a power supply to the water-cooling system 9 , and the water-cooling system 9 starts to operate. When the signal 61 indicates the B state, the power supply switch 71 is OFF, the power 62 from the power supply is suspended, and the operation of the water-cooling system 9 is stopped.
Additionally, when an OS operates and a circuit 52 operates, power is supplied to the circuit 52 including the CPU 2 on the printed circuit board 1 b . In this case, an operation signal 65 is outputted from the circuit 52 to an operation LED 53 , and the operation LED lights up. Supply of power to the circuit 52 is suspended when the OS is shut down and an information processing operation of the information processing blade 1 is ended. In that case, the operation signal 65 is stopped and the operation LED is turned off.
The fixing terminal driving section 44 raises the fixing terminals 45 , when receiving the signal 63 for the operation to raise the fixing terminals 45 . As a result, the water-cooling head 3 is movable. The fixing terminal driving section 44 lowers the fixing terminals 45 , when receiving the signal 63 for the operation to lower the fixing terminal 45 . As a result, the water-cooling head 3 is fixed onto the CPU 2 .
FIG. 5 is a perspective view showing the structure of the information processing apparatus according to the embodiment of the present invention. FIG. 5 shows the information processing blade computer 12 provided with a plurality of information apparatus 13 . Each reference numeral is the same as that in FIGS. 1 and 2 .
The information processing apparatus main body 11 has a plurality of slots (not shown) for housing the information processing blade computers 1 . Each of the plurality of slots houses the information processing blade computer 1 . The water-cooling head 3 is connected to one end of the water passage 10 , and extends onto the CPU 2 of the information processing blade 1 . The water-cooling system 9 is connected to the other end of the water passage 10 , and is arranged in the information processing apparatus main body 11 . The water-cooling system 9 is provided to each of the plurality of slots (however, only the rightmost water-cooling system is shown in FIG. 5 where the guide 5 is not shown). By providing the water-cooling system 9 in correspondence to the individual information processing blade 1 , it becomes easy to perform management of every information processing blade 1 in the information processing apparatus 13 .
FIG. 6 is a side view showing the structure of the information processing apparatus according to the embodiment of the present invention. FIG. 6 shows the information processing apparatus 13 provided with a plurality of information processing blade computers 12 mentioned above. Each reference numeral is the same as that in FIGS. 1 and 2 .
As shown in FIG. 6 , the water-cooling system 9 may be shared by the plurality of information processing blade computers 12 housed in the plurality of slots. In this case, the water-cooling system 9 is structured to control an amount of water flowing through the water passage 10 , for each water passage. Since only the single water-cooling system 9 is required, an occupied area can be reduced compared with the case where the water-cooling system 9 is provided individually.
Next, a method of inserting the information processing blade 1 into the information processing apparatus main body 11 of the present invention. FIGS. 7A to 7D are side views showing the method of inserting the information processing blade 1 into the information processing apparatus main body 11 of the present invention.
Referring to FIG. 7A , in the slot of the information processing apparatus main body 11 , the water passage 10 with a front edge connected with the water-cooling head 3 extends from the back plate 8 toward the back plate 8 . The position of the water-cooling head 3 is set such that the water-cooling head 3 comes between guides 5 a and 5 b when the information processing blade 1 is inserted into the slot.
Next, referring to FIG. 7B , the information processing blade 1 is inserted into the slot. At this time, the water-cooling head 3 is guided between the guides 5 a and 5 b . As the water-cooling head 3 is inserted between the guides 5 a and 5 b , the water passage 10 is deformed along the guides 5 a and 5 b . Additionally, with respect to the direction vertical to the attached drawing (paper surface), the water passages 10 a and 10 b are not substantially deformed, causing little misalignment.
Next, referring to FIG. 7C , the insertion of the information processing blade 1 into the slot is completed by connecting the connectors 6 and 7 , and moving the water-cooling head 3 onto the CPU 2 . At this time, the fixing terminals 45 do not push the water-cooling head 3 . The fixing terminals 45 a and 45 b also have the effect of preventing the water-cooling head 3 from being excessively moved. When the fixing terminals 45 a and 45 b prevent the excessive movement of the water-cooling head 3 , deformation of the water passages 10 a and 10 b functions as a buffer against displacement.
Next, referring to FIG. 7D , the water-cooling head fixing mechanism 4 closely fixes the water-cooling head 3 on the CPU 2 by the fixing terminals 45 ( 45 a to 45 d ) based on the operation of the operation switch 41 . As a result, the water-cooling head 3 is ready to cool the CPU 2 . The water-cooling head fixing mechanism 4 stops the suspension of power supply to the circuit 52 on the printed circuit board 1 b , and instructs the water-cooling system 9 to circulate water. Then, the power is supplied to the circuit 52 , and the water circulation between the water-cooling system 9 and the water-cooling head 3 is started.
The information processing blade 1 can be inserted into the information processing apparatus main body 11 in the above way. A method of taking out the information processing blade 1 from the information processing apparatus main body 11 is opposite to the above description, and description of the method is not given.
Next, an operation of the water-cooling head fixing mechanism 4 will be described with reference to FIGS. 4 and 8 . FIG. 8 is a flow chart showing the operation of the water-cooling head fixing mechanism 4 .
(1) Step S 01
The operation switch 41 is operated by the user, and the operation switch 41 takes either the A state or the B state.
(2) Step S 02
The control section 42 determines the state of the operation switch 41 to be either the A state (operation to fix the water-cooling head 3 (operation to take the first state)) or the B state (operation to detach the water-cooling head 3 (operation to take the second state)).
(3) Step S 03
In case of the operation to fix the water-cooling head 3 (the A state), the control section 42 outputs the signal 63 indicating the A state to the fixing terminal driving section 44 . The fixing terminal driving section 44 drives the driving mechanism (not shown), to lower the fixing terminals 45 . Consequently, the water-cooling head 3 is closely fixed on the upper surface of the CPU 2 .
(4) Step S 04
The control section 42 outputs the signal 61 indicating the A state to the power supply switch 71 . Then, the power supply switch 71 is ON, and the power 62 is supplied to the water-cooling system 9 . Consequently, the water circulation between the water-cooling system 9 and the water-cooling head 3 is started. As a result, it is possible to supply the power to the circuit 52 including the CPU 2 on the printed circuit board 1 b.
(5) Step S 05
In case of the operation to detach the water-cooling head 3 (the B state), the control section 42 outputs the signal 61 indicating the B state to the power supply switch 71 . Then, the power supply switch 71 is OFF, and the supply of the power 62 to the water-cooling system 9 is suspended. Consequently, the water circulation between the water-cooling system 9 and the water-cooling head 3 is suspended. However, before this, the supply of power to the circuit 52 including the CPU 2 on the printed circuit board 1 b is already suspended.
(6) Step S 06
The control section 42 outputs the signal 63 indicating the B state to the fixing terminal driving section 44 . The control section 42 drives the driving mechanism (not shown), to raise the fixing terminals 45 . Consequently, the water-cooling head 3 is off from (detached from) the upper surface of the CPU 2 .
In the above way, the operation of the water-cooling head fixing mechanism 4 is performed, and the water-cooling head 3 is fixed or detached.
Additionally, the operations of the water-cooling head fixing mechanism 4 in FIG. 7D in mounting the water-cooling head 3 , are same as the operations of S 01 to S 04 in FIG. 8 . The operation of the water-cooling head fixing mechanism 4 in FIG. 7D when the water-cooling head 3 is taken out, is the operation of S 01 , S 02 , S 05 , and S 06 in FIG. 8 .
In the above description, the cooling of the CPU 2 is performed. However, the present invention is also applicable to the cooling of other chips and heat-generating members in the information processing blade computer 12 . Additionally, only the cooling is performed in the above description. However, it is also possible to set the temperature of chips and members to a desired temperature, by providing the water-cooling system 9 with a temperature adjusting function, to set the temperature of water or other heat mediums to a given temperature. That is, the temperature of desired chips and members can be set to a desired temperature without substantially affecting other members of the information processing blade computer 1 , because of the use of a heat medium.
According to the present invention, in an information processing apparatus containing information processing blade computers 12 of a blade structure, cooling is carried out by a water-cooling head having a structure independent of the blade computer, as a mechanism to cool a semiconductor chip that the temperature increases to a high temperature like a CPU. The water-cooling head can be fixed after mounting the blade computer, and detached from the semiconductor chip before taking out the blade computer. Thus, it is possible to insert and remove the information processing blade computer. It is also possible to use a cooling method of water cooling, thereby improving cooling performance. In addition, since there is no need to use a fan for air cooling and a heat sink, the size of the blade computer can be reduced and noise caused by the cooling can be reduced.
|
An information processing blade computer includes a board having a blade structure such that the board is stored in a main body of an information processing apparatus; a part contained in a circuit which is mounted on the board to execute an process, wherein heat is generated during an operation of the part; and a holding mechanism provided to detachably hold a heat exchange section on the part for heat exchange with the part.
| 7
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method for the real time measurement of bit wear during oilwell drilling.
2. Background Information
In T. Warren, "Factors Affecting Torque for a Roller Cone Bit," appearing in Jour. Pet. Tech. (September 1984), Volume 36, pages 1500-1508, a model was proposed for the torque of a roller cone bit. The model was derived from the theory of the rolling resistance of a wheel or cutter. For a pure rolling action, without bearing friction, the model shows that ##EQU1## where M is the time averaged torque required to rotate the bit under steady state conditions, R is the rate of penetration, N is the rotary speed of the bit, W is the axial force applied to the bit, and d is the bit diameter. a 2 is a dimensionless constant that is determined by the bit geometry, and in principle, is independent of rock properties.
Soft formation bits have cones that are not true geometrical cones, and the axes of the cones are offset from the center of the bit. These two measures create a large degree of gouging and scraping in the cutting action of the bit. This effect is taken into account by adding another dimensionless bit constant, a 1 , to the model ##EQU2## In practice, the constant a 1 includes the effect of bearing friction. This contributes less than 10% of the total bit torque under typical operating conditions.
Generally a 1 has a much greater value for soft formation bits than for hard formation bits because of the longer teeth and the gouging action. a 2 is generally greater for hard formation bits than for soft formation bits because hard formation bits drill by a rolling action that crushes and grinds the rock.
Warren confirmed the validity of the model (2) on both field and laboratory data and showed that it is insensitive to moderate changes in factors such as bit hydraulics, fluid type and formation type. This does not mean that rock properties do not affect torque, but rather than the effect of rock properties on bit torque is sufficiently accounted for by the inclusion of penetration per revolution, R/N, in the torque model.
SUMMARY OF THE INVENTION
In field tests with MWD tools, the observed torque was found to systematically decrease from its expected value with distance drilled. This phenomenon has also been observed by Applicants in a large number of examples, particularly with drilling clays, shales, or other soft formations that tend to deform plastically under the bit. It appears to be associated with bit tooth wear.
The reduction of bit torque with tooth wear corresponds to a change in one or both of the coefficients a 1 , a 2 . A reduction in tooth length results in a tooth flat, or blunting. This gives rise to less tooth penetration and consequently reduces the gouging and scraping action of the bit. As a result Applicants expect a significant reduction in a 1 with tooth wear. However, an even reduction in tooth length does not greatly alter the geometry of the cones. Thus, Applicants do not expect a large variation in a 2 and make the assumption that it remains constant.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustrating the action of a single blunt tooth.
FIG. 2 shows the force-penetration relationship for a wedge-shaped indentor.
FIG. 3 shows a cross plot of T D and √R D for Pierre shale drilling test.
FIG. 4 shows a log of measured data from Pierre shale drilling test.
FIG. 5 shows a drilling efficiency log computed from Pierre shale drilling test data.
FIG. 6 shows a cross plot of T D and √R D for the start of a new bit run on a Gulf Coast well.
FIG. 7 shows a log of MWD data from a bit run on a Gulf Coast well.
FIG. 8 shows a drilling efficiency log computed from a bit run on a Gulf Coast well.
DESCRIPTION OF PREFERRED EMBODIMENTS
In the appendix a simple set of analytical drilling equations is derived using a few assumptions about the physical processes involved in drilling. The equations are primarily intended for milled tooth bits drilling formations that deform plastically under the bit.
For simplicity, the drilling equations are given in dimensionless terms which are defined as:
______________________________________T.sub.D = M/(Wd) the dimensionless torque (3)R.sub.D = R/(Nd) the dimensionless penetration rate (4)E.sub.D = σ/σ(f) the dimensionless bit efficiency (5)W.sub.D = 2W/(σd.sup.2) the dimensionless weight-on-bit (6)F.sub.D = f/(kd) the dimensionless tooth flat (7)______________________________________
where f is the average or effective tooth flat (see FIG. 1), σ is the effective rock shear strength (as defined in the appendix), and σ(f) is a function which represents the apparent strength of the rock to a bit with average tooth flat f. σ(f) is always greater than σ, and σ(0) equal σ. σ is a measure of the in situ shear strength of the rock, and as such is noramlly considered to be a function of the rock matrix, the porosity, and the differential pressure between the mud and the pore fluids. σ is the slope of the force penetration curve when a sharp wedge shaped indentor is pushed into a rock (see FIG. 2). For a blunt tooth, the force penetration curve is displaced so that a threshold force is needed before penetration can begin. For a given axial load, σ(f) is the slope from the origin to the appropriate point on the force penetration curve. k is related to the number of tooth rows on the bit that bear the load at any one time. Typically k is of the order of 1 to 4.
In theory, E D is a positive value less than 1. For a sharp bit, E D is equal to 1. As wear occurs, E D decreases. E D also decreases as the rock becomes harder. It can be increased by increasing the weight-on-bit.
The drilling equations are readily expressed in terms of the dimensionless terms (3) to (7) as ##EQU3##
W.sub.D =R.sub.D /(4a.sub.1 E.sub.D) (9)
F.sub.D =W.sub.D (1-E.sub.D) (10)
where a 1 and a 2 are the coefficients of equation (2) determined for a sharp bit.
Equation (8) is equivalent to (2) with the efficiency term E D accounting for the wear. Equation (8) does not define a straight line of T D versus R D since E D depends upon W when the bit is blunt. This means that a 1 and a 2 can only be determined by empirical methods when data come from a sharp new bit.
Equation (10) shows how the tooth flat is connected with the efficiency E D . Equation (9) shows how the penetration rate is related to the weight-on-bit and tooth wear.
In practice, W and M are the downhole values of weight-on-bit and bit torque as measured by a measurements while drilling (MWD) system. The constants a 1 and a 2 are determined from a cross-plot of T D versus √R D for data coming from a sharp bit, or from previously tabulated values. Then the other terms are computed on a foot by foot basis as follows:
(i) compute T D and R D
(ii) solve (8) for E D
(iii) solve (9) for W D
(iv) compute σ(0) and σ(f) from (5) and (6)
(v) compute F D from (10) and f from (7)
The computed data displayed in the form of a drilling log is called the Mechanical Efficiency Log.
The appendix describes a simple way of including in the model the effects of friction between the teeth flats and the rock. It amounts to an adjustment of E D as follows:
E.sub.D becomes [E.sub.D -μ tan θ]/[1-μ tan θ]
where μ is the coefficient of friction between the rock and the teeth flats and θ is the semi-angle of the bit teeth (see FIG. 2).
EXAMPLES
(i) Laboratory Study
Three similiar cores of Pierre Shale were drilled with 8.5 inch IADC 1-3-6 type bits under controlled laboratory conditions. The first core was drilled with a new bit (teeth graded T0) using seven different sets of values of weight-on-bit and rotary speed. The second and third cores were drilled with field worn bits of the same type using nine and ten different sets of values of weight-on-bit and rotary speed respectively (see FIG. 4). The bit used to drill the second core was half worn and graded T2 to T4. The bit used to drill the third core was more worn and graded T5 to T7 depending upon the assessor. We shall call the new bit #1; the second bit #2 bit; and the most worn bit #3 bit. The bearings of the worn bits were considered to be in very good working order. Each set of values of weight-on-bit and rotary speed was maintained for about 30 seconds on average. In each test the mud flow rate was kept constant at 314 gal./min. (1190 l/min.) and the borehole pressure at 2015 psi (13.9 MPa). An isotropic stress of 2100 psi (14.5 MPa) was applied to the boundaries of the cores.
FIG. 3 shows a cross-plot of M/(Wd) versus the square root of R/(Nd) for the three different bits. The new bit defines a reasonable straight line with intercept (a 1 ) 7.56×10 -2 and slope (a 2 ) 0.238 (determined from a least-squares fit). The relatively low slope is typical of an IADC series 1 bit.
Data corresponding to the #2 and #3 bits lie beneath the line. This clearly demonstrates the reduction in M/(Wd) or a 1 with wear.
A computer processed interpretation of the data was made using the technique descibed above with the following parameters.
a 1 =7.56×10 -2
a 2 =0.238
μ=0.3
θ=20°
Logs of the effective rock shear strength, σ(0), and σ(f) are shown in FIG. 5 with the drilling efficiency, E D , and the dimensionless tooth flat, F D .
The efficiency of the new bit, E D , is seen to be close to 1. On average the efficiency of the #2 bit is seen to be less than the #1 bit, and the efficiency of the #3 less than the #2 bit. For each bit the efficiency is maximized when the weight-on-bit is greatest. Although the change in E D from the #2 to the #3 bit was not as much as might have been expected, the overall trend is clear. It suggests that the initial wear of bit teeth has a greater effect than additional wear at a later stage in the life of the bit.
The dimensionless tooth flat shows some point to point variation. This arises from inaccuracies in the model when the input weight-on-bit and rotary speed are varied right across the commercial range.
The logs of σ(0) and σ(f) clearly show how the apparent rock strength to a blunt bit increases with wear, and how σ(f) can be reduced by increasing the weight-on-bit.
The interpretation of σ(0) shows that the in situ strengths of the two first cores were fairly consistent at about 17.5 kpsi (121 MPa), and that the third core appeared to be somewhat stronger, particularly in the central portion.
In practice, field variations in weight-on-bit and rotary speed are much smaller than those used in the drilling test and better results can be expected. Sample points corresponding to a weight-on-bit of 21.5 klbs (120 kN) and a rotary speed of 80 RPM are indicated in FIG. 5. These points clearly show the effect of wear on a given rock when input drilling parameters are kept constant. The results are summarized below.
______________________________________ #1 #2 #3______________________________________E.sub.D 1.0 0.74 0.56F.sub.D 0 9.9 12.5f (ins) 0 0.25 0.32______________________________________
The values of f were computed using k=3.
(ii) Field Example with MWD
FIG. 7 is a log of drilling data from a single bit run through a shale sand sequence in the Gulf Coast of the U.S.A. The bit was a new IADC 121/4 inch 1-1-6 type bit and was pulled out of the hole with almost all the teeth worn away. The data shown in FIG. 7 are the downhole weight-on-bit, the downhole torque, the rotary speed (as measured at the surface) and the rate of penetration calculated over intervals of five feet. The downhole weight-on-bit and the downhole torque were measured using an MWD tool placed in the bottom hole assembly above the bit, a near bit stabilizer, and one drill collar.
T D and R D were first computed on a foot by foot basis. Then in order to determine a 1 and a 2 a cross-plot was made of the data from 5410-5510 feet (FIG. 6). The data from the 5365 to 5409 feet were ignored in the determination of a 1 and a 2 because the MWD tool was about 50 feet above the bit and would record the torque at the bit plus the torque at stabilizers between the MWD tool and the bit. In the course of pulling a bit and running a new bit, it is possible for the hole to swell, resulting in extra (MWD) torque until the stabilizers below the MWD tool are in the "fresh" hole.
Despite only small variations in weight-on-bit over the interval 5410-5510 feet, the cross-plot defines a reasonable straight line with intercept (a 1 ) 7.45×10 -2 and slope (a 2 ) 0.231 (determined by the least-square method, with a correlation coefficient of 0.74). The variation about the line is typical of the "noise" seen in field data. It is interesting to note that the calculated values of a 1 and a 2 are very similar to those obtained in the laboratory tests.
A computer processed interpretation of the data was made using the values of a 1 and a 2 above and a rock/tooth friction coefficient μ=0.3. Logs of the effective rock shear shrength σ(0), and σ(f) are shown in FIG. 8 with the drilling efficiency E D , the dimensionless tooth flat, F D , and the rate of penetration. The processed data were averaged over intervals of 5 feet to smooth out some of the noise.
Since the downhole weight-on-bit is fairly constant, the trend in the dimensionless efficiency, E D , in the shales is a good measure of the state of wear of the bit. The efficiency is close to 1 until a sand section at about 5850 feet, when the efficiency drops off significantly and rapidly to just below 0.8. This also corresponds to a large increase in rotary speed. Thus we can assume that the combined effects of the sand and the high rotary speed resulted in some significant blunting of the sharp teeth. Below this depth the trend of E D is decreasing during the high RPM sections and more constant in the lower RPM sections. This clearly shows how wear rate is associated with rotation speed. The final average value of E D is about 0.26.
Those places where E D is greater than 1, or equivalently where σ(f) is less than σ(0), can be interpreted as places in which stabilizers between the MWD tool and the bit are rubbing against the formation. When these stabilizers lose a significant amount of torque the result is high E D and low F D values. Thus those places were the sharpness seems to suddenly increase, probably correspond to bit depths were stabilizers were rubbing the formation.
The interpretation of F D is similar to that of E D except that F D is more sensitive to the sand sections. Sand sections in this well are associated with high rates of penetration. A trend line has been drawn through the values of F D corresponding to the shales. If it is assumed that the tooth row factor k equals 3 in the shale sections, then the effective tooth flat is
______________________________________ depth f (ins)______________________________________ 5800 0 5890 .40 6160 .66 6370 1.14 6450 1.40______________________________________
Clearly the final value of f is not very reliable because of the extreme nature of the wear.
A method has been presented for inferring the wear of soft formation milled tooth bits from MWD measurements of weight-on-bit and torque in formations that drill by a gouging and scraping action. The theory leads to an interpretation technique (Mechanical Efficiency Log) based on a simple measure of drilling efficiency, E D .
For a new bit, E D is close to 1. As the teeth wear, E D decreases towards 0, however E D can be increased by increasing the weight-on-bit. From E D it is possible to compute a dimensionless tooth flat, F D , that is proportional to the effective average flatness of the teeth. With knowledge of E D or F D it is possible to compute what the penetration rate would have been with a sharp bit and hence calculate the effective in situ shear strength of the rock.
The interpreted data are inherently variable as a result of the raw data, however the underlying trends observed in E D and F D in rock like shales appear to give a reliable indication of tooth wear. With improved data processing and further experience, it could become possible to accurately predict the wear of milled teeth bits in real time from MWD measurements of weight-on-bit and torque.
APPENDIX--DERIVATION OF DRILLING EQUATIONS
Suppose that the teeth on the bit penetrate the rock a distance, x, and that the bulk of drilling is achieved by the gouging and scraping action of the bit. The action of a blunt tooth is shown schematically in FIG. 1.
Assume that the force per unit length of tooth needed to gouge the rock in situ, G, is proportional to the depth of indentation.
G=τx (A-1)
Equation A-1 is an approximation to the failure or penetration curves that can be observed in plastically deforming materials. In this paper, the constant of proportionality, τ, is thought of as the effective in situ shear strength of the rock. If it is assumed that τ is independent of the tooth velocity, then the main factors affecting τ are the rock matrix, the differential pressure between the mud and the pore pressure, and the porosity.
In soft plastic rocks, we shall assume that all the penetration comes from gouging and scraping and that the chipping and crushing action is of minor importance. The penetration per revolution is then proportional to the depth of indentation.
R/N=Sx (A-2)
The dimensionless constant S is proportional to the average gouging velocity of the bit teeth divided by the rotation speed. It is the proportion of the cross-sectional area of the hole that is cut to a depth x in one revolution of the bit.
If M 1 is the average torque expended on gouging, then the work done on gouging per revolution (2πM 1 ) is proportional to τ and the cross-sectional area cut out in one revolution, Sπ(d/2) 2 .
2πM.sup.1 =τxπSπ(d/2).sup.2 M.sup.1 =Sτxd.sup.2 /8 (A-3)
It is interesting to note that equations (A-2) and (A-3) show that the specific energy expended in gouging, S.E., defined as
S.E.=2M.sup.1 N/[(d/2).sup.2 R] (A-4)
is equal to τ, the effective shear strength of the rock.
Having established the relationship between M 1 and x, it is necessary to express x in terms of the axial load, W. For long milled tooth bits with intersecting teeth on different cones, the total axial load is distributed over approximately one bit radius. However the maximum force on a tooth occurs when that tooth row bears all the load, thus the average maximum force per width of tooth pushing into the rock, F, is given by:
F=kW/(d/2) (A-5)
where k is a dimensionless number associated with the number of tooth rows. k is expected to take a value between 1 and 4.
For wedge shaped indentors penetrating plastically deforming materials, the force required to penetrate is approximately proportional to the cross-sectional area of the tooth in contact with the deforming material (see FIG. 2). For a blunt wedge that is loaded on the wedge flat and one face
F=σ[f+x tan θ] (A-6)
where f is the average tooth flat (shown schematically in FIG. 1), θ is the semi-tooth angle (typically 20°), and σ is a constant of proportionality related to the rock strength. Note that when the tooth flat f is greater than zero, a threshold force of σ f is required before indentation can begin.
Using equation (A-5) and (A-6) ##EQU4## If the function σ(f) is defined as follows
σ(f)=σ/[1-(d/2)fσ/kW] (A-8)
then ##EQU5## σ(f) is the apparent strength of the rock as it appears to a blunt bit with average tooth flat, f, at a weight-on-bit of W. Clearly σ(f) is never smaller than σ, and σ(0) equals σ. The dependency of σ(f) on W is such that the rock appears harder at low weight-on-bit than it does at high weight-on-bit (see FIG. 2).
Using equation (A-9) to eliminate x in equations (A-3) and (A-2) respectively
M.sup.1 /(Wd)=[Sk/(4 tan θ)][τ/σ(f)] (A-10)
dR/(8NW)=[Sk/(4 tan θ)]/σ(f) (A-11)
The ratio of these equations is the specific energy, τ. Equation (A-10) describes how the coefficient a 1 , varies with wear. For a new bit
a.sub.1 =[Sk/(4 tan θ)][τ/σ(0)] (A-12)
This term depends upon the rock unless τ/σ is a constant.
From the definition of τ(A-1) and σ(A-6)
G/F=τ/(σ tan θ) (A-13)
If we resolve forces along the workface of the tooth (see FIG. 1) and ignore friction between the rock and the tooth
G/F=1/tan θ (A-14)
Combining (A-13) and (A-14) gives
τ=σ[=σ(0)]
Thus for a new bit, a 1 is predicted to be a constant, as observed experimentally by Warren 1 .
Defining E D as
E.sub.D =σ(0)/σ(f) (A-15)
the modified torque equation becomes ##EQU6## E D can be thought of as the efficiency of the bit for a given rock type, tooth wear, and weight-on-bit. E D is equal to 1 for a new bit and then decreases with wear. It is less in hard rocks than in soft rocks. The efficiency of a worn bit can be increased by increasing the weight-on-bit.
Once E D is known, it is straightforward to compute the average tooth flat, f. From (A-8)
f=[2kW/(σd)][1-E.sub.D ] (A-17)
If we define a dimensionless tooth flat, F D , and a dimensionless weight-on-bit, W D by
F.sub.D =f/kd (A-18)
W.sub.D =2W/(σd.sup.2) (A-19)
we are left with the following simple set of drilling equations ##EQU7##
W.sub.D =R.sub.D /(4a.sub.1 E.sub.D) (A-21)
F.sub.D =W.sub.D (1-E.sub.D) (A-22)
where (A-21) comes from (A-11) and (A-22) from (A-17).
Once a 1 and a 2 are known for a new bit, it is possible to compute T D and R D on a foot by foot basis, then calculate E D from (A-20), W D from (A-21), and F D from (A-22).
Frictional Effects
It is a simple matter to add to the model the effect of friction between the flats of the worn teeth and the rock if the coefficient of friction is known. The force on the tooth flat in a direction perpendicular to the motion is the same as the threshold force needed for indentation, σf. Suppose μ is the dynamic coefficient of friction between the teeth and the rock. Then equation (A-1) becomes
G=τx+μσf (A-23)
Using this value of G in all the equations leading to (A-10) gives ##EQU8## Thus if E D 1 is defined as the dimensionless efficiency including friction
E.sub.D.sup.1 =E.sub.D +μ tan θ(1-E.sub.D) (A-25)
then ##EQU9##
E.sub.D =[E.sub.D.sup.1 -μ tan θ]/[1-μ tan θ](A-27)
and equations (A-26) and (A-27) replace equation (A-20).
NOMENCLATURE
a 1 , a 2 =dimensionless constants in torque model
d=bit diameter
E D =dimensionless bit efficiency
F D =dimensionless tooth flat
f=tooth flat
F=penetration force on a tooth
G=side force on a tooth
k=dimensionless constant related to the number of tooth rows
M=bit torque
M 1 =component of bit torque expended in gouging
N=bit rotation speed
R=rate of penetration
R D =dimensionless penetration rate
S=bit penetration per revolution/tooth penetration
T D =dimensionless torque
W=axial load on bit
W D =dimensionless weight-on-bit
x=tooth penetration
TORQ=measured torque
WOB=measured weight-on-bit
ROP=rate of penetration
ROT=rate of turn (RPM)
τ=effective in situ shear strength of the rock
σ=effective "penetration" strength of the rock
σ(f)=effective "penetration" strength of the rock to a blunt tooth with flat f
θ=semi-tooth angle
μ=friction coefficient between rock and bit teeth
|
A method for measuring the wear of milled tooth bits during oilwell drilling uses surface and subsurface wellsite sensors to determine averaged values of penetration rate, rotation speed and MWD (measurements-while-drilling) values of torque and weight-on-bit to obtain a real time measurement of tooth wear, drilling efficiency and the in situ shear strength of the rock being drilled.
| 4
|
This application is a continuation of application Ser. No. 10/003,261 filed Dec. 6, 2001 now U.S. Pat. No. 6,506,666 which, in turn, is a divisional of application Ser. No. 09/571,718 filed May 15, 2000 now U.S. Pat. No. 6,342,445, which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to the field of thin dielectric films. More specifically, the invention relates to the formation of an SrRuO 3 film by deposition utilizing independent deposition segments for each of the dissimilar precursor compositions.
2. Description of the Related Art
Barium strontium titanate, BaSrTiO 3 is one of the most promising candidates as a dielectric material for post-1-Gbit dynamic random access memory capacitors. However, as device sizes continue to shrink, the thickness of the dielectric must be reduced in order to increase the accumulated charge capacitance and reduce the capacitor area,. In thin dielectric films with thickness on the order of several tens of nm, a low leakage current and a higher dielectric constant are required. However, when a dielectric is made very thin, unwanted changes, such as an increase in leakage current and a decrease in the dielectric constant relative to the bulk, may occur. Although the origins of these phenomena are not completely understood, they are known to depend greatly on the materials used for the capacitor electrodes.
Currently, there are numerous possible candidates for the electrodes used in BaSrTiO 3 capacitors, including Pt, Ir, Ru and RuO2. However, SrRuO 3 is one of the most promising candidates for an electrode material having an improved performance with respect to capacitance, leakage degradation and lattice match for BaSrTiO 3 .
In the formation of thin films, layers and coatings on substrates, a wide variety of source materials have been employed. These source materials include reagents and precursor materials of widely varying types, and in various physical states. To achieve highly uniform thickness layers of a conformal character on the substrate, vapor phase deposition has been used widely. In vapor phase deposition, the source material may be of initially solid form which is sublimed or melted and vaporized to provide a desirable vapor phase source reagent. Alternatively, the reagent may be of normally liquid state, which is vaporized, or the reagent may be in the vapor phase in the first instance. Conventionally, these reagents may be used in mixture with one another in a multicomponent fluid which is utilized to deposit a corresponding multicomponent or heterogeneous film material such as SrRuO 3 . Such advanced thin film materials are increasingly important in the manufacture of microelectronic devices and in the emerging field of nanotechnology. For such applications and their implementation in high volume commercial manufacturing processes, it is essential that the film morphology, composition and stoichiometry be closely controlled. This in turn requires highly reliable and efficient methods for deposition of source reagents to the locus of film formation.
Various technologies well known in the art exist for applying thin films to substrates or other substrates in manufacturing steps for integrated circuits (ICs). For instance, Chemical Vapor Deposition (CVD) is a often-used, commercialized process. Also, a relatively new technology, Atomic Layer Deposition (ALD), a variant of CVD, is now emerging as a potentially superior method for achieving uniformity, excellent step coverage, and transparency to substrate size. ALD however, exhibits a generally lower deposition rate (typically about 100 ang/min) than CVD (typically about 1000 ang/min).
Chemical vapor deposition (CVD) is a particularly attractive method for forming thin film materials such as SrRuO 3 because of the conformality, composition control, deposition rates and microstructural homogeneity. Further, it is readily scaled up to production runs and the electronics industry has a wide experience and an established equipment base in the use of CVD technology which can be applied to new CVD processes. In general, the control of key variables such as stoichometry and film thickness and the coating of a wide variety of substrate geometries is possible with CVD. Forming the thin films by CVD permits the integration of SrRuO 3 into existing device production technologies.
ALD, although a slower process than CVD, demonstrates a remarkable ability to maintain ultra-uniform thin deposition layers over complex topology. This is at least partially because ALD is not flux dependent as CVD processes are. In other words, CVD requires specific and uniform substrate temperature and precursors to be in a state of uniformity in the process chambers in order to produce a desired layer of uniform thickness on a substrate surface. This flux-independent nature of ALD allows processing at lower temperatures than with conventional CVD processes.
However, in either case, when the film being deposited is a multicomponent material, such as SrRuO 3 , rather than a pure element, controlling the deposition of the film is critical to obtaining the desired film properties. In the deposition of such materials, which may form films with a wide range of stoichiometries, the controlled delivery of the source reagents into the reactor chamber is essential.
The present invention is directed to controlling the delivery of source reagents into the reactor chamber to produce thin films of SrRuO 3 .
SUMMARY OF THE INVENTION
The present invention is directed to a method of fabricating an SrRuO 3 thin film. The method utilizes a multi-step deposition process for the separate control of the Ru reagent, relative to the Sr reagent, which requires a much lower deposition temperature than the Sr reagent.
A Ru reagent gas is supplied by a bubbler and deposited onto a substrate at temperatures below 200° C. Following the deposition of the Ru reagent, the Sr liquid reagent is vaporized and deposited onto the Ru layer at temperatures above 200° C.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other advantages and features of the invention will become more apparent from the detailed description of the invention given below with reference to the accompanying drawings in which:
FIG. 1 is a schematic representation of an apparatus according to the present invention as employed for the fabrication of an SrRuO 3 film;
FIG. 2 is a schematic representation of a multiple layer film formed utilizing SrRuO 3 fabricated in accordance with a method of the present invention; and
FIG. 3 illustrates in block diagram form a processor based system including a memory device employing a capacitor having a conductor formed of an SrRuO 3 film fabricated in accordance with a method of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will be described as set forth in FIGS. 1-3. Other embodiments may be utilized and structural or logical changes may be made without departing from the spirit or scope of the present invention. Although the invention is illustrated in the drawings in connection with CVD processes, the invention may also be practiced using ALD processes as well. In general, the invention may be applicable wherever deposition is utilized for the deposition of SrRuO 3 thin films. Like items are referred to by like reference numerals.
The term “substrate” used in the following description may include any semiconductor-based structure that has an exposed silicon surface. Structure must be understood to include silicon-on insulator (SOI), silicon-on sapphire (SOS), doped and undoped semiconductors, epitaxial layers of silicon supported by a base semiconductor foundation, and other semiconductor structures. The semiconductor need not be silicon-based. The semiconductor could be silicon-germanium, germanium, or gallium arsenide. When reference is made to substrate in the following description, previous process steps may have been utilized to form regions or junctions in or on the base semiconductor or foundation.
Referring now to the drawings, FIG. 1 illustrates a reaction chamber 39 coupled by a precursor feed line 17 and branch feed line 21 further connecting to a bubbler 1 . Bubbler 1 comprises a reaction vessel 5 containing the Ru precursor or reagent, such as tricarbonyl (1-3 cyclohexadiene) ruthenium (Ru), ruthenium acetylacetonate, ruthenocene, triruthenium dodecacarbonyl or tris (2,2,6,6-tetramethyl -3,5-heptanedionato) ruthenium, which is connected to a gas carrier vessel 3 , by a carrier feed line 7 . The gas carrier vessel 3 contains a carrier gas such as Ar, He, N 2 , CO or any other gases inert to a Ru precursor for effecting the transport of the vapor precursor Ru to the reaction chamber 39 . The reaction vessel 5 is maintained at a temperature of about 25° C. The reaction vessel 5 is also coupled to an exhaust or bypass line 4 containing flow control valve 6 , whereby the flow of precursor vapor may be bypassed from the reaction chamber. Further, branch feed line 21 is provided with flow control valve 15 therein which may be selectively opened or closed to flow the precursor to the reaction chamber 39 or to terminate the flow of precursor vapor to the reactor by closure of the valve. Flow control valve 15 may also be partially opened to regulate the flow therein of the precursor vapor.
Further, as shown in FIG. 1 the precursor feed line 17 is also coupled to branch feed line 23 connecting to the vaporizer unit 20 . Vaporizer unit 20 has an interior volume 25 therein containing a vaporizer element 22 for effecting vaporization of the liquid precursor such as, Sr(2,2,6,6-tetramethyl-3,5-heptanedionate) 2 (“Sr (THD)” 2 ), or Sr bis(triisopropylcyclopentadienyl), flowed to the vaporizer unit for vaporization of the precursor therein to form precursor vapor. Vaporizer branch line 23 is provided with flow control valve 19 therein, which may be selectively opened or closed to flow the precursor to the reaction chamber 39 or to terminate the flow of precursor vapor to the reactor by closure of the valve. The vaporizer unit 20 is also coupled to an exhaust or bypass line 29 containing flow control valve 27 , whereby the flow of precursor vapor may be bypassed from the reaction chamber 39 . Flow control valve 19 may also be partially opened to regulate the flow there through of the precursor vapor.
Vaporizer 20 receives liquid Sr precursor in line 31 , having pump 33 disposed therein. As used herein, the term “pump” is intended to be broadly construed to include all suitable motive fluid driver means, including, without limitation, pumps, compressors, ejectors, eductors, mass flow controllers, pressure-building circuits, peristaltic drivers, and any other means by which fluid may be conducted through conduit, pipe, line or channel structures. Supply vessel 37 containing liquid Sr precursor (for instance, Sr (THD) 2 in a solution of about 0.1M butyl acetate) is coupled by line 31 to pump 33 which receives the Sr precursor and flows the precursor to vaporizer unit 20 in line 31 .
Hence, the vaporized precursors are flowed from the bubbler 1 and vaporizer unit 20 in precursor feed line 17 to the reaction chamber 39 , in which the precursor vapors of Ru and Sr are contacted with a substrate 43 on support 41 to deposit a film of the desired character, and with spent precursor vapor being exhausted from the reaction chamber 39 in line 45 , for recycle, treatment or other disposition thereof.
With the FIG. 1 arrangement, the Ru precursor is first deposited on substrate 43 in reaction chamber 39 which is maintained at a pressure of about 0.5-10 torr, preferably around 3 torr. The substrate 43 surface temperature is maintained at about 150° C.-600° C., preferably at temperatures below 200° C. The Ru precursor is deposited to a thickness of about 50-500 A and the quantity of the Ru precursor gas is maintained at about 30-50 sccm. The deposition time is approximately 2-10 minutes.
After deposition of a Ru precursor, the Sr precursor is deposited on substrate 43 in reaction chamber 39 which is maintained at a pressure of about 0.5-10 torr, preferably around 3 torr. The substrate 43 surface temperature is maintained at about 325° C.-700° C., preferably at temperatures above 200° C. The Sr precursor is deposited to a thickness of about 50-500A and the quantity of the Sr precursor gas is maintained at about 30-50 sccm. The deposition time is around 1-4 minutes. Following the deposition of Ru and Sr a post annealing process is performed at a temperature about 550° C. 14 850° C. for about 10 seconds to about 30 minutes, preferably around 700° C. for about 30 seconds.
Thus, the present invention provides a unique, independent method of depositing each of the components necessary for the fabrication of an SrRuO 3 film. Accordingly, separate control of the Ru reagent which requires a much lower deposition temperature than Sr reagent is thereby facilitated, for the purpose of optimizing the SrRuO 3 film formation process to yield a desired SrRuO 3 film on the substrate 43 in the reaction chamber 39 .
FIG. 2 is a schematic representation of a container capacitor 200 for memory cells; said capacitor having SrRuO 3 conductor fabricated according to the present invention. A first insulating layer 201 provides electrical isolation for underlying electronic devices such as thin film field effect transistors (FETs). A second insulating layer (not shown) is formed over the first insulating layer 201 , and a via etched through the second insulating layer which may act as a template for the container capacitor 200 . Via walls are lined with a conductive material 203 , namely SrRuO 3 film fabricated by the method of the present invention. A planarizing etch is conducted to remove excess SrRuO 3 over the top surface of the second insulating layer. The remaining second insulating layer may then be etched away to expose an outside surface 205 . The SrRuO 3 film 203 represents the bottom or storage electrode of the container capacitor 200 . A thin dielectric layer 207 is then formed over SrRuO 3 film 203 , followed by a second conductive layer 209 (e.g., also SrRuO 3 film), which represents the top or reference electrode for the container capacitor 200 . By following the contours of the three-dimensional container structure, the effective electrode surface area is substantially increased, allowing for substantially greater capacitance. Also, contact is made between the container capacitor 200 and an underlying active area 211 of the semiconductor substrate 213 between narrowly spaced transistor gates 215 (e.g., DRAM word lines), as shown in FIG. 2 . The actual contact is made by a contact conductive plug 217 which can be formed prior to formation of the container capacitor structure.
A typical processor based system which includes a memory device, e.g. RAM 460 containing capacitor having SrRuO 3 conductors fabricated according to the present invention is illustrated generally at 400 in FIG. 3. A computer system is exemplary of a system having integrated circuits, such as for example memory circuits. Most conventional computers include memory devices permitting storage of significant amounts of data. The data is accessed during operation of the computers. Other types of dedicated processing systems, e.g., radio systems, television systems, GPS receiver systems, telephones and telephone systems also contain memory devices which can utilize the present invention.
A processor based system, such as a computer system 400 , for example, generally comprises a central processing unit (CPU) 410 , for example, a microprocessor, that communicates with one or more input/output (I/O) devices 440 , 450 over a bus 470 . The computer system 400 also includes the random access memory (RAM) 460 , read only memory (ROM) 480 and may include peripheral devices such as a floppy disk drive 420 and a compact disk (CD) ROM drive 430 which also communicate with CPU 410 over the bus 470 . RAM 460 preferably has storage capacitor which includes SrRuO 3 conductors formed as previously described with reference to FIG. 1 . It may also be desirable to integrate the processor 410 and memory 460 on a single IC chip.
While preferred embodiments of the invention have been described and illustrated above, it should be understood that these are exemplary of the invention and are not to be considered as limiting. Additions, deletions, substitutions, and other modifications can be made without departing from the spirit or scope of the present invention. Accordingly, the invention is not to be considered as limited by the foregoing description but is only limited by the scope of the appended claims.
|
A method of fabricating an SrRuO 3 thin film is disclosed. The method utilizes a multi-step deposition process for the separate control of the Ru reagent, relative to the Sr reagent, which requires a much lower deposition temperature than the Sr reagent. A Ru reagent gas is supplied by a bubbler and deposited onto a substrate. Following the deposition of the Ru reagent, the Sr liquid reagent is vaporized and deposited onto the Ru layer.
| 2
|
FIELD
[0001] The present disclosure relates generally to abrasive articles, and more particularly to back-up pad/abrasive disc combinations.
BACKGROUND
[0002] Back-up pads are used in the abrasives field to support an abrasive article, such as a disc or sheet during abrading. These abrasive articles can be in various forms, such as a disc, a sheet, or a polygon and, may optionally, contain holes or slits to aid in dust extraction. The back-up pad includes a generally planar major surface, to which the abrasive article, such as a disc or sheet, may be attached. Although back-up pads may be hand held, back-up pads are more commonly used in conjunction with a powered abrading apparatus such as electric or pneumatic sanders.
[0003] Abrasive discs and sheets (hereinafter collectively “discs”) may be attached to a back-up pad in various ways. One attachment method includes an abrasive disc having pressure sensitive adhesive (PSA) on one surface thereof, such that the abrasive disc may be adhered to the major surface of the back-up pad. The major surface of the back-up pad may have, for example, a smooth foam, vinyl, or cloth surface to facilitate attachment of the abrasive disc. An example of such a back-up pad is available from 3M Company of St. Paul, Minn., under the designation “STIKIT” brand back-up pad. An example of an abrasive disc for attachment to that back-up pad is available from the same company under the designation “STIKIT” brand abrasive disc.
[0004] A second type of back-up pad includes a major surface having a plurality of hooks projecting therefrom. The hooks are adapted to engage certain structures provided on the back face of an abrasive disc to releasably attach the disc to the back-up pad. An example of such a back-up pad is available from the 3M Company of St. Paul, Minn., under the designation “HOOKIT” brand back-up pad, and an example of an abrasive disc for attachment to that back-up pad is available from the same company under the designation “HOOKIT” brand abrasive disc. Alternatively, the back-up pad major surface can include engaging structures to cooperate with hooks on an abrasive disc. An example of such an assembly is available from 3M Company under the designation “HOOKIT II” brand back-up pad and abrasive disc.
SUMMARY
BRIEF DESCRIPTION OF THE DRAWING
[0005] The present disclosure will be further explained with reference to the appended Figures, wherein like structures are referred to by like numerals throughout the several views, and wherein:
[0006] FIG. 1 is a section view of an example embodiment of a back-up pad and abrasive disc combination according to the present disclosure;
[0007] FIG. 2 is an example embodiment of a disc according to the present disclosure;
[0008] FIG. 3 is example embodiment of a disc according to the present disclosure;
[0009] FIG. 4 an example embodiment of a disc according to the present disclosure;
[0010] FIG. 5 an example embodiment of a disc according to the present disclosure;
[0011] FIG. 6 an example embodiment of a disc according to the present disclosure
[0012] FIG. 7 an example embodiment of a disc according to the present disclosure; and
[0013] FIG. 8 an example embodiment of a disc according to the present disclosure.
DETAILED DESCRIPTION
[0014] Generally, the invention of the present disclosure is directed to an abrasive article including a back-up pad removably attached to an abrasive disc. Within the context of this disclosure, removably attached means that the disc is secured to the back-up such that it will not detach during an abrading operation, but can be removed from the back-up pad via manual means, e.g., taken off by hand. The abrasive disc includes a plurality of perforations or holes therethrough for allowing passage of debris (swarf, dust, particles, metal, etc.) from a workpiece into the area or volume between the back-up pad and the abrasive disc.
[0015] FIG. 1 illustrates an exemplary article 105 including back-up pad 110 with an abrasive article 130 attached thereto. Abrasive layer 111 of article 130 comprises a plurality of abrasive particles 120 attached to a flexible backing 112 by adhesive coating 121 . The backing 112 has a front side 113 and a backside 114 . Attachment layer 115 is provided as a pressure sensitive adhesive layer (PSA) to releasably attach the abrasive article 130 (layers 111 and 112 ) to the facing layer 116 provided on the front surface 117 of molded foam layer 118 . Foam layer 118 , on its rear surface 119 , is attached to a rigid metal backing plate 122 . A threaded stud 123 is fixed in a known manner to the back side of the rigid backing plate 122 to allow attachment of the back-up pad 110 to a suitable tool or drive means (not shown) capable of, for example, rotatably driving the pad 110 and the article 130 around the longitudinal axis of threaded stud 123 . The back-up pad 110 is substantially impermeable to matter that is removed during the abrading process.
[0016] Various perforation (interchangeably, also holes) configurations in the abrasive disc can be used with the particle impermeable back up pad. FIG. 2 illustrates a 5-hole disc 230 , which is typically 3-8 inches (76.2-203.2 mm) in diameter. The holes 250 are spaced-regularly around the disc 230 , at about 72 degree intervals. Such discs are available under the trade designation “DUST-FREE SANDING DISCS—5 HOLE,” from 3M Company, St. Paul, Minn. FIG. 2 illustrates an 8-hole disc 330 , which is typically 3-8 inches (76.2-203.2 mm) in diameter. The holes 350 are spaced-regularly around the disc 330 , at about 45 degree intervals. Such discs are available under the trade designation “DUST-FREE SANDING DISCS—8 HOLE,” from 3M Company, St. Paul, Minn.
[0017] While the above-described discs include circular holes (or perforations), other shapes can be used, either singly or in combination. Referring to FIG. 4 , an exemplary disc 420 includes alternating rectangular shaped perforations 452 arranged regularly around the disc 420 . Triangular perforations 452 are placed between the rectangular perforations near the periphery of the disc 420 .
[0018] FIG. 5 illustrates an 8-perforation disc 520 , which is typically 3-8 inches (76.2-203.2 mm) in diameter. The perforations 550 are spaced-regularly around the disc 520 , at about 45-degree intervals. The perforations 550 have an end 551 near the periphery of the disc 520 and extend inwardly along a diameter of the disc 520 to a second end 553 near the center of the disc 520 .
[0019] FIG. 6 illustrates an 8-perforation disc 630 , which is typically 3-8 inches (76.2-203.2 mm) in diameter. The perforations 650 , 652 are spaced-regularly around the disc 630 . The perforations 650 , 652 are arcuate and have a circularly-shaped end 651 , 653 near the periphery of the disc 630 and extend inwardly to a second cusp-shaped end 655 , 657 near the center of the disc 630 .
[0020] FIG. 8 illustrates a 13-perforation disc 820 , which is typically 3-8 inches (76.2-203.2 mm) in diameter. Eight perforations 850 are spaced-regularly around the disc 820 near the disc 820 periphery, at about 45-degree intervals. The remaining five perforations 850 include a center hole and an X-shaped layout of the remaining four perforations surrounding the center hole.
[0021] Other possible arrangements include the holes or perforations distributed over the entire disc, both uniformly and non-uniformly. The holes or perforations can also be distributed over annular sections of the disc. The perforations on a given disc can be of uniform size, or can be of various shapes and sizes.
[0022] To increases the amount of debris that can be accommodated between the disc and the back-up pad, means for accumulating the debris can be optionally included. For example, the back-up pad can have an undulating surface, wherein the low points in the surface will allow more debris to be trapped. The back-up pad can also include cavities, which allows debris to be trapped. An interface pad can also be included between the back-up pad and the disc, adding further debris holding capacity. An exemplary interface pad is available under the trade designation “SOFT INTERFACE PAD,” available from 3M Company, St. Paul, Minn.
[0023] The back-up pad of the invention can be used in any of a variety of desired abrading applications so long as it is properly designed to meet the requirements of the given abrading application. The foam material and mixing proportions of the components of the foam should be formulated to meet the needs of the desired abrading application.
[0024] It is within the capability of one of ordinary skill in the art to select the back-up pad to meet the requirements of the abrading for which the pad is used. It is to be understood that the term abrading, and its variants, as used herein are meant to include operations used to reduce or refine a workpiece surface through frictional contact between the workpiece surface and an abrasive article, such as grinding, sanding, finishing, cleaning or polishing operations. These abrading applications can vary widely from final polishing of ophthalmic lenses to heavy stock removal of metal parts. These abrading applications can also involve either abrading by hand or abrading with a machine as the mode of driving the abrasive article in motion. The abrading motions may include a linear motion, random motion, rotary motion, oscillation, random orbital motion, combinations thereof or the like.
[0025] The shape of the foam back-up pad may be a square, triangle, rectangle, oval, circle, pentagon, hexagon, octagon, polygon, or any other suitable shape. The diameter for a circular back-up pad ranges from about 0.5 to 50 inches (1.25 cm to 127.0 cm), typically 1 to 30 inches (2.5 cm to 76.2 cm). The length and/or width of the back-up pad can range from about 0.05 to 50 inches (0.13 cm to 127.0 cm), typically 1 to 30 inches (2.5 cm to 76.2 cm). In some instances, a coated abrasive article will overhang the back-up pad by a very slight amount, i.e., typically less than 0.1 inches (0.25 cm), preferably less than 0.05 inches (0.13 cm). The thickness of the foam body member generally will range from between about 0.2 cm to 7.0 cm typically 0.5 cm to 5.0 cm, and preferably between 1.0 cm. to 3.0 cm.
[0026] The foam back-up layer, as used in most abrading applications, will be molded to present a pair of substantially parallel spaced major surfaces or faces. Referring to FIG. 1 , the front face 117 of the foam back-up pad 110 provides a surface upon which a pad-facing layer 116 can be provided. Examples of materials useful for forming the front facing layer include cloth, nonwoven substrates, treated cloth, treated nonwoven substrates, polymeric films and the like. Examples of preferred front facing materials include loop fabric, cloth sheeting, vinyl sheeting, hooks, nylon coated cloths, vinyl coated nonwovens, vinyl coated cloth, hook faced materials, and the like. The loop fabric can be a knitted loop, brushed loop, a chenille stitched loop, and the like. The polyurethane material of the foam layer 118 is bonded to the pad-facing layer 116 and can be hardened in-situ on the pad facing. For instance, a polyurethane material can be foamed directly to the back side of a pad facing such as loop fabric, thereby adhering to the pad facing. Alternatively, the front facing material can be adhesively bonded to the polyurethane foam. If the polyurethane is foamed onto the front facing material, the front facing material preferably is first sealed to prevent undesired excessive penetration of the foam therethrough.
[0027] If the foam back-up pad is intended to be used in machine driven applications, it will typically have some type of mechanical attachment system opposite the side of the loop fabric to secure the back-up pad to the machine. One such system comprises rigid backing plate 122 fixed to the rear surface 119 of the foam back-up pad 110 with threaded stud 123 fixed to the plate 122 (e.g., by welding) for attachment of the foam pad 110 to a drive motor, such as described in U.S. Pat. No. 4,844,967 (Goralski), incorporated herein by reference. Backing plate 122 is affixed (e.g., by rivets) to a larger diameter fiberglass plate (not shown) or an equivalent member, and the foam surface 119 is bonded directly to the fiberglass to thereby affix the mounting system to the back-up pad 110 . Any of a variety of systems or means can be provided for detachable coupling of the foam pad 110 to different types of drive motor assemblies. Such means are known in the art and may include, for example, central concentric openings extending through the foam and the backing plate and accommodating the threaded end of a headed bolt, with the bolt head abutting the surface of the backing plate affixed to the foam with the head of the bolt positioned in the central opening of the foam and the threaded end of the bolt engaging the drive member of a drive motor assembly. For random orbital applications, the support member may contain a threaded studded or other attachment system for mounting onto the machine. Other means that can be provided to adapt the back-up pad for operation with drive mechanisms include those disclosed in U.S. Pat. No. 4,631,220 (Clifton), incorporated herein by reference. It will be understood that the invention is not limited by the specific mounting system employed, and those skilled in the art will appreciate that the specific mounting system employed for use with a specific back-up pad will depend on the type of tool to be used with the pad.
[0028] For manual abrasive operations held in the hand, various shapes or configurations of foam back-up pads may be utilized. Two such types include hand pads and foamed back-up pads used on long planing boards. The strength and other physical properties required for these manual abrasive operations is less than those for random orbital applications where the strength and physical property requirements of the foam become much more significant. The physical properties of the foam depend on the end use application. As the back-up pad is used in abrading applications, there can be a manual grip handle associated with it.
[0029] In some instances, it is preferred to incorporate a pressure sensitive adhesive onto the backside of the abrasive article so that the backing of the abrasive article can be secured to the facing layer of the foam back-up pad. Representative examples of pressure sensitive adhesives suitable for this invention include latex crepe, rosin, acrylic polymers and copolymers e.g., polybutylacrylate, polyacrylate ester, polyvinyl ethers, e.g. polyvinyl n-butyl ether, alkyd adhesives, rubber adhesives, e.g., natural rubber, synthetic rubber, chlorinated rubber, and mixtures thereof. The preferred pressure sensitive adhesive is an isooctylacrylate: acrylic acid copolymer.
[0030] Alternatively, a hook and loop type attachment system may be employed to secure the abrasive article to the facing of the foam back-up pad. The hook fabric may be on the backside of the abrasive article with hooks on the front side of the back-up pad. Otherwise, the hooks may be on the backside of the abrasive article with the loops on the front side of the back-up pad. This hook and loop type attachment system is further described in U.S. Pat. No. 4,609,581 (Ott); U.S. Pat. No. 5,254,194 (Ott et al.); U.S. Pat. No. 6,579,162 (Chesley et al.); U.S. Pat. No. 5,505,747 (Chesley et al.); U.S. Pat. No. 5,607,345 (Barry et al.); and U.S. patent publication No. 03-0159363-A1 (Chesley et al.); each of which is incorporated herein by reference. The opposite exposed front side of the abrasive article has an abrasive coating that is responsible for the abrading action.
EXAMPLES
[0031] The following materials were obtained from 3M Company, Saint Paul, Minn. As noted, some materials were subsequently modified for evaluation purposes.
“AD1”: A P320 grade alumina, resin bonded, 5-inch (12.7 cm) diameter abrasive disc, commercially available under the trade designation “210U P320 STIKIT DISC”; “AD2”: A 5-hole P320 grade alumina, resin bonded, 5-inch (12.7 cm) diameter abrasive paper disc, commercially available under the trade designation “210U P320 STIKIT DUST-FREE DISC”, wherein a single center-hole, 1⅜ inch (3.5 cm) diameter, was die punched out of the abrasive film disc; “AD3”: A P400 grade alumina, resin bonded, 5-inch (12.7 cm) diameter abrasive disc, commercially available under the trade designation “210U P400 STIKIT DISC”; “AD4”: A 5-hole P400 grade alumina, resin bonded, 5-inch (12.7 cm) diameter abrasive paper disc, commercially available under the trade designation “210U P400 STIKIT DUST-FREE DISC”, wherein a single center-hole, 1⅜ inch (3.5 cm) diameter, was die punched out of the abrasive film disc; “AD5”: A P400 grade alumina, resin bonded, 5-inch (12.7 cm) diameter abrasive paper disc, commercially available under the trade designation “210U P400 HOOKIT II DISC”; “AD6”: A 5-hole P400 grade alumina, resin bonded, 5-inch (12.7 cm) diameter abrasive paper disc, commercially available under the trade designation “210U P400 HOOKIT II DUST-FREE DISC”, wherein a single center-hole, 1⅜ inch (3.5 cm) diameter, was die punched out of the abrasive film disc; “AD7”: A P400 grade alumina, resin bonded, 6-inch (15.2 cm) diameter abrasive paper disc, having a stearate antiloading supersize, commercially available under the trade designation “216U P400 FRE-CUT HOOKIT II DISC”; “AD8”: A 6-hole P400 grade alumina, resin bonded, 6-inch (15.2 cm) diameter abrasive paper disc, having a stearate antiloading supersize, commercially available under the trade designation “216U P400 FRE-CUT HOOKIT II DUST-FREE DISC” “AD9”: A 9-hole P400 grade alumina, resin bonded, 6-inch (15.2 cm) diameter abrasive paper disc, having a stearate antiloading supersize, commercially available under the trade designation “216U P400 FRE-CUT DUST-FREE HOOKIT II DISC”; “AD10”: A P500 grade alumina, resin bonded, 5-inch (12.7 cm) diameter abrasive film disc, commercially available under the trade designation “360L P500 HOOKIT II”; “AD11”: As per “AD10”, wherein a single center-hole, 1⅜ inch (3.5 cm) diameter, was die punched out of the abrasive film disc; “AD12”: A 5-hole P500 grade alumina, resin bonded, 5-inch (12.7 cm) diameter abrasive film disc, commercially available under the trade designation “360L P500 HOOKIT II DUST-FREE DISC”, wherein a single center-hole, 1⅜ inch (3.5 cm) diameter, was die punched out of the abrasive film disc; “AD13”: A P1000 grade alumina, resin bonded, 6-inch (15.2 cm) diameter abrasive film disc, commercially available under the trade designation “260L P1000 HOOKIT II DISC”; “AD14”: A 6-hole P1000 grade alumina, resin bonded, 6-inch (15.2 cm) diameter abrasive film disc, commercially available under the trade designation “260L P1000 HOOKIT II DUST-FREE DISC”; “AD15”: A P1000 grade alumina, resin bonded, 6-inch (15.2 cm) diameter abrasive film disc, commercially available under the trade designation “260L P1000 STIKIT DISC”; “AD16”: A 6-hole P1000 grade alumina, resin bonded, 6-inch (15.2 cm) diameter abrasive film disc, commercially available under the trade designation “260L P1000 STIKIT DUST-FREE DISC”; “AD17”: A P1000 grade alumina, resin bonded, 6-inch (15.2 cm) diameter abrasive film disc, commercially available under the trade designation “260L P1000 HOOKIT DISC”; “AD18”: A 6-hole P1000 grade alumina, resin bonded, 6-inch (15.2 cm) diameter abrasive film disc, commercially available under the trade designation “260L P1000 HOOKIT DUST-FREE DISC”; “AD19”: A P320 grade alumina, resin bonded, 5-inch (12.7 cm)×3-inch (7.6 cm) rectangular abrasive paper sheet, commercially available under the trade designation “334U P320 HOOKIT II”; “AD20”: As per “AD19”, wherein 13 holes of ⅛-inch (0.32 cm) diameter, in an evenly distributed 3×3/2×2 array, were die punched out of the abrasive sheet, having the hole pattern as illustrated in FIG. 8 ; “BP1”: Back-up pad having pressure sensitive adhesive as a means for attaching abrasive discs, available under the trade designation “STIKIT LOW PROFILE DISC PAD”; “BP2”: Back-up pad having hooks as a means for attaching abrasive discs in a hook and loop mechanical fastener system, available under the trade designation “HOOKIT LOW PROFILE DISC PAD”; “BP3”: Back-up pad having loops as a means for attaching abrasive discs in a hook and loop mechanical fastener system, available under the trade designation “HOOKIT II DISC PAD”; “BP4”: As per backup pad BP1, wherein a polypropylene mask having a pressure sensitive adhesive coated macro structure, 0.317 mm×0.317 mm×0.35 mm height, and 0.156 mm channels between macro structures, was laminated to the face of the back up pad; “BP5”: Hand-held back-up pad having pressure sensitive adhesive as a means for attaching abrasive discs, available under the trade designation “HOOKIT II CENTER WATER FEED FOAM DISC PAD”; “BP6”: A hard hand sanding block, 2¾-inch (7.0 cm)×5-inch (12.7 cm), commercially available under the trade designation “HOOKIT II HAND BLOCK”; “TP1”: A mild steel test panel coated with a grey primer, commercially available under the trade designation “URO 1140S” from E. I. DuPont de Nemours Company, Wilmington, Del.; “TP2”: A mild steel test panel coated with a powder primer, commercially available under the trade designation “PCV 70118” from PPG Industries, Pittsburgh, Pa.; “TP3”: A mild steel test panel coated with a urethane clearcoat, commercially available under the trade designation “DCU 2021” from PPG Industries; “TP4”: A mild steel test panel coated with a primer, commercially available under the trade designation “TAUPE U28RW035K” from BASF Automotive Refinish Technologies, Inc., Southfield, Mich.; “TP5”: A mild steel test panel coated with black primer, commercially available under the trade designation “SIKKENS COLORBUILD BLACK” from Akzo Nobel Coatings Inc., Norcross, Ga.
Test Methods
[0063] The following test methods were used.
[0000] Off-Hand Abrasion Test.
[0064] An abrasive disc was secured to the appropriate size backup pad according to the respective attachment system. The disc pad was then attached to a dual action sander, commercially available as model number “57015”, from the Dynabrade Company, Clarence, N.Y. Abrasion tests were run for up to 138 seconds, in various intervals, over three adjacent sections of the test panel, at an air pressure of up to 620.5 kPa (90 Psi) and a disc-to-panel angle of 0-2.5 degrees.
[0000] Surface Finish
[0065] Surface finish (Rz) is the average individual roughness depths of a measuring length, where an individual roughness depth is the vertical distance between the highest point and the lowest point. The surface finish of abraded test panels were measured using a profilometer under the trade designation “PERTHOMETER MODEL M4P-127527” from Mahr Corporation, Cincinnati, Ohio. Surface finish values were measured at five points within each of the three abraded sections of the test panel at the end of the third sanding interval.
[0000] Cut Rate
[0066] Cut-rate refers to the ability of the abrasive article to remove stock material or surface particles from the workpiece. The cut rate is the amount of weight loss of the test panel during the sanding operation. The test panel was weighed with an accurate electronic balance before the sanding test began. Using the sample test fixture the painted panel was sanded as described above. After each sanding cycle the test panel was cleaned of accumulated swarf by blowing with compressed air. The test panel was re-weighed to establish the weight loss (cut) during each sanding interval. The cumulative weight loss for each sanding interval was then recorded. The tests were run in triplicate.
[0000] Stiction
[0067] Sanding a smooth abrasive coating may create what is known in the industry as “stiction”, whereby the abrasive coating may stick to the workpiece surface, with unwanted results. It is preferred to minimize stiction in fine finishing applications.
Examples 1-5 & Comparatives A-D
[0068] Samples of test panel TP1 were sanded according to the method described above at a pressure of 620.5 kPa (90 Psi). Results are listed in Table 1.
TABLE 1 Sanding Total Abrasive Back- Interval Cut Rate Cut Disc up Pad (seconds) (grams) (grams) Example 1 AD2 BP1 30, 60, 90 Not 6.0 Measured Comparative A AD1 BP1 30, 60, 90 Not 6.6 Measured Example 2 AD2 BP4 30, 60, 90 Not 7.2 Measured Comparative B AD1 BP4 30, 60, 90 Not 6.1 Measured Example 3 AD4 BP1 30, 60, 90 1.79, 1.68, 5.0 1.51 Example 4 AD4 BP4 30, 60, 90 2.08, 1.92, 5.7 1.66 Comparative C AD3 BP1 30, 60, 90 1.84, 1.53, 4.8 1.46 Example 5 AD6 BP3 30, 60, 90 Not 5.2 Measured Comparative D AD5 BP3 30, 60, 90 Not 3.6 Measured
Examples 6-8 & Comparatives E-G
[0069] Samples of test panel TP2 were sanded according to the method described above at a pressure of 620.5 kPa (90 Psi). Results are listed in Table 2.
TABLE 2 Sanding Abrasive Back- Interval Total Cut Disc up Pad (seconds) Improvement Example 6 AD6 BP3 30, 60, 90, 148% 120 Comparative E AD5 BP3 30, 60, 90, 100% 120 Example 7 AD6 BP3 30, 60, 90, 144% 120 Comparative F AD5 BP3 30, 60, 90, 100% 120 Example 8 AD8 BP3 30, 60, 90, 150% 120 Comparative G AD7 BP3 30, 60, 90, 100% 120
Example 9 & Comparative H
[0070] Samples of test panel TP1 were sanded according to the method described above at a pressure of 620.5 kPa (90 Psi). Results are listed in Table 3.
TABLE 3 Sanding Total Abrasive Back- Interval Cut Rate Cut Finish (microinches)/ Disc up Pad (seconds) (grams) (grams) (micrometers) Example 9 AD9 BP3 30, 60, 90, 120 1.86, 1.42, 5.86 146/125 1.34, 1.24 (3.71/3.18) @30/120 s Comparative H AD7 BP3 30, 60, 90, 120 1.36, 0.95, 4.26 147/130 1.01, 0.95 (3.73/3.30) @30/120 s
Examples 10-11 & Comparative I
[0071] Samples of test panel TP1 were sanded according to the method described above at a pressure of 620.5 kPa (90 Psi). Results are listed in Table 4.
TABLE 4 Sanding Total Abrasive Back- Interval Cut Rate Cut Finish (microinches)/ Disc up Pad (seconds) (grams) (grams) (micrometers) Example 10 AD11 BP3 30, 60, 90, 120 1.82, 1.31, 5.42 104/88 1.16, 1.13 (2.64/2.24) @30/120 s Example 11 AD12 BP3 30, 60, 90, 120 1.88, 1.40, 5.76 106/92 1.25, 1.23 (2.69/2.34) @30/120 s Comparative I AD10 BP3 30, 60, 90, 120 1.50, 1.10, 4.73 108/90 1.11, 1.02 (2.74/2.29) @30/120 s
Examples 12-14 & Comparatives J-L
[0072] Samples of test panel TP3 were sanding according to the method described above at a pressure of 248.2 kPa (36 Psi). An interface pad, commercially available under the trade designation “HOOKIT II SOFT INTERFACE PAD” from 3M Company, was applied between the abrasive disc and the back-up pad. Results are listed in Table 5. Three different lots of “260L P1000 HOOKIT II DISC” and “260L P1000 HOOKIT II DUST-FREE DISC” were evaluated.
TABLE 5 Sanding Abrasive Back- Interval Total Cut Finish (microinches)/ Disc up Pad (seconds) (grams) (micrometers) Example 12 AD14, Lot 1 BP3 23, 46, 69, 0.30 76.8 92, 115, (1.95) 138 Comparative J AD13, Lot 1 BP3 23, 46, 69, 0.35 81.0 92, 115, (2.06) 138 Example 13 AD14, Lot 2 BP3 23, 46, 69, 0.35 89.1 92, 115, (2.26) 138 Comparative K AD13, Lot 2 BP3 23, 46, 69, 0.33 87.3 92, 115, (2.22) 138 Example 14 AD14, Lot 3 BP3 23, 46, 69, 0.21 53.3 92, 115, (1.35) 138 Comparative L AD13, Lot 3 BP3 23, 46, 69, 0.25 56.4 92, 115, (1.43) 138
Examples 15-16 & Comparatives M-N
[0073] Samples of test panel TP2 were sanded according to the method described above at a pressure of 275.8 kPa (40 Psi) using a STIKIT disc pad. Results are listed in Table 6.
TABLE 6 Abrasive Back- Sanding Interval Cut Rate Finish (microinches)/ Disc up Pad (seconds) (grams) (micrometers) Example 15 AD16 BP1 23, 46, 69, 0.16, 0.27, 36.9 92, 115, 0.42, 0.54 (0.94) 138 Comparative M AD15 BP1 23, 46, 69, 0.19, 0.35, 33.5 92, 115, 0.51, 0.65 (0.85) 138 Example 16 AD16 BP4 23, 46, 69, 0.22, 0.44, 30.8 92, 115, 0.64, 0.85 (0.78) 138 Comparative N AD15 BP4 23, 46, 69, 0.21, 0.47, 31.5 92, 115, 0.69, 0.84 (0.80) 138
Example 17 & Comparative O
[0074] Samples of test panel TP4, moistened with a thin film of water, were hand sanded using HOOKIT II discs attached to hand HOOKIT II center water feed back up pad. Results are listed in Table 7.
TABLE 7 Sanding Total Abrasive Back- Interval Cut Disc up Pad (seconds) (grams) Stiction Example 17 AD6 BP5 30 30.3 Low stiction Comparative O AD5 BP5 30 33.3 High stiction
Example 18 & Comparative P
[0075] Samples of test panel TP5, were dry hand sanded using HOOKIT II sheets attached to hard hand sanding block BP6, in a series of 4 intervals of 5 strokes (backward-forward) each. Cut performance and stiction ratings, as an average of triplicate samples, are listed in Table 8.
TABLE 8 Abrasive Back- Cut Rate Disc up Pad (grams) Stiction Example 18 AD20 BP6 0.47, 1.05, No stiction 1.34 Comparative P AD19 BP6 0.49, 1.02, High stiction 1.24
Examples 19-21 & Comparatives Q-S
[0076] Samples of test panel TP3 were sanded according to the method described above at a pressure of 248.2 kPa (36 Psi). With respect to Example 20 and Comparative R, an interface pad, commercially available under the trade designation “HOOKIT SOFT INTERFACE PAD” from 3M Company, was applied between the abrasive disc and the back-up pad. With respect to Example 21 and Comparative S, an interface pad, commercially available under the trade designation “HOOKIT II SOFT INTERFACE PAD” from 3M Company, was applied between the abrasive disc and the back-up pad. Results are listed in Table 9.
TABLE 9 Abrasive Back- Sanding Interval Cut Rate Finish (microinches)/ Disc up Pad (seconds) (grams) (micrometers) Example 19 AD16 BP1 30, 60, 0.40, 0.69, 84.8 120 1.02, (2.15) Comparative Q AD15 BP1 30, 60, 90, 0.33, 0.58, 78.9 120 0.97 (2.00) Example 20 AD18 BP2 30, 60, 90, 0.32, 0.67, 74.2 120 1.25 (1.89) Comparative R AD17 BP2 30, 60, 90, 0.31, 0.62, 73.4 120 1.12 (1.86) Example 21 AD14 BP3 30, 60, 90, 0.30, 0.62, 71.5 120 1.12 (1.82) Comparative S AD13 BP3 30, 60, 90, 0.31, 0.62, 73.7 120 1.10 (1.87)
Examples 22 - 24 & Comparatives T-V
[0077] Samples of test panel TP2 were sanded according to the method described above at a pressure of 275.8 kPa (40 Psi). With respect to Examples 23-24 and Comparatives U-V, interface pads, as described previously, were applied between the abrasive disc and the back up pad. Results are listed in Table 10.
TABLE 10 Abrasive Back- Sanding Interval Cut Rate Finish (microinches)/ Disc up Pad (seconds) (grams) (micrometers) Example 22 AD16 BP1 15, 30, 45, 0.25, 0.38, 40.1 60 0.62 (1.02) Comparative T AD15 BP1 15, 30, 45, 0.16, 0.36, 48.0 60 0.69 (1.22) Example 23 AD18 BP2 15, 30, 45, 0.22, 0.46, 33.3 60 0.82 (0.85) Comparative U AD17 BP2 15, 30, 45, 0.20, 0.36, 43.0 60 0.63 (1.09) Example 24 AD14 BP3 30 0.17, 0.38, 38.1 0.77 (0.97) Comparative V AD13 BP3 30 0.17, 0.40, 39.4 0.68 (1.00)
[0078] The abrasive disc, the means for the attachment of the article to the back-up pad, the foam facing layer, the rigid backing plate and threaded stud, as mentioned above in connection with the discussion above, while useful and necessary from a practical standpoint to the present invention, can be supplied by known means and constructions in the field and thus should require no further details than that provided herein to be understood by one of ordinary skill in the art.
|
An abrasive article and methods of making and using the same are disclosed. The abrasive article includes a particle impermeable back-up pad attached to an abrasive disc. The abrasive disc includes a plurality of perforations therethrough. When the abrasive article is moved and contacted against a workpiece, debris from the workpiece is captured between the back-up pad and workpiece.
| 1
|
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of pending U.S. patent application Ser. No. 13/613,407, filed on Sep. 13, 2012, which is a continuation of U.S. patent application Ser. No. 12/206,427, filed on Sep. 8, 2008, now U.S. Pat. No. 8,295,399, which is a continuation of U.S. patent application Ser. No. 11/955,443, filed Dec. 13, 2007, now U.S. Pat. No. 7,545,882, which is a divisional application of U.S. patent application Ser. No. 10/827,445, filed Apr. 20, 2004, now U.S. Pat. No. 7,359,457, which is a continuation of U.S. patent application Ser. No. 09/627,070, filed Jul. 27, 2000, now U.S. Pat. No. 6,993,092, the disclosures of which are expressly incorporated herein by reference in their entireties.
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a transmission apparatus, reception apparatus and digital radio communication method, which is used for digital radio communications.
Description of the Related Art
As a conventional digital modulation system, a technology described in the Unexamined Japanese Patent Publication No. HEI 1-196924 is known. This is the technology which the transmitting side configures a frame by inserting 1 known pilot symbol for every N data symbols and the receiving side estimates a frequency offset and amount of amplitude distortion by using the pilot symbol, and removes these frequency offset and amplitude distortion and demodulates.
Here, in the case of a radio communication, fluctuations in the transmission path occur due to fading and in terrestrial mobile communication in particular, fluctuations in the transmission path are not uniform. When fluctuations in the transmission path are intense, the interval of inserting a pilot symbol must be shorter to prevent deterioration of the data demodulation error rate. On the contrary, when fluctuations in the transmission path are gentle, extending the interval of inserting a pilot symbol does not deteriorate the data demodulation error rate so much.
On the other hand, when the level of a reception signal on the receiving side is small, a modulation system used must be highly resistant to errors for information symbols. On the contrary, when the level of a reception signal on the receiving side is large, higher priority can be given to a modulation system of high transmission efficiency for information symbols.
However, in the conventional digital modulation system above, the pilot symbol insertion interval and the information symbol modulation system are fixed. Therefore, when fluctuations in the transmission path are intense or the level of the reception signal of the receiver is small, error resistance during data demodulation reduces and the quality of data deteriorates. On the other hand, when fluctuations in the transmission path are gentle or the level of the reception signal on the receiving side is large, the data transmission efficiency cannot be improved despite the excessive data quality.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a transmission apparatus, reception apparatus and digital radio communication method capable of flexibly improving the data transmission efficiency and the quality of data.
The present invention attains the above object by changing the interval of inserting a known pilot symbol, binary phase (BPSK: Binary Phase Shift Keying) modulation symbols or quadrature phase (QPSK: Quadrature Phase Shift Keying) modulation symbols and the modulation system of information symbols according to the communication situation such as fluctuations in the transmission path and the level of a reception signal.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects and features of the invention will appear more fully hereinafter from a consideration of the following description taken in connection with the accompanying drawing wherein one example is illustrated by way of example, in which;
FIG. 1 is a block diagram showing a configuration of a transmission apparatus according to Embodiment 1 of the present invention;
FIG. 2 illustrates examples of a frame configuration of a signal transmitted from the transmission apparatus of Embodiment 1 of the present invention;
FIG. 3 is a layout of signal points of 16QAM and a known pilot symbol on an in-phase I-quadrature Q plane;
FIG. 4 is a layout of signal points of 8PSK modulation and a known pilot symbol on an in-phase I-quadrature Q plane;
FIG. 5 is a block diagram showing a configuration of a reception apparatus according to Embodiment 1 of the present invention;
FIG. 6 is a block diagram showing a configuration of a transmission apparatus according to Embodiment 2 of the present invention;
FIG. 7 illustrates examples of a frame configuration of a signal transmitted from the transmission apparatus of Embodiment 2 of the present invention;
FIG. 8 is a layout of signal points of 16QAM and BPSK modulation on an in-phase I-quadrature Q plane;
FIG. 9 is a layout of signal points of 8PSK modulation and BPSK modulation on an in-phase I-quadrature Q plane;
FIG. 10 is a block diagram showing a configuration of a reception apparatus according to Embodiment 2 of the present, invention;
FIG. 11 is a block diagram showing a configuration of a transmission apparatus according to Embodiment 3 of the present invention;
FIG. 12 illustrates examples of a frame configuration of a signal transmitted from the transmission apparatus of Embodiment 3 of the present invention;
FIG. 13 is a layout of signal points of 16QAM and QPSK modulation on an in-phase I-quadrature Q plane;
FIG. 14 is a layout of signal points of BPSK modulation and QPSK modulation on an in-phase I-quadrature Q plane;
FIG. 15 is a block diagram showing a configuration of a reception apparatus according to Embodiment 3 of the present invention;
FIG. 16 is a block diagram showing a configuration of a transmission apparatus according to Embodiment 4 of the present invention;
FIG. 17 illustrates examples of a frame configuration of a signal transmitted from the transmission apparatus of Embodiment 4 of the present invention;
FIG. 18 is a layout of signal points of BPSK modulation on an in-phase I-quadrature Q plane;
FIG. 19 is a layout of signal points of QPSK modulation on an in-phase I-quadrature Q plane;
FIG. 20 is a block diagram showing a configuration of a reception apparatus according to Embodiment 4 of the present invention;
FIG. 21 is a block diagram showing a configuration of a transmission apparatus according to Embodiment 5 of the present invention;
FIG. 22 illustrates examples of a frame configuration of a signal transmitted from the transmission apparatus of the Embodiment 5 of the present invention;
FIG. 23 is a layout of signal points of 16QAM, a known pilot symbol and symbols before and after the pilot symbol on an in-phase I-quadrature Q plane;
FIG. 24 is a layout of signal points of 8PSK modulation, a known pilot symbol and symbols before and after the pilot symbol on an in-phase I-quadrature Q plane; and
FIG. 25 is a block diagram showing a configuration of a reception apparatus according to Embodiment 5 of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the attached drawings, embodiments of the present invention will be explained in detail below.
Embodiment 1
Embodiment 1 describes a digital radio communication method by which the interval of inserting a known pilot symbol and the modulation system of information symbols are changed according to the communication situation.
FIG. 1 is a block diagram showing a configuration of a transmission apparatus according to this embodiment. As shown in FIG. 1 , the transmission apparatus according to this embodiment mainly consists of frame configuration determination section 101 , quadrature baseband modulation section 102 , pilot symbol generation section 103 , frame configuration section 104 , and LPFs (Low Pass Filters) 105 and 106 , transmission radio section 107 and transmission antenna 108 .
Frame configuration determination section 101 judges the communication situation based on transmission path information which shows the degree of fluctuations of the transmission path due to fading and data transmission speed information which shows the transmission speed of transmission data based on the level of a reception signal and decides the interval of inserting a known pilot symbol and the modulation system of a transmission digital signal. Then, frame configuration determination section 101 outputs a signal indicating the determined modulation system to quadrature baseband modulation section 102 and outputs a signal indicating the determined interval of inserting the known pilot symbol to frame configuration section 104 . By the way, details of the method of determining a frame configuration by frame configuration determination section 101 will be described later.
Here, when an identical frequency band is used for the uplink and the downlink, the situation of fluctuations in the transmission path due to fading can be estimated from a transition in the result of measuring the reception level of the modulated signal transmitted from the other end of communication on the receiving side, which is not shown in the figure, of the communication apparatus in which the transmission apparatus shown in FIG. 1 is mounted. Furthermore, the transmission apparatus shown in FIG. 1 can recognize the situation of fluctuations in the transmission path due to fading, by the reception apparatus, which is the other end of communication of the transmission apparatus shown in FIG. 1 , measuring the reception level of the modulated signal transmitted from the other end of communication, estimating the situation of fluctuations in the transmission path due to fading based on the transition of the measurement result.
Then, when an identical frequency band is used for the uplink and the downlink, the transmission speed of the transmission data can be determined from a result of measuring the reception level of the modulated signal transmitted from the other end of communication on the receiving side, which is not shown in the figure, of the communication apparatus in which the transmission apparatus shown in FIG. 1 is mounted. Furthermore, the transmission apparatus shown in FIG. 1 can recognize the transmission speed of the transmission data by the reception apparatus, which is the other end of communication of the transmission apparatus shown in FIG. 1 , measuring the reception level of the pilot symbol transmitted from the other end of communication and determining the transmission speed of the transmission data based on the measurement result.
Quadrature baseband modulation section 102 modulates a transmission digital signal to a quadrature baseband signal with the modulation system indicated from frame configuration determination section 101 and outputs the in-phase component and the quadrature component of the quadrature baseband signal to frame configuration section 104 .
Pilot symbol generation section 103 generates a pilot symbol known between the transmitting and receiving sides and outputs the in-phase component and the quadrature component of the known pilot symbol to frame configuration section 104 .
Frame configuration section 104 inserts the known pilot symbol output from pilot symbol generation section 103 into the output signal of quadrature baseband modulation section 102 at the insertion interval instructed from frame configuration determination section 101 and composes a frame.
LPF 105 lets pass only a predetermined frequency band section of the in-phase component output from frame configuration section 104 , LPF 106 lets pass only a predetermined frequency band section of the quadrature component output from frame configuration section 104 .
Transmission radio section 107 transmits a radio frequency signal as the electric wave from transmission antenna 108 after performing radio processing on the output signals of LPF 105 and LPF 106 .
Next, examples of the method of determining a frame configuration by frame configuration determination section 101 of the transmission apparatus shown in FIG. 1 above will be explained.
FIG. 2 illustrates examples of a frame configuration of a signal transmitted from the transmission apparatus of this embodiment and shows a time-symbol relationship. ( 201 ) is a frame configuration when the modulation system of information symbols is 16-value quadrature amplitude modulation (16QAM: 16 Quadrature Amplitude Modulation) and a known pilot symbol interval is N symbols. ( 202 ) is a frame configuration when the modulation system of information symbols is 16QAM and a known pilot symbol interval is M symbols. ( 203 ) is a frame configuration when the modulation system of information symbols is 8 phases (8PSK: 8 Phase Shift Keying) modulation and a known pilot symbol interval is N symbols. ( 204 ) is a frame configuration when the modulation system of information symbols is 8PSK modulation and a known pilot symbol interval is M symbols. Suppose N<M at this time.
Frame configuration determination section 101 selects one of ( 201 ), ( 202 ), ( 203 ) or ( 204 ) in FIG. 2 as the optimal frame configuration based on the transmission path information and the request data transmission speed information.
For example, in the case of high-speed fading, frame configuration determination section 101 sacrifices data transmission efficiency on the receiving side and selects a frame configuration of either ( 201 ) or ( 203 ) in FIG. 2 so that the interval of inserting a known pilot symbol becomes narrower to prevent deterioration of the data demodulation error rate and maintain the quality of data. On the other hand, in the case of low-speed fading, frame configuration determination section 101 selects a frame configuration of either ( 202 ) or ( 204 ) in FIG. 2 to widen the interval of inserting a known pilot symbol to improve the data transmission efficiency.
Also, when the level of the reception signal is large, frame configuration determination section 101 gives priority to data transmission efficiency on the receiving side and selects a frame configuration of either ( 201 ) or ( 202 ) in FIG. 2 adopting 16QAM as the modulation system of information symbols. On the other hand, when the level of the reception signal is small, frame configuration determination section 101 gives priority to increasing error resistance while sacrificing data transmission efficiency on the receiving side and selects a frame configuration of either ( 203 ) or ( 204 ) in FIG. 2 adopting 8PSK as the modulation system of information symbols.
FIG. 3 shows a signal point layout according to the 16QAM modulation system on the in-phase I-quadrature Q plane and signal point layout of a known pilot symbol. Signal point 301 is the signal point of a known pilot symbol and signal points 302 are the signal points of 16QAM modulation symbols. FIG. 4 shows a signal point layout according to the 8PSK modulation system on the in-phase I-quadrature Q plane and signal point layout of a known pilot symbol. Signal point 401 is the signal point of a known pilot symbol and signal points 402 are the signal points of 8PSK modulation symbols.
FIG. 5 is a block diagram showing a configuration of the reception apparatus according to this embodiment. As shown in FIG. 5 , the reception apparatus' according to this Embodiment mainly consists of reception antenna. 501 , reception radio section 502 , transmission path distortion estimation section 503 and detection section 504 .
Reception radio section 502 receives the radio signal received by reception antenna 501 as an input, performs predetermined radio processing and outputs the in-phase component and the quadrature component of the reception quadrature baseband signal.
Transmission path distortion estimation section 503 receives the in-phase component and the quadrature component of the quadrature baseband signal as inputs, extracts the signal of the known pilot symbol shown in FIG. 3 and FIG. 4 above, estimates the amount of transmission path distortion from the reception condition of the known pilot symbol and outputs the amount of transmission path distortion to detection section 504 .
Detection section 504 receives the in-phase component and the quadrature component of the quadrature baseband signal as inputs, detects information symbols based on the amount of transmission path distortion and outputs a reception digital signal.
Thus, changing the interval of inserting a known pilot symbol and the modulation system of information symbols according to the communication situation such as fluctuations in the transmission path and the level of the reception signal can improve both the data transmission efficiency and the quality of data at the same time.
Here, this embodiment explains two kinds of the interval of inserting a known pilot symbol, but the present invention is not limited to this. Furthermore, this embodiment explains two kinds of the modulation system of information symbols, 16QAM and the 8PSK modulation, but the present invention is not limited to this.
Furthermore, this embodiment only explains the frame configuration of information symbols and a known pilot symbol shown in FIG. 2 , but since it is also possible to consider a frame configuration in which signals such as a symbol for synchronization to adjust timing between the receiver and transmitter and a symbol to correct an error on the receiver side are inserted, the present invention is not limited to the frame configuration composed of only information symbols and known pilot symbol.
Embodiment 2
Embodiment 2 describes a digital radio communication method by which the interval of inserting a BPSK modulation symbol and the modulation system of information symbols other than the above BPSK modulation symbol are changed according to the communication situation.
FIG. 6 is a block diagram showing a configuration of the transmission apparatus according to this Embodiment. Here, in the transmission apparatus shown in FIG. 6 , the components common to those in the transmission apparatus shown in FIG. 1 are assigned the same reference numerals as those in FIG. 1 and their explanations will be omitted.
In the transmission apparatus in FIG. 6 , frame configuration determination section 601 differs in the way of operation from the frame configuration determination section 101 in FIG. 1 . Also, when compared to FIG. 1 , the transmission apparatus in FIG. 6 adopts the configuration with BPSK symbol modulation section 602 , instead of pilot symbol generation section 103 , added.
Frame configuration determination section 601 judges the communication situation, determines the interval of inserting a BPSK modulation symbol and the modulation system of a transmission digital signal, outputs a signal indicating the determined modulation system to quadrature baseband modulation section 102 and outputs a signal indicating the interval of inserting the determined BPSK modulation symbol to quadrature baseband modulation section 102 , BPSK symbol modulation section 602 and frame configuration section 104 .
BPSK symbol modulation section 602 performs BPSK-modulation on the transmission digital signal at the timing indicated from frame configuration determination section 601 and outputs the in-phase component and the quadrature component of the BPSK modulation symbol to frame configuration section 104 .
FIG. 7 illustrates examples of a frame configuration of a signal transmitted from the transmission apparatus of this embodiment and shows a time-symbol relationship. ( 701 ) is a frame configuration when the modulation system of information symbols is 16QAM and a BPSK modulation symbol interval is N symbols. ( 702 ) is a frame configuration when the modulation system of information symbols is 16QAM and a BPSK modulation symbol interval is M symbols. ( 703 ) is a frame configuration when the modulation system of information symbols is 8PSK modulation and a BPSK modulation symbol interval is N symbols. ( 704 ) is a frame configuration when the modulation system of information symbols is 8PSK modulation and a BPSK modulation symbol interval is M symbols. Suppose N<M at this time.
Frame configuration determination section 601 selects one of ( 701 ), ( 702 ), ( 703 ) or ( 704 ) in FIG. 7 as the optimal frame configuration based on the transmission path information and the request data transmission speed information.
For example, in the case of high-speed fading, frame configuration determination section 601 sacrifices data transmission efficiency on the receiving side and selects a frame configuration of either ( 701 ) or ( 703 ) in FIG. 7 so that the interval of inserting a BPSK modulation symbol becomes narrower to prevent deterioration of the data demodulation error rate and maintain the quality of data. On the other hand, in the case of low-speed fading, frame configuration determination section 601 selects a frame configuration of either ( 702 ) or ( 704 ) in FIG. 7 to widen the interval of inserting a BPSK modulation symbol to improve the data transmission efficiency.
Furthermore, when the level of the reception signal is large, frame configuration determination section 601 gives priority to data transmission efficiency on the receiving side and selects a frame configuration of either ( 701 ) or ( 702 ) in the FIG. 7 adopting 16QAM as the modulation system of information symbols. On the other hand, when the level of the reception signal is small, frame configuration determination section 601 gives priority to increasing error resistance while sacrificing data transmission efficiency on the receiving side and selects a frame configuration of either ( 703 ) or ( 704 ) in FIG. 7 adopting 8PSK as the modulation system of information symbols.
FIG. 8 shows a signal point layout according to the 16QAM modulation system on the in-phase I-quadrature Q plane and signal point layout of BPSK modulation symbols. Signal points 801 are the signal points of BPSK modulation symbols and signal points 802 are the signal points of 16QAM modulation symbols. FIG. 9 shows a signal point layout according to the 8PSK modulation system on the in-phase I-quadrature Q plane and signal point layout of BPSK modulation symbols. Signal points 901 are the signal points of BPSK modulation symbols and signal points 902 are the signal points of 8PSK modulation symbols.
FIG. 10 is a block diagram showing a configuration of the reception apparatus according to this Embodiment. In the reception apparatus shown in FIG. 10 , the components common to the reception apparatus shown in FIG. 5 are assigned the same reference numerals as those in FIG. 5 and their explanations will be omitted.
In the reception apparatus in FIG. 10 , transmission path distortion estimation section 1001 differs in the way of operation from transmission path distortion estimation section 503 in FIG. 5 and detection section 1002 differs in the way of operation from detection section 504 in FIG. 5 .
Transmission path distortion estimation section 1001 receives the in-phase component and the quadrature component of the quadrature baseband signal as inputs, extracts the signals of the BPSK modulation symbols shown in FIG. 8 and FIG. 9 above, estimates the amount of transmission path distortion from the reception condition of the BPSK modulation symbols and outputs the amount of transmission path distortion to detection section 1002 .
Detection section 1002 receives the in-phase component and the quadrature component of the quadrature baseband signal as inputs, detects information symbols and BPSK modulation symbols based on the amount of transmission path distortion and outputs a reception digital signal.
Thus, in this embodiment, by sending information with BPSK modulation symbols, instead of a known pilot symbol, inserted, it is possible to improve the transmission speed compared with Embodiment 1.
Here, this embodiment describes two kinds of the interval of inserting BPSK modulation symbols but the present invention is not limited to this. Also, this embodiment describes two kinds of the modulation system of information symbols, 16QAM and 8PSK modulation, but the present invention is not limited to this.
Furthermore, this embodiment describes the frame configuration of only information symbols and BPSK modulation symbols shown in FIG. 7 but the present invention is not limited to this frame configuration.
Embodiment 3
Embodiment 3 describes a digital radio communication method by which the interval of inserting QPSK modulation symbols and the modulation system of information symbols other than the above QPSK modulation symbols are changed according to the communication situation.
FIG. 11 is a block diagram showing a configuration of the transmission apparatus according to this Embodiment. In the transmission apparatus shown in FIG. 11 , the components common to those in the transmission apparatus shown in FIG. 1 are assigned the same reference numerals as those in FIG. 1 and their explanations will be omitted.
In the transmission apparatus in FIG. 11 , frame configuration determination section 1101 differs in the way of operation from the frame configuration determination section 101 in FIG. 1 . Also, when compared to FIG. 1 , the transmission apparatus in FIG. 11 adopts a configuration with QPSK symbol modulation section 1102 , instead of pilot symbol generation section 103 , added.
Frame configuration determination section 1101 judges the communication situation, determines the interval of inserting QPSK modulation symbols and the modulation system of a transmission digital signal, outputs a signal indicating the determined modulation system to quadrature baseband modulation section 102 and outputs a signal indicating the determined interval of inserting QPSK modulation symbols to quadrature baseband modulation section 102 , QPSK symbol modulation section 1102 and frame configuration section 104 .
QPSK symbol modulation section 1102 performs QPSK-modulation on a transmission digital signal at the timing indicated from frame configuration determination section 1101 and outputs the in-phase component and the quadrature component of the QPSK modulation symbol to frame configuration section 104 .
FIG. 12 illustrates examples of a frame configuration of a signal transmitted from the transmission apparatus of this embodiment and shows a time-symbol relationship. ( 1201 ) is a frame configuration when the modulation system of information symbols is 16QAM and a QPSK modulation symbol interval is N symbols. ( 1202 ) is a frame configuration when the modulation system of information symbols is 16QAM and a QPSK modulation symbol interval is M symbols. ( 1203 ) is a frame configuration when the modulation system of information symbols is 8PSK modulation and a QPSK modulation symbol interval is N symbols. ( 1204 ) is a frame configuration when the modulation system of information symbols is 8PSK modulation and a QPSK modulation symbol interval is M symbols. Suppose N<M at this time.
Frame configuration determination section 1101 selects one of ( 1201 ), ( 1202 ), ( 1203 ) or ( 1204 ) in FIG. 12 as the optimal frame configuration based on the transmission path information and the request data transmission speed information.
For example, in the case of high-speed fading, frame configuration determination section 1101 sacrifices data transmission efficiency on the receiving side and selects a frame configuration of either ( 1201 ) or ( 1203 ) in FIG. 12 so that the QPSK modulation symbol insertion interval becomes narrower to prevent deterioration of the data demodulation error rate and maintain the quality of data. On the other hand, in the case of low-speed fading, frame configuration determination section 1101 selects a frame configuration of either ( 1202 ) or ( 1204 ) in FIG. 12 to widen the interval of inserting QPSK modulation symbols to improve the data transmission efficiency.
Furthermore, when the level of the reception signal is large, frame configuration determination section 1101 gives priority to data transmission efficiency on the receiving side and selects a frame configuration of either ( 1201 ) or ( 1202 ) in FIG. 12 adopting 16QAM as the modulation system of information symbols. On the other hand, when the level of the reception signal is small, frame configuration determination section 1101 gives priority to increasing error resistance while sacrificing data transmission efficiency on the receiving side and selects a frame configuration of either ( 1203 ) or ( 1204 ) in FIG. 12 adopting 8PSK as the modulation system of information symbols.
FIG. 13 shows a signal point layout according to the 16QAM modulation system on the in-phase I-quadrature Q plane and signal point layout of QPSK modulation symbols. Signal points 1301 are the signal points of QPSK modulation symbols and signal points 1302 are the signal points of 16QAM modulation symbols. FIG. 14 shows a signal point layout according to the 8PSK modulation system on the in-phase I-quadrature Q plane and signal point layout of QPSK modulation symbols. Signal points 1401 are the signal points of QPSK modulation symbols and signal points 1402 are the signal points of 8PSK modulation symbols.
FIG. 15 is a block diagram showing a configuration of the reception apparatus according to this embodiment. In the reception apparatus shown in FIG. 15 , the components common to the reception apparatus shown in FIG. 5 are assigned the same reference numerals as those in FIG. 5 and their explanations will be omitted.
In the reception apparatus in FIG. 15 , transmission path distortion estimation section 1501 differs in the way of operation from transmission path distortion estimation section 503 in FIG. 5 and detection section 1502 differs in the way of operation from detection section 504 in FIG. 5 .
Transmission path distortion estimation section 1501 receives the in-phase component and the quadrature component of the quadrature baseband signal as inputs, extracts the signals of the QPSK modulation symbols shown in FIG. 13 and FIG. 14 above, estimates the amount of transmission path distortion from the reception condition of the QPSK modulation symbols and outputs the amount of transmission path distortion to detection section 1502 .
Detection section 1502 receives the in-phase component and the quadrature component of the quadrature baseband signal as inputs, detects information symbols and QPSK modulation symbols based on the amount of transmission path distortion and outputs a reception digital signal.
Thus, in this embodiment, by sending information with QPSK modulation symbols, instead of a known pilot symbol, inserted, it is possible to improve the transmission speed compared with Embodiment 1 and Embodiment 2.
Here, this embodiment describes two kinds of the interval of inserting QPSK modulation symbols but the present invention is not limited to this. Also, this embodiment describes two kinds of the modulation system of information symbols, 16QAM and 8PSK modulation, but the present invention is not limited to this.
Furthermore, this embodiment describes the frame configuration of only information symbols and QPSE modulation symbols shown in FIG. 12 but the present invention is not limited to this frame configuration.
Embodiment 4
Embodiment 4 describes a digital radio communication method by which the modulation system of information symbols is changed according to the communication situation and when the modulation system of information symbols uses 8 or more values, a known pilot symbol is inserted with the insertion interval changed according to the communication situation.
FIG. 16 is a block diagram showing a configuration of the transmission apparatus according to this Embodiment. In the transmission apparatus shown in FIG. 16 , the components common to those in the transmission apparatus shown in FIG. 1 are assigned the same reference numerals as those in FIG. 1 and their explanations will be omitted.
In the transmission apparatus in FIG. 16 , frame configuration determination section 1601 differs in the way of operation from the frame configuration determination section 101 in FIG. 1 .
Frame configuration determination section 1601 determines the modulation system of a transmission digital signal based on the communication situation and outputs a signal indicating the determined modulation system to quadrature baseband modulation section 102 . Also, when the determined modulation system uses 8 or more values, frame configuration determination section 1601 determines the interval of inserting a pilot symbol based on the communication situation and outputs a signal indicating the determined interval of inserting the pilot symbol to frame configuration section 104 . Also, when the determined modulation system uses 8 fewer values, frame configuration determination section 1601 outputs a signal giving an instruction for stopping the generation of pilot symbols to pilot symbol generation section 103 .
Pilot symbol generation section 103 generates a pilot symbol known between the transmitting and receiving sides and outputs the in-phase component and the quadrature component of the known pilot symbol to frame configuration section 104 . However, when instructed to stop the generation of pilot symbols from frame configuration determination section 1601 , pilot symbol generation section 103 stops operation.
FIG. 17 illustrates examples of a frame configuration of a signal transmitted from the transmission apparatus of this embodiment and shows a time-symbol relationship. ( 1701 ) is a frame configuration when the modulation system of information symbols is BPSK. ( 1702 ) is a frame configuration when the modulation system of information symbols is QPSK.
The ranking of the frame configurations shown in FIG. 2 and FIG. 17 in descending order of resistance to fading speed is ( 1701 ), ( 1702 ), ( 203 ), ( 201 ), ( 204 ) and ( 202 ). Furthermore, the ranking in descending order of error resistance is ( 1701 ), ( 1702 ), ( 203 ), ( 204 ), ( 201 ) and ( 202 ). On the other hand, the ranking in descending order of data transmission efficiency on the receiving side is ( 202 ), ( 201 ), ( 204 ), ( 203 ), ( 1702 ) and ( 1701 ).
Frame configuration determination section 1601 selects one of ( 201 ), ( 202 ), ( 203 ) or ( 204 ) in FIG. 2 of ( 1701 ) or ( 1702 ) in FIG. 17 above as the optimal frame configuration based on the transmission path information and the request data transmission speed information.
FIG. 18 shows a signal point layout according to the BPSK modulation method on the in-phase I-quadrature Q plane and signal points 1801 are the signal points of BPSK symbols.
FIG. 19 shows a signal point layout according to the QPSK modulation method on the in-phase I-quadrature Q plane and signal points 1901 are the signal points of QPSX symbols.
FIG. 20 is a block diagram showing a configuration of the reception apparatus according to this embodiment. In the reception apparatus shown in FIG. 20 , the components common to those in the reception apparatus shown in FIG. 5 are assigned the same reference numerals as those in FIG. 5 and their explanations will be omitted.
In the reception apparatus in FIG. 20 , transmission path distortion estimation section 2001 differs in the way of operation from transmission path estimation section 503 in FIG. 5 and detection section 2002 differs in the way of operation from detection section 504 in FIG. 5 .
Transmission path distortion estimation section 2001 receives the in-phase component and the quadrature component of the quadrature baseband signal as inputs, estimates the amount of transmission path distortion from the reception condition of the BPSK modulation symbol shown in FIG. 18 or the QPSK modulation symbol shown in FIG. 19 and outputs the amount of transmission path distortion to detection section 2002 .
Detection section 2002 receives the in-phase component and the quadrature component of the quadrature baseband signal as inputs, detects information symbols based on the amount of transmission path distortion and outputs a reception digital signal.
In this way, by changing the modulation system of information symbols according to the communication situation such as fluctuations in the transmission path and the level of the reception signal, inserting a known pilot symbol when the information symbol modulation system is a multi-value modulation system with 8 or more values and changing the interval of inserting the above known pilot symbol according to the communication situation, it is possible to improve both the data transmission efficiency and the quality of data at the same time.
Here, in this embodiment, the transmission apparatus in FIG. 16 can also have a configuration equipped with BPSK symbol modulation section 602 shown in FIG. 6 instead of pilot symbol generation section 103 .
In this case, frame configuration determination section 1601 determines the modulation system of the transmission digital signal based on the communication situation. For example, frame configuration determination section 1601 selects one of ( 701 ), ( 702 ), ( 703 ) or ( 704 ) in FIG. 7 above or ( 1701 ) or ( 1702 ) in FIG. 17 as the optimal frame configuration.
Then, frame configuration determination section 1601 outputs the signals indicating the determined modulation system to quadrature baseband modulation section 102 . Also, when the determined modulation system uses 8 or more values, frame configuration determination section 1601 determines the interval of inserting BPSK modulation symbols based on the communication situation and outputs a signal indicating the determined interval of inserting the BPSK nodulation symbols to BPSK symbol modulation section 602 and frame configuration section 104 . Furthermore, when the determined modulation system is 8 fewer values, frame configuration determination section 1601 outputs a signal giving an instruction for stopping the generation of BPSK modulation symbols to BPSK symbol modulation section 602 .
BPSK symbol modulation section 602 performs BPSK-modulation on a transmission digital signal at the timing indicated from frame configuration determination section 1601 and outputs the in-phase component and the quadrature component of the BPSK modulation symbols to frame configuration section 104 . However, when instructed to stop the generation of BPSK modulation symbols from frame configuration determination section 1601 , BPSK symbol modulation section 602 stops operation.
Transmission path distortion estimation section 2001 receives the in-phase component and the quadrature component of the quadrature baseband signal as inputs, estimates the amount of transmission path distortion from the reception condition of the BPSK modulation symbols shown in FIG. 8 and FIG. 9 above, the BPSK modulation symbols shown in FIG. 18 or the QPSK modulation symbols shown in FIG. 19 and outputs the amount of transmission path distortion to detection section 2002 .
Furthermore, in this embodiment, the transmission apparatus in FIG. 16 . can also have a configuration equipped with QPSK symbol modulation section 1102 shown in FIG. 11 instead of pilot symbol generation section 103 .
In this case, frame configuration determination section 1601 determines the modulation system of the transmission digital signal based on the communication situation. For example, frame configuration determination section 1601 selects one of ( 1201 ), ( 1202 ), ( 1203 ) or ( 1204 ) in FIG. 12 above or ( 1701 ) or ( 1702 ) in FIG. 17 as the optimal frame configuration.
Then, frame configuration determination section 1601 outputs a signal indicating the determined modulation system to quadrature baseband modulation section 102 . Also, when the determined modulation system uses 8 or more values, frame configuration determination section 1601 determines the interval of inserting QPSK modulation symbols based on the communication situation and outputs a signal indicating the determined interval of inserting the QPSK symbols to QPSK symbol modulation section 1102 and frame configuration section 104 . Also, when the determined modulation system is 8 fewer values, frame configuration determination section 1601 outputs a signal giving an instruction for stopping the generation of QPSK modulation symbols to QPSK symbol modulation section 1102 .
QPSK symbol modulation section 1102 performs QPSK-modulation on a transmission digital signal at the timing indicated from frame configuration determination section 1601 and outputs the in-phase component and the quadrature component of the QPSK modulation symbols to frame configuration section 104 . However, when instructed to stop generating QPSK modulation symbols from frame configuration determination section 1601 , QPSK symbol modulation section 1102 stops operation.
Transmission path distortion estimation section 2001 receives the in-phase component and the quadrature component of the quadrature baseband signal as inputs, estimates the amount of transmission path distortion from the reception condition of the QPSK modulation symbols shown in FIG. 13 or FIG. 14 and the BPSK modulation symbols shown in FIG. 18 or the QPSK modulation symbol shown in FIG. 19 and outputs the amount of transmission path distortion to detection section 2002 .
Here, this embodiment explains two kinds of the interval of inserting a known pilot symbol, but the present invention is not limited to this. Also, this embodiment explains two kinds of the multi-value modulation system with 8 or more values of information symbols, 16QAM and the 8PSK modulation, but the present invention is not limited to this.
Furthermore, this embodiment describes the frame configurations in FIG. 2 , FIG. 7 , FIG. 12 and FIG. 17 but the present invention is not limited to these frame configurations.
Furthermore, the BPSK modulation method and the QPSK modulation method of the modulation system of information symbols of the present invention are not limited to the signal point layouts shown in FIG. 18 and FIG. 19 but π/2 shift BPSK modulation or π/4 shift QPSK modulation can also be used.
Embodiment 5
Embodiment 5 describes a digital radio communication method by which the interval of inserting a known pilot symbol, the number of signal points with one symbol immediately before and after a known pilot symbol (hereinafter referred to as “symbols before and after a pilot”) and signal point layout and the modulation system of information symbols other than those symbols are changed.
FIG. 21 is a block diagram showing a configuration of the transmission apparatus according to this embodiment. In the transmission apparatus shown in FIG. 21 , the components common to those in the transmission apparatus shown in FIG. 1 are assigned the same reference numerals as those shown in FIG. 1 and their explanations will be omitted.
In the transmission apparatus in FIG. 21 , frame configuration determination section 2101 differs in the way of operation from frame configuration determination section 101 in FIG. 1 . Furthermore, the transmission apparatus in FIG. 21 adopts a configuration with symbols before and after a pilot modulation section 2102 added compared to FIG. 1 .
Frame configuration determination section 2101 determines the interval of inserting a known pilot symbol and the modulation system of a transmission digital signal based on the communication situation. In this case, frame configuration determination section 2101 uses different modulation systems for symbols before and after a pilot and for other information symbols.
Then, frame configuration determination section 2101 outputs a signal indicating the modulation system of symbols before and after a pilot to symbols before and after a pilot modulation section 2102 , outputs a signal indicating the modulation system of other information symbols to quadrature baseband modulation section 102 and outputs a signal indicating the interval of inserting the determined known pilot symbol to symbols before and after a pilot modulation section 2102 and frame configuration section 104 .
Symbols before and after a pilot modulation section 2102 modulates on a transmission digital signal by predetermined modulation system at the timing indicated from frame configuration determination section 2101 and outputs the in-phase component and the quadrature component of the symbols before and after a pilot to frame configuration section 104 .
FIG. 22 illustrates examples of a frame configuration of a signal transmitted from the transmission apparatus of this embodiment and shows a time-symbol relationship. ( 2201 ) is a frame configuration when the modulation system of information symbols is 16QAM and a known pilot symbol interval is N symbols. ( 2202 ) is a frame configuration when the modulation system of information symbols is 16QAM and a known pilot symbol interval is 1 symbols. ( 2203 ) is a frame configuration when the modulation system of information symbols is 8PSK modulation and a known pilot symbol interval is N symbols. ( 2204 ) is a frame configuration when the modulation system of information symbols is 8PSK modulation and a known pilot symbol interval is M symbols. Suppose N<M at this time.
Signal point 2211 is 1 symbol immediately before the known pilot symbol when the information symbol modulation system is 16QAM and signal point 2212 is 1 symbol immediately after the known pilot symbol when the information symbol modulation system is 16QAM. Signal point 2213 is 1 symbol immediately before the known pilot symbol when the information symbol modulation system is 8PSK modulation and signal point 2214 is 1 symbol immediately after the known pilot symbol when the information symbol modulation system is 8PSK modulation.
Frame configuration determination section 2101 selects one of ( 2201 ), ( 2202 ), ( 2203 ) or ( 2204 ) in FIG. 22 as the optimal frame configuration based on the transmission path information and the request data transmission speed information.
For example, in the case of high-speed fading, frame configuration determination section 2101 sacrifices data transmission efficiency on the receiving side and selects a frame configuration of either ( 2201 ) or ( 2203 ) in FIG. 22 so that the interval of inserting a known pilot symbol becomes narrower to prevent deterioration of the data demodulation error rate and maintain the quality of data. On the other hand, in the case of low-speed fading, frame configuration determination section 2101 selects a frame configuration of either ( 2202 ) or ( 2204 ) in FIG. 22 to widen the interval of inserting a known pilot symbol to improve the data transmission efficiency.
Furthermore, when the level of the reception signal is large, frame configuration determination section 2101 gives priority to data transmission efficiency on the receiving side and selects a frame configuration of either ( 2201 ) or ( 2202 ) in FIG. 22 adopting 16QAM as the modulation system of information symbols. On the other hand, when the level of the reception signal is small, frame configuration determination section 2101 gives priority to increasing error resistance while sacrificing data transmission efficiency on the receiving side and selects a frame configuration of either ( 2203 ) or ( 22041 in FIG. 22 adopting 8PSK as the modulation system of information symbols.
FIG. 23 shows a signal point layout according to the 16QAM modulation method on the in-phase I-quadrature Q plane and a signal point layout according to a known pilot symbol and a signal point layout of symbols before and after a pilot. Signal point 2301 is the signal point of a known pilot symbol, signal points 2302 are the signal points of 16QAM modulation symbols and signal points 2303 are the signal points of symbols before and after a pilot.
FIG. 24 shows a signal point layout according to the 8PSK modulation system on the in-phase I-quadrature Q plane, a signal point layout of a known pilot symbol and a signal point layout of symbols before and after a pilot. Signal points 2401 , 2401 -A and 2401 -B are the signal points of 8PSK modulation symbols, 2401 -A is the signal point of the known pilot symbol, 2401 -A and 2401 -B are the signal points of symbols before and after a pilot and straight line 2402 is the straight line formed by linking the signal point of the known pilot symbol and the origin on the in-phase I-quadrature Q plane.
FIG. 25 is a block diagram showing a configuration of the reception apparatus according to this embodiment, In the reception apparatus shown in FIG. 25 , the components common to those in the reception apparatus shown in FIG. 5 are assigned the same reference numerals as those shown in FIG. 5 and their explanations will be omitted.
In the reception apparatus in FIG. 25 , transmission path estimation section 2501 differs in the way of operation from transmission path estimation section 503 and detection section 2502 differs in the way of operation from detection section 504 in FIG. 5 .
Transmission path distortion estimation section 2501 receives the in-phase component and the quadrature component of the quadrature baseband signal as inputs, extracts the signal of the known pilot symbol shown in FIG. 23 and FIG. 24 above, estimates the amount of transmission path distortion from the reception condition of the known pilot symbol and outputs the amount of transmission path distortion to detection section 2502 .
Detection section 2502 receives the in-phase component and the quadrature component of the quadrature baseband signal as inputs, detects information symbols including symbols before and after a pilot based on the amount of transmission path distortion and outputs a reception digital signal.
Thus, changing the interval of inserting a known pilot symbol and the modulation system of information symbols according to the communication situation such as fluctuations in the transmission path and the level of the reception signal can improve both the data transmission efficiency and the quality of data at the same time.
Furthermore, as shown in FIG. 23 and FIG. 24 , by arranging two or more signal points before and after a pilot on the straight line formed by linking the origin and the signal point of the known pilot symbol on the in-phase I-quadrature Q plane, it is possible for the reception apparatus in FIG. 25 to suppress deterioration of the estimation accuracy of reference phase and the amount of frequency offset by the pilot symbol, even if symbol synchronization is not established completely when a reference phase and the amount of frequency offset is estimated from the pilot signal. When detection section 116 performs detection, this allows the bit error rate characteristic based on the carrier-to-noise ratio to be improved.
Here, this embodiment can be combined with Embodiment 4 above. That is, when the determined modulation system uses 8 or more values, frame configuration determination section 2101 in FIG. 21 determines the interval of inserting a pilot symbol based on the communication situation and outputs a signal indicating the interval of inserting the determined pilot symbol to symbols before and after a pilot modulation section 2102 and frame configuration section 104 . Furthermore, when the determined modulation system uses 8 fewer values, frame configuration determination section 2101 outputs a signal giving an instruction for stopping the generation of pilot symbols to symbols before and after a pilot modulation section 2102 and pilot symbol generation section 103 .
Pilot symbol generation section 103 generates a pilot symbol known between the transmitting and receiving sides and outputs the in-phase component and the quadrature component of the known pilot symbol to frame configuration section 104 . However, when instructed to stop the generation of pilot symbols from frame configuration determination section 2101 , pilot symbol generation section 103 stops operation.
Symbols before and after a pilot modulation section 2102 performs BPSK-modulation or QPSK-modulation on a transmission digital signal at the timing indicated from frame configuration determination section 2101 and outputs the in-phase component and the quadrature component of the symbols before and after a pilot to frame configuration section 104 . However, when instructed to stop the generation of pilot symbols from frame configuration determination section 2101 , symbols before and after a pilot modulation section 2102 stops operation.
This allows the effect of Embodiment 4 to be attained in addition to the effect of this embodiment as described above.
Here, this embodiment describes two kinds of modulation system of information symbols, 16QAM and 8PSK modulation, but the present invention is not limited to this.
Furthermore, this embodiment explains only the configuration of information symbols, a known pilot symbol, symbols before and after a pilot in FIG. 22 , but the frame configuration of the present invention is not limited to the frame configuration composed of only information symbols, a known pilot symbol, symbols before and after a pilot.
As described above, according to the present invention, by changing the interval of inserting a known pilot symbol, BPSK modulation symbols or QPSK modulation symbols and the modulation system of information symbols according to the communication situation of fluctuations in the transmission path and the level of the reception signal, etc., it is possible to improve both the data transmission efficiency and the quality of data at the same time.
The present invention is not limited to the above described embodiments, and various variations and modifications may be possible without departing from the scope of the present invention.
This application is based on the Japanese Patent. Application No. HEI 11-213289 filed on Jul. 28, 1999, entire content of which is expressly incorporated by reference herein.
|
A transmission method includes modulating a transmission signal using a modulation scheme selected from a plurality of modulation schemes, to generate a first symbol sequence and generating at least one second symbol including a pilot symbol generated using a PSK modulation scheme. The method includes changing an insertion interval of the second symbol to be inserted in the first symbol sequence, to generate a modulation signal and transmitting the modulation signal. The second symbol is configured for synchronization in a reception apparatus.
| 7
|
This application is a continuation of currently pending in International application No. PCT/EP2004/001921 filed Feb. 26, 2004 which claims priority of German Patent Application No 103 08 831.8 filed Feb. 27, 2003.
BACKGROUND OF THE INVENTION
The invention relates to a rotary piston machine of the type having a housing, a prismatic cavity in the housing, the cross section of this cavity being an oval, and a rotary piston movable in this cavity, the cross section of this rotary piston being also an oval, the order of the rotary piston oval being different from the order of the oval forming the cross section of the cavity. The rotary piston, in operation, moves, in consecutive intervals of motion, from one blocking position to the next. In each such blocking position, the axis about which the rotary piston rotates, changes from one position to another one. Thus the rotary piston, alternatingly, rotates about different axes of rotation. During this rotary movement, two working chambers are defined between the inner wall of the cavity and the rotary piston, the volume of one working chamber increasing, while the volume of the respective other working chamber decreases. The rotary piston has an axial aperture therethrough with an internal gear, which meshes with gear means for driving the rotary piston machine or for being driven thereby.
In mathematics, an “oval” is a non-analytical, closed, convex figure which is composed of circular arcs. The circular arcs join each other continuously and differentially. In the points in which the circular arcs join, the curve is continuous. Also the tangents of the two joining circular arcs coincide there. The curve is differentiable. In the points, where the circular arcs of different radii of curvature join, the second derivative, which determines the curvature, makes a saltus. The oval consists, alternatingly, of circular arcs having a first, smaller radius of curvature and a second, larger radius of curvature. The order of the oval is determined by the number of pairs of circular arcs having the first and second radii of curvature. An oval of second order or bi-oval is “ellipse-like” with two diametrically opposite circular arcs of smaller diameter and two circular arcs of larger diameter.
Rotary piston machines of this type are known.
U.S. Pat. Nos. 3,967,594 and 3,996,901 disclose rotary piston machines having an oval rotary piston in an oval cavity. The cross section of the rotary piston is bi-oval. This bi-oval rotary piston is movable in a tri-oval chamber. In this prior art rotary piston machine, complex transmissions are provided to transmit the rotary movement of the rotary piston to an output shaft.
DE 199 20 289 C1 describes a rotary piston machine, wherein the cross section of a prismatic cavity defined in a housing is tri-oval with three pairs of continuously and differentially joining first and second circular arcs of alternatingly a smaller radius of curvature and a larger radius of curvature. A rotary piston having bi-oval cross section is guided in this cavity. The bi-oval cross section of the rotary piston is formed of alternatingly first and second circular arcs with the smaller and larger, respectively, radii of curvature of the tri-oval cross section of the cavity, these circular arcs, again, joining continuously and differentially. The bi-oval rotary piston, in the cavity, carries out the intervals of motion with “jumping” instantaneous axes of rotation described above. The rotary movement of the rotary piston is picked-off in a very simple way: A shaft extends centrally through the tri-oval cavity, i.e. along the line of intersection of the planes of symmetry of the cavity. The shaft carries a pinion. The rotary piston has an oval aperture with an internal gear. The long axis of the cross section of the aperture extends along the short axis of the bi-oval cross section of the rotary piston. The pinion continuously meshes with the internal gear.
In the prior art rotary piston machine, a housing defines a prismatic cavity, the cross section of which is such an oval of odd order, thus, for example, an oval of third order. The cavity has cylindrical inner wall sections with, alternatingly, the first, smaller and the second, larger radii of curvature. In such an oval of third (fifth or seventh or higher) order, rotary piston is rotatable, the cross section of which is an oval, the order of this rotary piston oval being by one smaller than the order of the oval of the cavity. Even though the oval used for the rotary piston has a higher order, it has a twofold symmetry, i.e. it is mirror-symmetrical with respect to two mutually orthogonal axes. This rotary piston has two diametrically opposite cylindrical surface sections, the radius of curvature of which is equal to the smaller (first) radius of curvature of the oval of the cavity. If the cross section of the rotary piston is an oval, the second, larger radius of curvature of this oval is equal to the second, larger radius of curvature of the oval defining the cavity. In a certain interval of motion, a first of these cylindrical surface sections of the rotary piston engages a cylindrical inner wall section complementary thereto of the cavity, which inner wall section has the same radius of curvature. The second, diametrically opposite cylindrical surface section of the rotary piston slides along the opposite, larger radius of curvature cylindrical inner wall section of the cavity. In this way, two working chambers are defined by the rotary piston, of which, during the rotation of the rotary piston, one increases in volume and one becomes smaller. In this interval of motion, the rotary piston rotates about an instantaneous axis of rotation. This instantaneous axis of rotation coincides with the cylinder axis of the first cylindrical surface section. This instantaneous axis of rotation has a well-defined position relative to the rotary piston. In this interval of motion, the instantaneous axis of rotation coincides, of course, also the housing-fixed cylinder axis of the smaller radius of curvature inner wall section, in which the rotary piston rotates. This rotation continues, until the second cylindrical surface section of the rotary piston reaches a blocking position. In the blocking position, the second cylindrical surface section engages the smaller diameter inner wall section joining the opposite inner wall section of larger diameter.
A further rotation of the rotary piston about the hitherto existing instantaneous axis of rotation is not possible. Therefore, the instantaneous axis of rotation, for the next interval of motion, “jumps” into another position, namely the cylinder axis of the second cylindrical surface section. Also this new instantaneous axis of rotation is in a well-defined position relative to the rotary piston. In the next interval of motion, this instantaneous axis of rotation coincides with the cylinder axis of the cylindrical inner wall section, in which now the second cylindrical surface section of the rotary piston is rotatably guided. In this interval of motion, the “first” cylindrical surface section slides along the opposite inner wall section of lager radius of curvature.
In a rotary piston machine of this type, the rotary piston rotates always with the same rotational direction but, alternatingly, about different instantaneous axes of rotation, the axes of rotation “jumping” after each interval of motion. Referenced to the rotary piston, two such instantaneous axes of rotation are defined, namely by the cylinder axes of the diametrically opposite cylindrical surface sections. Referring to the housing and the cavity defined therein, the instantaneous axis of rotation jumps between the “corners” of the oval. Thus, the cylinder axes of the inner wall sections having smaller radii of curvature.
During each interval of motion, the volume of one working chamber increases up to a maximum value, while the volume of the respective other working chamber decreases down to a minimum value. In the ideal case, when the cross section of the rotary piston also is an oval, the volume of the working chamber increases from virtually zero to the maximum value and decreases to virtually zero, respectively. Such a rotary piston machine can be designed as a two stroke or four stroke internal combustion engine or as an engine with external combustion such as a steam engine. It may, however, also be designed to operate as a pneumatic motor, as a hydraulic motor or as a pump.
DE 199 20 289 C1 discloses rotary piston machine, wherein a rotary piston, the cross section of which is an oval of second order, is movable in a cavity, the cross section of which is an oval of third order. For transmitting the movement of the rotary piston, there is a single output shaft extending centrally through the cavity. The output shaft extends through an oval aperture of the rotary piston and carries a pinion. The pinion is in mesh with an internal gear on the inner wall of the aperture.
In the prior art rotary piston machine, the order of the oval defining the cavity is always by one larger than the order of the oval defining the cross section of the rotary piston. A bi-oval rotary piston is guided in a tri-oval cavity. In the blocking positions, the instantaneous axes of rotation of the rotary piston jump relative to the rotary piston between two positions, but jump between at least three positions relative to the housing. The smaller radius section of the rotary piston moves translatorily along the larger radius inner wall section of the cavity. This may cause sealing problems with the sealing between the working chambers. A further problem results from the fact that, in each working cycle, consecutively more than two working chambers is formed, which travel around along the inner wall of the housing.
A similar design is disclosed in applicants' U.S. patent application Ser. No. 10/773,093, filed Aug. 8, 2002 (=WO 03/014527). For ensuring that the kinematics of the instantaneous axis of rotation is unambiguously defined in the blocking positions, one rotational axis is temporarily fixed by mechanical means, in such blocking position.
Luxembourg patent 45,663 to Bleser, filed Mar. 16, 1964 and granted Mar. 30, 1965, describes an internal combustion engine in the form of a rotary piston engine, wherein a housing has an oval cavity and the cross section of the rotary piston is also an oval, wherein, however the order of the oval of the cavity is smaller than the order of the oval of the rotary piston. Thus the cross section of the cavity is an oval of second order, while the cross section of the rotary piston is an oval of third order. Two working chambers are defined between the inner wall of the cavity and the rotary piston. When the rotary piston rotates, the volume of one of the chambers increases, while the volume of the respective other one of the chambers is reduced. The rotary piston rotates always in the same rotary direction but in consecutive intervals of motion from one blocking position to the next blocking position. When the rotary piston has reached one blocking position by rotating about a first axis of rotation, it rotates further to the next blocking position about a second axis of rotation. With this structure, there are two housing-fixed axes of rotation, and the rotary piston, in consecutive intervals of motion, alternatingly rotate about these two axes.
To transmit the rotary motion of the rotary piston, the rotary piston has an aperture therethrough, which forms an oval similar to the contour of the rotary piston. This aperture forms an internal gear.
Two spaced, parallel shafts extend through the aperture. The axes of the shafts coincide with the two axes, about which the rotary piston rotates alternatingly. Pinions are provided on the shafts and mesh with the internal gear of the aperture.
SUMMARY OF THE INVENTION
It is an object of the invention to improve the seal between the working chambers of the cavity.
It is a further object of the invention to ensure, in a rotary piston machine of the type mentioned above, unambiguous kinematics with unambiguous movements of the rotary piston in the blocking positions of the rotary piston.
A more specific object of the invention is to reduce the number of the instantaneous axes of rotation occurring referenced to the housing.
A still further object of the invention is to design a rotary piston machine of the type mentioned above such that only two working chambers are defined, which are opposite each other in fixed angular positions and the volumes of which increase and decrease alternatingly.
To this end, in accordance with one aspect of the invention, a rotary piston machine comprises a housing defining a prismatic cavity with a cavity wall therein, the cross section of said prismatic cavity being a cavity oval which is formed by circular arcs of, alternatingly, smaller and larger radii, an order of said an order of said cavity oval being defined by a first number of pairs of said smaller radius and larger radius circular arcs. A rotary piston is guided for rotary movement in said cavity and has a cross section which is also an oval formed by circular arcs of, alternatingly, said smaller and larger radii, an order of said piston oval being defined by a second number of pairs of said smaller radius and larger radius circular arcs. Said order of said cavity oval is by one smaller than the order of said piston oval. Said rotary piston moves in consecutive intervals of motion from one blocking position, in which a pair of said smaller and larger radii circular arcs of said rotary piston engage a pair of smaller and larger radii, respectively, circular arcs of said cavity, to an adjacent end position, in which another pair of said smaller and larger radii circular arcs of said rotary piston engage a pair of smaller and larger radii, respectively, circular arcs of said chamber. Said rotary piston, during said consecutive intervals of motion rotating, in the same rotational direction, alternatingly about one of two different axes, said axes are located, relative to said cavity, in the centers of curvature of said larger radius circular arcs. In each such interval of motion one larger radius circular arc of said rotary piston slides along a larger radius circular arc of said chamber while a smaller radius circular arc of said rotary piston engages an opposite larger radius circular arc of said chamber. Transmission means are provided for transmitting rotary motion about said two axes. Thereby, when said rotary piston reaches a blocking position, there is an associated larger diameter cavity circular arc, in which the larger diameter piston circular arc was slidingly guided during the preceding interval of motion. Means are provided for temporarily providing, when said rotary piston has reached one of said blocking positions, reduced rotary speed of the rotary motion of said rotary piston about that one of said axes which is located in the center of curvature of said associated larger radius circular arc, as compared to the rotary speed about the other axis.
In the locking position, the kinematics of the rotary piston in the cavity is not unambiguous. Instead of a further rotary movement, transverse forces could occur, for example by feeding a fluid under pressure into the volume-minimized working chamber or by igniting a fuel mixture. Such transverse forces could result in jamming of the rotary piston in the chamber. In order to solve this problem and to obtain unambiguous kinematics, means are provided for reducing, when a blocking position has been reached, the rotary motion of said rotary piston about that one of said axes which is located in the center of curvature of said associated larger radius circular arc, as compared to the rotary speed about the other axis. This forced speed reduction ensures that the rotary piston continues to rotate about the axis which is thus forced to rotate at a lower speed. This forced selection of rotary speed need only take place for a short time, until the rotary piston has rotated out of the blocking position. The forced reduction of rotary speed can be effected in that braking means temporarily brake a respective one of the two axes. This can be achieved quite easily.
On one side, a peripheral section of the rotary piston rotates rather slowly along a peripheral section of the inner wall of the cavity having large radius of curvature. The slower movement reduces the sealing problems. On the opposite side, a peripheral section of the rotary piston slides with large radius of curvature on a large radius of curvature peripheral section of the inner wall. This results in a large sealing surface
The two shafts meshing with the internal gear rotate alternatingly at lower and higher rotary speed. By means of a differential gear or a free wheel, a constant rotary speed of a driving or driven shaft coupled with both shafts can be provided.
According to another aspect of the invention, a rotary piston machine comprises a housing defining a prismatic cavity therein, the cross section of said prismatic cavity being a cavity oval which is formed by circular arcs of, alternatingly, smaller and larger radii, an order of said an order of said cavity oval being defined by a first number of pairs of said smaller radius and larger radius circular arcs. A rotary piston is guided for rotary movement in said cavity and has a cross section which is also an oval formed by circular arcs of, alternatingly, said smaller and larger radii, an order of said piston oval being defined by a second number of pairs of said smaller radius and larger radius circular arcs. Said order of said chamber oval being different from the order of said piston oval. Said rotary piston and said cavity define blocking positions in which said smaller diameter circular arc of said rotary piston closely engages one of said smaller diameter circular arcs of said cavity and an adjacent one of said larger diameter circular arcs of said rotary piston closely engages an adjacent one of said larger diameter circular arcs of said cavity, movement of said rotary piston from one of said blocking positions to the next one defining intervals of motion. Said rotary piston, during said consecutive intervals of motion rotates, in the same rotational direction, alternatingly about different axes. Thereby, variable volume working chambers are defined between said cavity wall and said rotary piston. For sealing between said working chambers, sealing ledges with sealing surfaces are provided, the radius of curvature one of said sealing surfaces being equal to said smaller radius of curvature and the radius of curvature of another one of said sealing surfaces being equal to said larger radius of curvature.
This ensures surface sealing engagement with both types of curved surfaces.
In accordance with a third aspect of the invention, an internal combustion engine is provided having at least one working chamber limited by a piston and means for fuel injection, wherein said fuel injection means are arranged in a separate ignition chamber communicating with said working chamber, and means for tuning said ignition chamber and fuel injected by said fuel injection means such that substantially only burnt, expanding combustion gas enters the working chamber.
Embodiments of the invention are described hereinbelow with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a cross sectional view of a rotary piston machine having two shafts, wherein a rotary piston, the cross section of which is an oval of third order, is guided in a cavity, the cross section of which is an oval of second order.
FIG. 2 is an illustration similar to FIG. 2 and shows the rotary piston in a blocking position.
FIG. 3 is an illustration similar to FIG. 2 and shows the rotary piston during the next interval of motion.
FIG. 4 shows a cross sectional view of a rotary piston machine having two shafts, wherein the rotary piston, the cross section of which is an oval of fifth order, is guided in a cavity, the cross section of which is an oval of fourth order.
FIG. 4A shows a modification of the arrangement of FIG. 4 .
FIG. 5 shows a cross sectional view of a rotary piston machine having two shafts, wherein a rotary piston, the cross section of which is an oval of seventh order, is guided in a cavity, the cross section of which is an oval of sixth order.
FIG. 6 is a schematic illustration of rotary speed regulating means used in a rotary piston machine of FIG. 1 .
FIG. 7A is a schematic enlarged illustration of a seal used in a rotary piston machine of the type illustrated in FIGS. 1 to 5 , sealing being effected between a sealing ledge and a surface section of the rotary piston having the smaller radius of curvature.
FIG. 7B is a schematic enlarged illustration of a seal used in a rotary piston machine of the type illustrated in FIGS. 1 to 5 , sealing being effected between a sealing ledge and a surface section of the rotary piston having the larger radius of curvature.
FIG. 8 shows, at an enlarged scale, a detail of the rotary piston machine of FIG. 4A .
FIG. 8A shows the detail of FIG. 8 at a further enlarged scale.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 , numeral 10 designates a housing. A cavity 12 is defined in this housing 10 . The cross section of the cavity represents an oval of second order or is “bi-oval”. Thus the cross section of the cavity is formed by two circular arcs 14 and 16 of relatively small radius of curvature and, alternating therebetween, two circular arcs 18 and 20 of relatively large radius of curvature. The circular arcs join continuously and differentially.
A rotary piston 22 is guided in cavity 12 . The cross section of the rotary piston 22 represents an oval of third order or is “tri-oval”. Accordingly, the circumference of the cross section consists of three pairs of circular arcs, each pair comprising a circular arc of relatively small radius of curvature 24 , 26 and 28 , respectively, and a circular arc of relatively large radius of curvature 30 , 32 and 34 , respectively. The circular arcs of small and large radii of curvature join alternatingly and also continuously and differentially. The small radii of curvature of the rotary piston 22 are equal to the small radii of curvature of the cavity 12 , and, in the same way, the large radii of curvature of the rotary piston 22 are equal to the large radii of curvature of the cavity 12 . The cross section of the cavity 12 looks similar to an ellipse. The cross section of the rotary piston looks similar to a triangle of arcs with rounded corners.
The rotary piston 22 has a central aperture 36 . The cross section of the aperture 36 represents also an oval of third order. This oval of third order is composed of three circular arcs of relatively small radii of curvature 38 , 40 and 42 and of three circular arcs of relatively large radii of curvature. The circular arcs 38 , 40 and 42 having small radii of curvature and the circular arcs 44 , 46 and 48 having large radii of curvature join alternatingly and continuously and differentially, whereby an oval similar to a triangle of arcs with rounded corners is formed. The planes of symmetry 50 , 52 and 54 of the aperture 36 coincide with the planes of symmetry of the rotary piston 22 .
The aperture 36 has an internal gear 56 . This internal gear 56 has three concave-arcuate gear racks 58 , 60 and 62 substantially along the circular arcs 44 , 46 and 48 , respectively. Between these concave-arcuate gear racks 58 , 60 and 62 , convex-arcuate (or straight) gear racks 64 , 66 and 68 are provided in the region of the circular arcs of small radius of curvature.
Two parallel shafts 70 and 72 with pinions 74 and 76 , respectively, extend through the aperture 36 . The axes of the shaft are located in the plane of symmetry 77 , extending through the circular arcs 18 and 20 , of the cavity 12 . The pinion of one shaft, in FIG. 1 the pinion 74 of shaft 70 , is located in the “corner of the triangle of arcs”, i.e. in the region of the circular arc 38 of small radius of curvature and meshes with the internal gear 56 , as will be described below. The pinion of the other shaft, in FIG. 1 pinion 76 of shaft 72 , meshes with the opposite concave-arcuate gear rack, in FIG. 1 the gear rack 60 .
The rotary piston 22 subdivides the bi-oval cavity 12 into two working chambers 80 and 82 . In FIG. 1 , the rotary piston machine is illustrated schematically as an internal combustion engine. Accordingly, an inlet valve 84 or 86 and an outlet valve 88 or 90 is shown for each working chamber 80 and 82 , respectively. Furthermore, a combustion chamber 92 or 94 with a spark plug or a fuel injector 98 and 98 communicates with each working chamber 80 and 82 , respectively. The working chambers 80 and 82 with the valves and spark plugs or fuel injectors are arranged symmetrical to the plane of symmetry passing through the circular arcs 14 and 16 of small radii of curvature.
Pairs of adjacent sealing ledges 100 A and 100 B and 102 A and 102 B are provided in the regions 18 and 20 , respectively, of large radii of curvature. The sealing ledges 100 A and 100 B and 102 A and 102 B, respectively, are symmetrical to the plane of symmetry passing through the circular arcs 18 and 20 of large radii of curvature of the cross section.
FIG. 7A shows the sealing ledges 100 A and 100 B with a position in the area of the transition from the small radius of curvature r 1 of the outer surface of the rotary piston 22 , on the right in FIG. 7A , to the area of the larger radius of curvature r 2 of this outer surface, on the left in FIG. 7A . The sealing ledge 100 A has a concave-cylindrical inner surface, the radius of curvature of which is equal to the larger radius of curvature r 2 . The sealing ledge 100 B has a concave-cylindrical inner surface, the radius of curvature of which corresponds to the smaller radius of curvature r 1 . It will be apparent, that the inner surface of the sealing ledge 100 A closely engages the surface of the rotary piston complementary thereto, in the area of the radius of curvature r 2 . In the area, in which the radius of curvature of the surface of the rotary piston is smaller, namely r 1 , a wedge-shaped gap 100 C is formed between the inner surface of the sealing ledge 100 A and the rotary piston 22 . The sealing ledge 100 B has a concave-cylindrical inner surface, the radius of curvature is equal to the smaller radius of curvature r 1 . It will be apparent, that the inner surface of the sealing ledge 100 B closely engages the surface of the rotary piston 22 complementary thereto, in the area of the radius of curvature r 1 of the rotary piston 22 . In the area, in which the radius of curvature of the surface of the rotary piston 22 is larger, namely r 2 , a wedge-shaped gap 100 D is formed between the sealing ledge 100 B and the rotary piston 22 . In the transition region illustrated, both sealing ledges, on a respective portion of the inner surface, are in surface contact with the outer surface of the rotary piston, whereby a surface-to-surface seal is ensured.
FIG. 7B shows, in similar manner, the seal in the area of the transition from the large radius of curvature r 2 to the smaller radius of curvature r 1 . When the pair of sealing ledges 100 A and 100 B engages an area of the rotary piston having large radius of curvature r 2 only or an area having small radius of curvature r 1 only, either the sealing ledge 100 A or the sealing ledge 100 B ensures a surface contact with its respective total inner surface.
The described arrangement operates as follows:
The rotary piston 22 rotates counter-clockwise in FIG. 1 . When doing so, the rotary piston 22 rotates about the shaft 70 and slides with low speed along the inner wall of the cavity 12 in the area of the large radius of curvature. The axis of the shaft 70 passes through the center of curvature of the circular arc 24 of smaller radius of curvature. The circular arc 24 is tangent to the circular arc 18 of the cross section of the cavity 12 . The opposite area of the outer surface of the rotary piston 22 with large radius of curvature engages the area of the inner wall of the cavity 12 corresponding to the circular arc 20 . This area of the inner wall has the same radius of curvature as the engaging area of the outer surface of the rotary piston. Thus, there is a shape-adapted surface-to surface engagement. During the rotary movement of the rotary piston, this area of the outer surface of the rotary piston slides along the corresponding area of the inner wall.
Thereby, the volume of the working chamber 80 is increased, while the volume of the working chamber 82 becomes smaller. During this process, the shaft 70 is rotated relatively slowly, while a relatively fast rotation of the shaft 72 occurs.
This movement is continued, until the right blocking position in FIG. 2 is reached. Then the area of the outer surface of the rotary piston is located in that area of the inner wall of cavity 12 , which corresponds to the circular arc 16 . Both areas have the same, namely the small radius of curvature. The areas of the outer surface of the rotary piston corresponding to the circular arcs 32 and 34 having the large radius of curvature engage that areas of the inner wall of cavity 12 , which correspond to the circular arcs 18 and 20 , respectively, of the cross section. These radii of curvature, again, are equal. Thus the volume of the working chamber 82 , apart from the combustion chamber 82 , is reduced to zero, while the working chamber 82 has its maximum volume. Then the shaft 72 with the pinion 76 is located in the region which corresponds to the circular arc 40 , thus, so to say, in the left lower “corner” of the triangle of arcs. The rotary piston 22 is, however, not able to further rotate about the shaft 70 as instantaneous axis of rotation.
This position is illustrated in FIG. 2 .
For a further rotation, which may, for example, be effected by igniting fuel in the combustion chamber 94 in an internal combustion engine or by conducting a working fluid into the working chamber 82 , the instantaneous axis of rotation “jumps” to the axis of shaft 72 . The rotary piston 22 can now continue to rotate counter-clockwise, but now about the shaft 72 .
The further motion sequence is then, referenced to the new instantaneous axis of rotation, the same as described before with reference to the shaft 70 as instantaneous axis of rotation.
Consecutive intervals of motion occur, when the rotary piston 22 rotates. Each interval of motion extends from one of the described blocking positions to the next one. In each interval of motion, the volume of one working chambers, for example 80 , increases from zero to a maximum, while the volume of the other working chamber decreases from the maximum down to zero. During the next interval of motion, it is the other way round: The volume of the working chamber 82 increases from zero ( FIG. 2 ) up to a maximum, while the volume of the working chamber 80 decreases again ( FIG. 3 ).
In the position of FIG. 2 , the kinematics is not unambiguous. Each of the two shafts could with its axis define an instantaneous axis of rotation. If then, for example, by working fluid conducted into the working chamber 82 , a force to the left is exerted on the rotary piston 22 , this force could result in a translatory motion in horizontal direction instead of a rotary motion about an instantaneous axis of rotation. Thereby, the rotary piston 22 would be wedged in the cavity 12 .
This risk can be avoided in that, in the position of FIG. 2 , rotary speed regulating means are used to temporarily compel a lower rotary speed of the shaft 72 than the rotary speed of shaft 70 . Then the rotary piston is forced to rotate about this shaft 72 , while the other shaft 70 permits the concave-arcuate gear rack to roll off on the pinion 74 .
This is schematically illustrated in FIG. 6 . Sensors 140 detect the position of the rotary piston 22 in the cavity 12 . The sensors signal when the rotary piston has reached a blocking position. Then a control device 142 , to which the signals from the sensors are applied, actuates devices 144 and 146 by which, alternatingly, depending on which blocking position had been reached, rotary speeds are temporarily, for a short time, rotary speeds are forced on shaft 70 or shaft 72 , respectively, For example, a lower rotary speed is forced on shaft 70 , and a higher rotary speed is forced on shaft 72 or vice versa. In the simplest case, these devices 144 and 146 may be braking devices which, in the blocking positions, are caused to act, alternatingly for a short time, on the shaft 70 or the shaft 72 , while the respective other shaft remains unbroken.
The radii of the reference circles of the pinions are substantially equal to the small radii of curvature of the oval of second order defining the aperture 36 . If the internal gear 56 followed the oval of the aperture continuously, then the pinions would be caught, each time, in the blocking positions of the rotary piston 22 . The “corners” of the “triangle of arcs” could not roll over the pinions. For this reason, the concave-arcuate gear racks are interconnected, in the region of the circular arcs 38 , 40 , 42 of smaller radii of curvature, are interconnected by short straight or convex-arcuate gear racks 64 , 66 or 68 , respectively. The convex-arcuate gear racks 64 , 66 and 68 permit the internal gear 56 , and thereby the rotary piston 22 , to continue its rotation. They are so dimensioned that, in each blocking position, one of the concave-arcuate gear racks 58 , 60 or 62 engages the pinion 74 or 76 immediately after the pinion 74 or 76 has disengaged the preceding gear rack 62 , 58 or 60 , respectively. In this way, each pinion continuously engages one of the concave-arcuate gear racks 64 , 66 or 68 . The short convex-arcuate or straight gear racks ensure transition without interrupting the form fit but also without blocking.
FIG. 4 shows a rotary piston machine having a cavity, the cross section of which represents an oval 106 of fourth order. A rotary piston 108 , the cross section of which represents an oval 110 of fifth order is guided in the cavity 108 . Also here, the rotary piston 108 has an aperture 112 , the shape of which represents an oval 114 of fifth order. The axes of symmetry of rotary piston 108 and aperture coincide. The aperture has an internal gear 116 . The internal gear 116 meshes with two pinions 118 and 120 . The pinions 118 and 120 are attached to two housing-fixed shafts 122 and 124 , respectively. The axes 126 and 128 of the shafts 122 and 124 , respectively extend in an axis of symmetry of the cavity 104 .
The rotary piston 108 subdivides the cavity into two working chambers 130 and 132 , of which, when the rotary piston rotates, alternatingly the volume of one is increased and the other one is decreased.
The operating cycle is similar to the operating cycle of the embodiment of FIGS. 1 to 3 . The rotary piston 108 rotates, for example, about the axis 126 of one shaft 122 up to a blocking position. Then the instantaneous axis of rotation jumps into the axis 128 of the other shaft 124 . The rotary piston continues to rotate counter-clockwise in FIG. 4 up to the next blocking position. Course of motion between two consecutive blocking positions is an “interval of motion”. In each interval of motion, the volume of the working chamber 130 increases from zero to a maximum and the volume of the working chamber 132 decreases from a maximum to zero, or vice versa. The working chambers are located always on both sides of the plane of symmetry containing the axes 126 and 128 . They do not travel around the cavity.
In FIG. 4 , valves and spark plugs or fuel injectors are (schematically) shown for each working chamber.
FIG. 4A shows a rotary piston machine similar to FIG. 4 . Corresponding elements bear the same reference numerals as there. Details of the rotary piston machine of FIG. 4A are shown, at an enlarged scale, in FIGS. 8 and 8A .
In the rotary piston machine of FIG. 4A , numeral 150 designates a fuel injector. The fuel injector extends into a combustion chamber. This combustion chamber is so dimensioned and shaped, that the injected fuel is combusted substantially in the combustion chamber only. Then only the expanding combustion gases emerge into the expanding working chamber. The injection may be metered time-dependent or dependent on the rotation of the rotary piston such that it is adapted to the change of volume of the working chamber 130 or 132 . There is no flame front within the working chamber. The propagation of flame fronts in an expanding working chamber presents problems in prior art rotary piston machines.
In the embodiment of FIGS. 8 and 8A , the combustion chamber comprises a spherical calotte-shaped recess of the housing, which communicates with a first conical space 156 tapering towards the working chamber. The space 156 is formed in an insert 158 , which is screwed in a threaded recess of the wall of the working chamber 130 or 132 . The combustion chamber 152 is closed by a grid or net 160 . The fuel injector 150 terminates in a cone rounded at the tip, injection taking place through nozzle openings in the surface of this cone.
The described arrangement of the fuel injector in a combustion chamber such that combustion takes place substantially within the combustion chamber and frame fronts in the working chambers are avoided, is also applicable to other machines, for example in reciprocating internal combustion engines.
FIG. 5 shows a rotary piston machine, wherein a rotary piston, the cross section of which represents an oval of seventh order, is guided in a cavity the cross section of which represents an oval sixth order. Setup and operation are, apart from the orders of the ovals, similar to that of the embodiment of FIG. 4 . Corresponding elements are designated by the same reference numerals as in FIG. 4 , however marked by the suffix “A”.
|
A rotary piston machine with a housing forming a prismatic cavity with a cavity wall. The cross section of the prismatic cavity is a cavity oval. A rotary piston is guided for rotary movement in the cavity. The rotary piston moves in consecutive intervals of motion from one blocking position to an adjacent end position. The rotary piston, during the consecutive intervals of motion rotates, in the same rotational direction, alternatingly about one of two different axes. A transmission arrangement transmits the rotary motion about two axes. When the rotary piston reaches a blocking position, there is an associated larger diameter cavity circular arc, in which the larger diameter piston circular arc was slidingly guided during the preceding interval of motion. To provide unambiguous kinematics of the system in this position, there is a device for temporarily providing, when said rotary piston has reached one of the blocking positions, reduced rotary speed of the rotary motion of said rotary piston about that one of the axes which is located in the center of curvature of the associated larger radius circular arc, as compared to the rotary speed about the other axis. Variable volume working chambers are defined between the wall of the cavity and the rotary piston. For sealing between these working chambers, sealing ledges with sealing surfaces are provided.
| 5
|
This is a continuation of co-pending application Ser. No. 07/200,698 filed on May 31, 1988, now abandoned.
BACKGROUND OF THE INVENTION
The invention relates to apparatus for processing relating to a stream of bits.
Bits in a stream that are transmitted from one processor to another typically need to be filtered (i.e., analyzed to determine what they mean) and processed in some manner based upon the result of the filtering. E.g., in a computer network (e.g., as described in Tanenbaum, A. S., Computer Networks, (Prentice-Hall, Inc. 1981), pp. 10-28 ("Tanenbaum")), the filtering of an incoming bit stream occurs in the lower layers of the network processor at a node; if the incoming bits are identified as being of interest to the node (e.g., having a destination address associated with the node in an address field of a frame of bits), the bits are stored and later used by upper layers.
In the local area network controller for Ethernet ("LANCE"), which is described in MOS Microprocessors and Peripherals 1985 Data Book, (Advanced Micro Devices, Inc., Sunnyvale, Calif. 1985) pp. 2-50 to 2-86 ("LANCE Specification", which is hereby incorporated by reference), the 48-bit Ethernet address is analyzed in a bit-by-bit compare, and frames that do not have addresses that match are discarded. When an address matches all the way through to the last bit in the address field, the frame is placed in data buffers for access by the upper layers. The upper layers do not know which address matched, only that one did. Thus the software associated with the upper layers must repeat the entire compare process.
SUMMARY OF THE INVENTION
In one aspect the invention features in general processing a bit stream by using a hardware comparator that compares first predetermined bits of a bit stream (e.g., a field of a frame), an index generator that generates an index based on the states of the predetermined bits, and a processor that accesses the index and processes a group of bits of the stream (e.g., a frame) in one of a plurality of different ways based upon the index. The processor thus need not compare the entire set of predetermined bits in order to determine how the group of bits should be processed, but simply accesses the index, which includes that information. The comparison involves comparison against a table of comparison values that are provided to the hardware comparator, and one of a plurality of different tables is provided in response to a table select control signal, providing great flexibility in filtering the bit stream.
In preferred embodiments, the predetermined bits that are compared could be, e.g., a destination address field indicating the intended recipient, a protocol field, or a field identifying a data compression algorithm. There also could be comparison of predetermined bits that identify a special message relating to management of a processor. There can be data buffers that receive and store portions of the bit stream and descriptor storages associated with respective data buffers for storing descriptor entries relating to the data stored in the data buffers; the indexes can be stored in the descriptor storages associated with the data buffers for access by the processor. The comparator can be programmable to compare different fields of the bit stream in response to a field select control signal; the field select control signal can include a start signal location and a length signal designating the length of the bit field to be used in the compare; the processor can control the field select control signal. The tables can be selected in response to a value generated as the result of an initial comparison of a field. The comparisons can be advantageously controlled without direct involvement of a host computer by using a chip control state machine, a memory state machine, and a table memory in which are stored: tables of comparison values; entries identifying the predetermined bits being compared; entries indicating whether the group of bits should be discarded and whether interrupts should be generated upon completion of a comparison; entries indicating further comparisons to be made; entries indicating whether an index should replace the predetermined bits in the bit stream; and entries indicating where the group of bits should be routed (e.g., to a port to another network or to a data buffer). The invention can be employed in a bridge that has at least one port to a different network, the index identifying the port; the processor can translate the fields of the bits in one network's protocol into another network's protocol. Ring buffers can be used to temporarily store bits of the stream while the index is being generated.
In another aspect the invention features in general processing source data bits using a hardware comparator that compares predetermined bits of the source data bits, an index generator that generates an index based on the states of the predetermined bits, and a processor that accesses the index and modifies the source data bits in one of a plurality of different ways prior to transmitting the source data bits as a stream of bits.
In preferred embodiments the index can identify transmit data to be placed in a frame to be transmitted; the transmit data are placed in a frame at a field prescribed by a start location signal and a length signal. The index could alternatively identify a data compression algorithm.
Other advantages and features of the invention will be apparent from the following description of a preferred embodiment thereof and from the claims. The particular details of the example of the preferred embodiment should not be construed to limit the scope of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment will now be described.
Drawings
FIG. 1 is a block diagram of a node of a local area network employing bit stream filtering according to the invention.
FIG. 2 is a block diagram showing a bit stream filtering circuit and related components at a node.
FIG. 3 is a block diagram showing the bit stream filtering circuit.
FIG. 4 is a diagram of a control entry and a table entry used in bit stream filtering according to the invention.
FIG. 5 is a flow description of cache logic of a cache state machine of the FIG. 3 circuit.
FIG. 6 is a flow description of chip control logic of a chip control state machine of the FIG. 3 circuit.
STRUCTURE AND OPERATION
Referring to FIG. 1, there is shown the network architecture for node 10 of a local area network, as described in Lauck, A. G., et al. "A Digital Network Architecture Overview", Digital Technical Journal, Number 3, September, 1986, pp. 10-24 (which is hereby incorporated by reference). Node 10 includes physical link modules 12, data link modules 14, routing modules 16, end communication modules 18, session control modules 20, network application modules 22, network management modules 24, and user modules 26. As is described in Tanenbaum, the network is organized as a series of layers, each layer being built on its predecessor and offering certain services to higher layers and shielding those layers from the details of how the offered services are actually implemented. In addition to communication between adjacent layers, there also are control lines between nonadjacent layers.
Referring to FIG. 2, bit stream filtering circuit 28 (an integrated circuit) resides in physical link modules 12 with LANCE features 29 (as described in the LANCE specification) and serial interface adapter ("SIA") 31 connected to other nodes via an Ethernet serial transmission line. Bit stream filtering circuit 28 filters, i.e., analyzes, the incoming bit stream from SIA 31 to generate an index indicating how the bit streams should be processed at the node. Bit stream filtering circuit 28 has access to random access memory ("RAM") 30, which is also accessed by upper layers and is controlled by host computer 32. Host computer 32 implements upper layers above physical link modules 12. Physical link modules 12 and RAM 30 can thus be accessed and controlled by upper layers. As is described in the LANCE specification, RAM 30 is used to provide memory locations for plural transmit and receive data buffers 45 (each buffer being used to store a frame, or portion of a frame, that has been received or will be transmitted) and descriptor storages for associated descriptor entries 47 that have pointers to respective data buffers 45 and characterize the data stored in the respective buffers 45. The LANCE descriptor entries have been extended to include control entries 60 (described in FIG. 4) relating to bit filtering according to the invention. Each descriptor entry potentially can have a plurality of associated control entries 60.
Referring to FIG. 3, bit stream filtering circuit 28 includes write-through ring buffers 34 for receiving a stream of bits over serial input line 36. Ring buffer select control is controlled by chip control state machine 38 to control routing of the bit stream to one of three ring buffers 34, which operate essentially as three shift registers that are each long enough to hold an Ethernet frame (1536 8-bit bytes). The output of ring buffers 34 is connected to serial transmitter 40 (for transmission of a serial bit stream to a separate network) and/or to serial-to-parallel converter 44. The data received from ring buffers 34 are provided by converter 44 in a parallel form for transfer through buffer decode and control line 42 to RAM 30.
Comparators 52 are controlled by chip control state machine 38. The bits traveling through a ring buffer 34 can be routed from a location between the ring buffer's input and output to pass through comparators 52 and be returned to the ring buffer 34 and continue traveling through it. Hardware comparators 52 compare predetermined bits (i.e., a field) with compare values loaded in table entries 62 in table cache memory 58 and indicate the results of the compares to chip control state machine 38. Chip control state machine 38 includes an index generator function to generate a 16-bit index based on the results of the compares. The index is stored in table cache memory 58 in the result field (FIG. 4) of a control entry 60 associated with the descriptor entry 47 for a data buffer 45 assigned to an incoming frame. Table cache memory 58 is controlled by cache state machine 54. Table cache memory 58 and cache state machine 54 thus comprise a comparison input means to provide a table of comparison values to comparators 52.
In operation, prior to receiving a frame (for example, from another node on the local area network) on serial input line 36, a control entry 60 is read from RAM 30 into table cache memory 58 via buffer decode and control line 42. The control entry (FIG. 4) includes "start bit" (identifying the start location of the field to be used for the compare), "length" (indicating the length of the field being compared), 2-bit "control" (to control chip actions after filtering has been completed: e.g., discard on false address comparison, interrupt host when finished), "table pointer" (identifying a table of comparison values to be stored in table cache memory 58 and used in the compare), and "result" (storage locations for receiving the 16-bit index). The descriptor entries 47 (including their control entries 60) stored in RAM 30 are determined by upper layers. Prior to receiving the frame, up to three tables of comparison values are stored in table cache memory 58 to be used by hardware comparators 52. The table pointer is used to fetch a table stored in RAM 30 and store it as the table entry 62 in table cache memory 58 associated with the control entry 60. The table pointer entry is thus used to generate a table select control signal used to select the table of comparison values. Table entries 62 (FIG. 4) include 14 comparison values (e.g., 48 bits if indicating Ethernet address) to be used by comparators 52 designated 1 to 14 in FIG. 3, and a further comparison value for use by a special comparator, discussed in detail below. Associated with each comparison value are (FIG. 4) an "enable" bit (indicating whether the value is to be used; e.g., there may be less than 14 comparison values in the table), and a 4-bit "link pointer" pointing to a further control entry 60 to be used in a further compare depending upon the results of an initial compare. Up to two link pointer entries can be used to identify two further control entries 60 to be initially fetched and stored in table cache memory 58. "Output select" indicates where to route the frame depending on the results of the compare. "Field replace" indicates whether the index generated should replace the field compared in the bit stream. If the first table entry 62 does include one or more table pointers identifying further control entries 60, they are fetched and stored in table cache memory 58, as indicated in the cache logic described in FIG. 5.
Node 10 can receive both Ethernet frames and frames meeting IEEE Standard 802.3 ("802.3 frames"). When the frame is received over input line 36, the frame goes into one of three ring buffers 34 as determined by chip control state machine 38. As indicated in the chip control logic described in FIG. 6, chip control state machine 38 uses the start bit and length of the control entry 60 to identify start and stop bits of the field compared by hardware comparators 52, which then compare the bits in the field identified as the bits are routed from a ring buffer 34 through comparators 52. The start bit and length bit stored in control entry 60 are thus used to generate a field select control signal to determine the field of bits that is compared. The bits are compared with bits of the comparison values of the table entry 62 in table cache memory 58, and a 16-bit index is generated by chip control state machine 38. For example, if the field being compared is the 48-bit destination Ethernet address, the table would include as values the 14 48-bit physical addresses that can be associated with node 10. The index is deposited by chip control state machine 38 in cache state machine 54, which in turn places the index in the result field in the respective control entry 60 in table cache memory 58.
Assuming the frame is to be temporarily stored in a data buffer 45 in RAM 30 and used by the upper layers at the node, the frame, upon leaving a ring buffer 34, is passed through serial-to-parallel converter 44 and buffer decode and control line 42 to the respective data buffer 45 in RAM 30. The result (index) of the control entry in table cache memory 58 is also placed in RAM 30, in the associated descriptor entry 47, which points to the respective data buffer 45. Synchronization and clocking of state machines 38, 54 are provided by the incoming bit stream, as indicated by synch line 57.
If the destination address does not match up with any of the 14 addresses in the table, the frame will be handled as determined by the state of the control field in control entry 60; e.g., the frame could be discarded. At the end of the compare, if the control field of the control entry 60 indicates interrupt, an interrupt is generated by chip control state machine 54 and provided to host 32. If the field replace entry of the table entry 62 is true, and, if there is a match, the index is used to replace the field that was compared in the frame.
The special comparator 52 (designated "0") is used to compare the 4-byte field in the incoming frame that is used either to indicate the length of the frame (if an 802.3 frame) or to identify protocol (if an Ethernet frame) to determine if the frame is an Ethernet frame or an 802.3 frame. If the value is less than or equal to the maximum length for an 802.3 frame, then the frame is identified as an 802.3 frame; if not, the frame is assumed to be an Ethernet frame; by convention all Ethernet protocol identifying numbers are greater than the maximum 802.3 frame length. The result of the special comparator can thus be used to select either the second table or third table in table cache memory 58 to be used in a further field comparison.
The initial index or the special comparator output thus might indicate that there should be a further compare on a different field using the second or third table stored in table cache memory 58, which table and field had been identified by link pointers and preloaded. Host 32 thus need not be interrupted, and different frames could be compared in different manners based upon the result of an initial compare without intervention by the host. A result (i.e., index) of an initial comparison can be stored in RAM 30 shortly after the initial comparison has been completed and before a frame has passed through ring buffers 34 and into a data buffer 45. At this time the associated table entry 62 and control entry 60 are no longer needed and can be deleted from table cache memory 58. The next comparison will use one of the two other table and control entries already stored, and the freed-up space in table cache memory 58 can be filled by a further table entry 62 and control entry 60 according to the cache logic of FIG. 5. The further control entry 60 and table entry 62 to be loaded are identified by an enabled link pointer in the presently used table entry 62. The results of the further comparison can also be stored in a descriptor entry 47 in RAM 30 and can be used to identify further comparisons. If necessary to do further compares, the frame can be fed back from a ring buffer output to a ring buffer input.
The upper layers of the node shown in FIG. 1 can access the data stored in RAM 30 and employ the indexes in the descriptor entry 47 to assist in and speed up processing. The upper layers thus function as a processor that accesses the index and processes bits in the frame in at least one of a plurality of different ways based on the index. For example, if the index identifies a destination address, there is no need to do a 48-bit software compare of the field of the destination address. The index could also identify a protocol which would be used by one of the upper layers in processing the data stored in the data buffer. The index could also identify a data compression algorithm, and an upper layer would expand the data according to the algorithm identified. The index could also indicate that the frame is to be transmitted via serial transmitter 40, acting as a bridge, to another network. In this case the use of three ring buffers 34 permits storage of a later frame while an earlier frame is being serially transmitted by transmitter 40 at a lower rate. Serial transmitter 40 can translate fields as bits pass through it. Comparators 52 could also identify a special message and generate an index related to management of the network and not related to a frame to be processed.
Other Embodiments
Other embodiments of the invention are within the scope of the following claims. For example, the comparison values could be generated by other means, the indexes could be used to process the bits in other ways, and the comparator output could be the index, in which case the comparator would also be functioning as an index generator.
Also, a hardware comparator could be used to process source data bits from upper layers before transmitting them. The comparator compares predetermined bits of the source data bits and generates an index used by a processor to modify the source data bits before transmitting them as a stream of data bits. E.g., the index can identify transmit data to be placed in a frame to be transmitted; the transmit data are placed in a frame at a field prescribed by a start location and a length signal. The index could alternatively identify a data compression algorithm.
|
Apparatus for processing a stream of bits including a hardware comparator that compares first predetermined bits of the stream, comparison input means to provide a table of comparison values to said hardware comparator for comparison with said predetermined bits of said stream, the comparison input means being programmmable to provide one of a plurality of different tables in response to a table select control signal, an index generator for generating an index based on the states of the predetermined bits, and a processor for accessing the index and processing a group of the bits in at least one of a plurality of different ways based on the index.
| 6
|
[0001] This application is a continuation of U.S. application Ser. No. 14/165,058 filed on Jan. 27, 2014, which is a continuation of U.S. application Ser. No. 13/398,774 filed on Feb. 16, 2012 (now U.S. Pat. No. 8,662,631), which claims priority to Japanese Patent Application No. 2011-032927, filed Feb. 18, 2011, the entireties of which are incorporated by reference herein.
BACKGROUND
[0002] 1. Technical Field
[0003] The present invention relates to an image processing device that applies image processes such as printing and scanning processes to process media including checks and recording paper, and to a structure for attaching a cover to the image processing device.
[0004] 2. Related Art
[0005] Check processing devices, often used at bank teller windows for example, that can print on checks and read check information depending upon the content of the particular check process are known from the literature. See, for example, Japanese Unexamined Patent Appl. Pub. JP-A-2008-207927, which describes a check processing device having plural roller pairs disposed along a U-shaped conveyance path through which checks and other processed media are conveyed for processing, that conveys a check or other slip by passing it sequentially from one roller pair to the next. An image scanner, magnetic head, and print unit are disposed along the conveyance path and used to image, read magnetic information from, and print on the checks or other processed media (referred to below as simply checks).
[0006] When a check becomes jammed in the conveyance path in this check processing device, the check must be removed from the conveyance path. To enable this, the check processing device described in JP-A-2008-207927 has a pair of covers that can pivot on a support shaft disposed in the center of the U-shaped conveyance path so that the covers can be opened when a check becomes stuck in the conveyance path. This makes removing a check stuck in the conveyance path easier by opening the covers and exposing the conveyance path to the outside.
[0007] While checks jammed in the conveyance path can be removed with the image processing device described in JP-A-2008-207927, the print unit can also be easily accessed from the outside because the print unit is exposed to the outside when the covers are open. Thus, the user can accidentally touch the print unit, which may damage the print unit.
SUMMARY
[0008] The present invention relates to an image processing device and a cover attachment structure that enable easy removal of processed media stuck in the conveyance path of the image processing device while also protecting the print unit and other image processing units from external exposure and potential damage.
[0009] One aspect of the invention is an image processing device having a conveyance path along which the device conveys process media in a specific conveyance direction; an image processing unit having a process surface disposed facing the conveyance path; first and second pivot pins extending in a direction that intersects the direction of conveyance adjacent the pins and are disposed along or adjacent the conveyance path with the process surface facing a portion of the conveyance path passing therebetween; and a first cover and a second cover that are disposed along the conveyance path and cover or enclose the conveyance path, and can open and close pivoting respectively on the first and second pivot pins. Typically, the first and second pivot pins are attached to the device so as to pivot about a pivotal axis that extends in a direction transverse to or intersects the conveyance direction, preferably substantially perpendicular to a plane through which the conveyance path extends.
[0010] By disposing the process surface near an area between the first and second pivot pins in the image processing device according to this aspect of the invention, the first cover and the second cover remain beside the process surface even when the covers are in an open position. As a result, the image processing unit can be protected from the outside even when the covers are opened to remove process media stuck in the conveyance path.
[0011] In an image processing device according to another aspect of the invention, the first pivot pin and the second pivot pin are preferably disposed respectively on the upstream side and downstream side of the process surface in the conveyance direction.
[0012] With the image processing device according to this aspect of the invention, the positions of the first pivot pin and the second pivot pin do not change even when the cover rotates, access to the image processing unit from the upstream side and downstream side of the conveyance path is prevented, and the image processing unit is protected from the outside.
[0013] In another aspect of the invention, preferably, the first and second covers can rotate to a position opposite the process surface with the conveyance path therebetween when in the open position.
[0014] In an image processing device according to this aspect of the invention, because the first and second covers can rotate to a position opposite the process surface with the conveyance path therebetween, the process surface is closed off by the first and second covers, and the image processing unit can be more reliably protected from the outside.
[0015] Even more preferably, the first cover and the second cover pivot horizontally.
[0016] In an image processing device according to this aspect of the invention, because the weight of the covers does not cause the covers to return to the closed position after the covers are opened, the image processing unit can be more reliably protected from the outside than in a configuration in which the first cover and the second cover pivot vertically.
[0017] Another aspect of the invention is an image processing device including: a conveyance path that conveys process media; an image processing unit disposed in a middle part of the conveyance path; and a pair of covers that are disposed along the conveyance path and cover the conveyance path, and are supported to open and close on a pair of pivot pins disposed to the middle part of the conveyance path; the image processing unit being disposed opposite the pair of pivot pins with the conveyance path therebetween.
[0018] In an image processing device according to this aspect of the invention, the portion of the covers near the image processing unit will not separate greatly from the conveyance path when the covers open and close because the image processing unit is located at a position opposite the pivot pins of the pair of covers. Because a large space is not formed near the image processing unit when the covers open and close, the image processing unit is protected from the outside.
[0019] In an image processing device according to another aspect of the invention, the pair of pivot pins are disposed in a direction intersecting the conveyance direction of the process medium in the conveyance path, and are separated from each other in the conveyance direction; the image processing unit has a process surface disposed facing the conveyance path; and the process surface is disposed positioned between the pair of pivot pins.
[0020] In an image processing device according to this aspect of the invention, a space is created in a position opposite the process surface, which allow for placement of an inkjet head capping mechanism, for example, in this space.
[0021] Preferably, the pair of covers pivot on their respective pivot pins of the pair of pivot pins, and can rotate to a position opposite the process surface with the conveyance path therebetween.
[0022] Because the pair of covers rotate to a position opposite the process surface with the conveyance path therebetween, the space opposite the image processing unit is closed by the covers in the image processing device according to this aspect of the invention, and access to the image processing unit from the direction opposite the process surface can be prevented. The image processing unit can therefore be reliably protected from the outside.
[0023] Even more preferably, in an image processing device according to another aspect of the invention, a capping member that closes the space opposite the image processing unit is disposed between the pair of pivot pins.
[0024] In the image processing device according to this aspect of the invention, access from the direction opposite the process surface is prevented by the capping member that closes the space opposite the process surface. The image processing unit can therefore be more reliably protected from the outside.
[0025] Preferably, in an image processing device according to another aspect of the invention, the image processing unit is a fluid ejection head having an ejection nozzle that ejects a fluid, and a capping mechanism that can close the ejection nozzle is positioned opposite the image processing unit with the conveyance path therebetween.
[0026] The image processing device according to this aspect of the invention can also protect the capping mechanism when the covers are open because the capping mechanism is located on the opposite side of the conveyance path as the image processing unit, which is protected from the outside even when the pair of covers are open. The ejection nozzle can also be more reliably protected by closing the space opposite the ejection nozzle with the capping mechanism.
[0027] Another aspect of the invention is an image processing device including: a conveyance path through which process media is conveyed; an image processing unit disposed with a process surface facing the conveyance path; and a pair of covers that pivot on a pair of pivot pins, respectively, the pair of pivot pins intersecting the conveyance direction of the conveyance path to open and close the conveyance path and are formed extending away from the pivot pins, being disposed on the upstream side and downstream side of the conveyance path, respectively, with the image processing unit between the pivot pins, covering the conveyance path when the conveyance path is closed, and rotating to a position opposite the process surface when the conveyance path is open.
[0028] Because the pair of covers rotate to a position opposite the process surface in this aspect of the invention, the process surface is covered by the covers when the conveyance path is opened in the image processing device, thereby protecting the process surface from the outside when the conveyance path is open.
[0029] Preferably, in this image processing device, the pair of covers pivot horizontally.
[0030] Because the pair of covers will be returned by their own weight to the closed position after opening, an image processing device according to this aspect of the invention protects the process unit from the outside more reliably than in a configuration in which the pair of covers pivot vertically.
[0031] In another aspect, the invention includes an attachment structure for a cover that can open and close to cover a conveyance path of a process media on which the image processing device performs an image process: the cover including an upstream-side cover that covers the upstream side of the conveyance path, and a downstream-side cover that covers the downstream side of the conveyance path; the upstream-side cover and the downstream-side cover are pivotally supported by and attached to open and close on an upstream-side pivot pin and a downstream-side pivot pin, respectively; the upstream-side pivot pin and downstream-side pivot pin being disposed opposite a protected part of the conveyance path where the image process is performed with the conveyance path therebetween.
[0032] With the cover attachment structure according to this aspect of the invention, the upstream-side pivot pin and downstream-side pivot pin are disposed opposite the protected part with the conveyance path therebetween, thereby shielding the protected part from the upstream and downstream sides of the conveyance path, and protecting the members disposed in the protected part from the outside.
[0033] In a cover attachment structure according to another aspect of the invention, a printhead that prints on the process media is disposed in the protected part.
[0034] An image processing device using the cover attachment structure according to this aspect of the invention protects the printhead, which can be easily soiled if touched by the user, even when the cover is open.
[0035] In a cover attachment structure according to another aspect of the invention, the printhead is an inkjet head, and a capping space is formed between the upstream-side pivot pin and the downstream-side pivot pin, a cap for the inkjet head being disposed within the capping space.
[0036] The cover attachment structure according to this aspect of the invention protects the inkjet head, which can easily be soiled if touched by the user, and the cap that protects the inkjet head, from the outside.
[0037] Other objectives and embodiments of the invention, as well as a fuller understanding of the invention, will become apparent upon reference to the following description and claims in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1 is an oblique view of a check processing device according to a preferred embodiment of the invention.
[0039] FIG. 2 is a top view of the check processing device according to a preferred embodiment of the invention.
[0040] FIG. 3 shows the check processing device in FIG. 2 when the access covers are open.
[0041] FIG. 4 shows the check processing device according to another embodiment of the invention when the access covers are open.
DESCRIPTION OF EMBODIMENTS
[0042] Embodiments of a check processing device according to the present invention are described below with reference to the accompanying figures.
Basic Structure
[0043] FIG. 1 is an oblique view of a check processing device 1 according to this embodiment of the invention. The check processing device 1 includes a main case 2 , a middle cover 13 affixed to the main case 2 , and a pair of access covers 11 , 12 that are pivotally connected to the middle cover 13 by hinges (pivot pins) 14 , 15 , respectively.
[0044] A conveyance path 3 for conveying checks as the processed media from the upstream side to the downstream side is formed around the outside of the main case 2 in a basic U-shaped configuration when seen from above. The pair of access covers 11 , 12 are formed along the conveyance path 3 on the outside of the conveyance path 3 so that they the access cover the upstream side and downstream sides of the conveyance path 3 , respectively. The middle cover 13 , disposed between the access covers 11 , 12 , covers the middle part of the conveyance path 3 . The hinges 14 , 15 are disposed with the pivot pins positioned in a direction that intersects the conveyance direction of the conveyance path 3 , and the access covers 11 , 12 are pivotally attached by hinges 14 , 15 to the middle cover 13 .
[0045] A paper feed unit 20 is disposed at the upstream end of the conveyance path 3 . The paper feed unit 20 includes an in-feed mechanism having a feed roller and a drive motor (not shown) that feeds checks to the upstream end of the conveyance path 3 , and a separation mechanism, such as a separation pad or a retard roller. Preferably, the loading pocket 21 of the paper feed unit 20 into which checks to be processed are dropped is open to the top and side of the check processing device 1 so that checks can be fed into the check processing device 1 from two directions, the top and the side. The checks, which have a printed surface on the front side, are loaded into the loading pocket 21 with the printed front side facing the outer side of the conveyance path 3 , and are conveyed standing vertically on edge through the conveyance path 3 .
[0046] A discharge unit 30 into which the checks are discharged is disposed at the downstream end of the conveyance path 3 . The discharge unit 30 includes a path selection mechanism 31 disposed rotatably to the main case 2 , and a first exit pocket 32 and second exit pocket 33 disposed downstream from the path selection mechanism 31 . Checks discharged from the conveyance path 3 are sorted by the path selection mechanism 31 into the first exit pocket 32 or the second exit pocket 33 , which are separated by a divider 34 .
[0047] The internal structure of the check processing device is described next with reference to FIG. 2 , which is a top view of the check processing device 1 wherein the internal parts are denoted by dotted lines.
[0048] A printhead (image processing unit) 40 is disposed in the main case 2 at a middle position midway between the upstream end and the downstream end of the conveyance path 3 (at the bottom of the U-shape of the conveyance path 3 ). The printhead 40 is disposed opposite the gap between the pair of hinges 14 , 15 with the ejection surface (process surface) 41 in which ejection nozzles are formed facing the conveyance path 3 . The check processing device 1 can be more compactly constructed by disposing the printhead 40 inside the main case 2 on the inside of the U-shaped conveyance path 3 .
[0049] An inkjet printhead that prints on checks by ejecting ink can be used as the printhead 40 . A line printhead 40 that extends across the width of the check (the dimension perpendicular to the conveyance direction) may also be used.
[0050] A capping mechanism 42 capable of capping the ejection nozzles in the ejection surface 41 when the printhead 40 is not printing is disposed between the hinges 14 , 15 opposite the ejection surface 41 with the conveyance path 3 passing therebetween, the capping mechanism 42 being covered by the middle cover 13 .
[0051] The capping mechanism 42 has a cap unit that covers the ejection surface 41 so that the ejection nozzles are closed, preventing evaporation of ink from the nozzles when not printing and preventing ink from clogging the nozzles. The capping mechanism 42 has a drive unit that moves the cap unit into contact with the ejection surface 41 when the printhead 40 is not printing, and retracts the cap unit from the ejection surface 41 to a position not interfering with check conveyance when the printhead 40 prints.
[0052] A magnet 51 capable of magnetizing magnetic ink printed on checks is disposed inside access cover 11 on the downstream side of the paper feed unit 20 . Downstream from the magnet 51 and upstream of the printhead 40 , a magnetic scanner 52 capable of reading magnetic information is disposed inside access cover 11 with the scanning surface facing the conveyance path 3 . A pressure pad 53 that presses checks to the scanning surface of the magnetic scanner 52 is disposed opposite the magnetic scanner 52 with the conveyance path 3 passing therebetween. An MICR head can be used as the magnetic scanner 52 .
[0053] Optical scanners 54 , 55 capable of reading the back and front sides of checks are disposed with the conveyance path 3 passing therebetween downstream from the printhead 40 on the main case 2 and access cover 12 , respectively, and can capture images of the front and back sides of the passing checks as the checks are conveyed along the conveyance path. Contact image scanners can be used as the optical scanners 54 , 55 .
[0054] The check processing device 1 also has a plurality of conveyance roller pairs 61 a to 64 b that convey checks from the upstream side to the downstream side of the conveyance path 3 . These plural conveyance roller pairs 61 a to 64 b are disposed with conveyance rollers 61 a, 62 a , 63 a, 64 a disposed to the main case 2 opposite conveyance rollers 61 b, 62 b, 63 b, 64 b disposed to the access covers 11 , 12 with the conveyance path 3 therebetween. The conveyance rollers 61 a , 62 a, 63 a, 64 a disposed within the main case 2 are connected by a common endless belt to a paper feed motor not shown, and are synchronously and rotationally driven so as to convey the process media along the conveyance path.
Basic Operation
[0055] Checks loaded into the loading pocket 21 of the check processing device 1 are, for example, fed by the in-feed roller (not shown) of the paper feed unit 20 , separated one at a time by the separation roller or other sheet separating mechanism, and conveyed to the upstream end of the conveyance path 3 .
[0056] The check conveyed into the conveyance path 3 from the paper feed unit 20 is held and conveyed by the first roller pair 61 a, 61 b, and magnetic ink on the check is magnetized by the magnet 51 . The check is pressed to the magnetic scanner 52 by the pressure pad 53 , and the magnetized magnetic ink is read by the magnetic scanner 52 . The magnetic information that is read is sent to an external host computer, for example. The check is then held by the second roller pair 62 a, 62 b, and conveyed through the curved part of the access cover 11 to the printhead 40 as the conveyance direction curves by approximately 90 degrees.
[0057] When the check is conveyed by the second roller pair 62 a, 62 b to the position opposite the printhead 40 , the printhead 40 prints on the back side of the check opposite the front side having the printed surface based on input from the external host computer, for example. The printed check is then held by the third roller pair 63 a, 63 b and conveyed to the optical scanners 54 , 55 while the conveyance direction curves approximately 90 degrees again through the curved part of the access cover 12 . The optical scanners 54 , 55 then read the back and front sides of the check, and send the captured image information to the host computer. After passing the optical scanners 54 , 55 , the check is held and conveyed by the fourth roller pair 64 a, 64 b, [ 4 b, sic] and discharged into the discharge unit 30 .
[0058] If the check information could not be read by the magnetic scanner 52 , the check can be conveyed without the back side being printed on by the printhead 40 and the path selection mechanism 31 rotated so that the check is discharged into the second exit pocket 33 . By discharging normally processed checks into the first exit pocket 32 , and discharging checks that were not normally processed into the second exit pocket 33 , checks that were correctly processed checks and checks that were not correctly processed can be easily separated and removed.
[0059] Because the check processing device 1 according to this embodiment of the invention can read and write checks in a single operation, check processing is made easier for the teller or other users processing checks.
Eliminating Paper Jams
[0060] In the check processing device 1 according to this embodiment of the invention, lock mechanisms 16 , 17 engages and holds the ends of the access covers 11 , 12 opposite the hinges 14 , 15 to the paper feed unit 20 and discharge unit 30 when in the closed cover position shown in FIG. 1 and FIG. 2 . Note that a variety of slide lock mechanisms or other locking mechanism known could be used for lock mechanisms 16 , 17 in accordance with the claimed invention.
[0061] The hinges 14 , 15 of the access covers 11 , 12 are disposed so as to extend in a direction intersecting the media conveyance direction (that is, vertically in line with the paper surface in the example shown in FIGS. 1-4 ). As a result, when the lock mechanisms 16 , 17 are released, the access covers 11 , 12 pivot on the hinges 14 , 15 as shown in FIG. 3 , so that the ends of the access covers 11 , 12 opposite the hinges 14 , 15 move away from the conveyance path 3 , and the conveyance path 3 is opened to the sides of the check processing device 1 without the access covers 11 , 12 interfering with each other.
[0062] Preferably, the pressure pad 53 , optical scanner 54 , and conveyance rollers 61 a , 62 a, 63 a, 64 a are attached to the main case 2 , and the magnet 51 , magnetic scanner 52 , optical scanner 55 , and conveyance rollers 61 b, 62 b, 63 b, 64 b are attached to the access covers 11 , 12 . In this embodiment, when the access covers 11 , 12 swing open, the conveyance path 3 is opened so that the plural conveyance rollers 61 a to 64 a, and the reading surfaces of the magnetic scanner 52 and optical scanners 54 , 55 are exposed to the outside.
[0063] Therefore, when a check becomes jammed during conveyance through the conveyance path 3 , the conveyance path 3 can be exposed to the side by opening the access covers 11 , 12 , and the check jammed in the conveyance path 3 can be easily removed from a side of the check processing device 1 without interfering with the magnetic scanner 52 or other parts.
Protecting the Printhead When the Access Covers are Open
[0064] In the check processing device 1 according to this embodiment of the invention, the hinges 14 , 15 of the access covers 11 , 12 are disposed near the ejection surface 41 of the printhead 40 . In this configuration, the parts of the access covers 11 , 12 near the hinges 14 , 15 therefore do not move greatly when the access covers 11 , 12 swing open to remove a check jammed in the conveyance path 3 , and remain closed to the ejection surface 41 even when the access covers 11 , 12 are open. Because a large space is not opened around the printhead 40 , external access to the printhead 40 is prevented by the access covers 11 , 12 , and the printhead 40 can be protected from the outside even when the access covers 11 , 12 are open.
[0065] The positions of the hinges 14 , 15 that are the pivot axes of the access covers 11 , 12 do not change when the access covers 11 , 12 pivot. As described above, the hinges 14 , 15 are located near the ejection surface 41 on the upstream and downstream sides of the ejection surface 41 in the conveyance direction, respectively. The ejection surface 41 of the printhead 40 is therefore sheltered from the upstream and downstream sides of the conveyance path 3 by the hinges 14 , 15 even when the access covers 11 , 12 are open. More specifically, the printhead 40 can be more reliably protected because the user cannot access the printhead 40 from the upstream or downstream sides of the conveyance path 3 .
[0066] Furthermore, the capping mechanism 42 and the middle cover 13 that covers the capping mechanism 42 are disposed as capping members in the space opposite the ejection surface 41 of the printhead 40 , thereby closing the space opposite the ejection surface 41 . The ejection surface 41 is thus covered by the capping mechanism 42 and middle cover 13 so as to prevent exposure to the outside even when the access covers 11 , 12 are open, thereby more reliably protecting the printhead 40 from the outside.
[0067] Yet further, as shown in FIG. 3 , the access covers 11 , 12 pivot to a position opposite the ejection surface 41 with the conveyance path 3 passing therebetween when the covers are open. This allows the printhead 40 to be more reliably protected since the open access covers 11 , 12 restrict access to the printhead 40 from the direction opposite the ejection surface 41 .
[0068] Additionally, positioning the hinges 14 , 15 of the access covers 11 , 12 to extend vertically allows the access covers 11 , 12 to pivot horizontally. This configuration allows the access covers 11 , 12 to be held open with improved stability than in a configuration in which the access covers 11 , 12 swing vertically where the access covers 11 , 12 may inadvertently swing closed due to their own weight. Thus, this aspect further allows jammed checks to be more easily removed, since the access covers 11 , 12 can be held in a more stable position while concurrently restricting access to and protecting the printhead 40 .
[0069] Although a preferred embodiment of the invention is described above, the technical scope of the invention is not limited to the scope of the foregoing embodiment. Thus, the foregoing embodiment can be modified and improved in many ways without departing from the scope of the accompanying claims as would be appreciated by one of ordinary skill in the art.
[0070] Although the printhead 40 is described as being an inkjet head in the foregoing embodiment, the present invention may be used with any image processing unit where protection from the outside is desired. For example, an optical scanner whose scanning accuracy can be reduced by soiling of the scanning surface could obviously be disposed in the protected part between the hinges 14 , 15 , similar to the embodiments described above. In addition, although the printhead 40 is described as being disposed in the protected part between hinges 14 , 15 in the foregoing embodiment, a configuration that disposes and protects plural units, such as the printhead and optical scanner, from the outside as needed in the protected part between the upstream and downstream access covers 11 , 12 would also be in accordance with the principles of the present invention.
[0071] Additionally, although the access covers 11 , 12 are described as pivotally attached by hinges 14 , 15 on the outside of the access covers 11 , 12 in the foregoing embodiment, a configuration in which pivot pins 14 a, 15 a are disposed on the printhead 40 side of the access covers 11 , 12 is also conceivable, such as shown in FIG. 4 for example.
[0072] Yet further, instead of pivoting to a position where the access covers 11 , 12 are completely opposite the printhead 40 as shown in FIG. 3 , the present invention may include a configuration in which the middle cover 13 prevents access from the direction opposite the printhead 40 , and the pivot pins 14 a, 15 a of the access covers 11 , 12 block access from the upstream and downstream sides of the printhead 40 , such as shown in FIG. 4 for example.
[0073] Furthermore, although the magnetic scanner 52 and optical scanner 55 are described as disposed within and attached to the access covers 11 , 12 , and the entire conveyance path 3 except for the part near the printhead 40 is open to the outside when the access covers 11 , 12 are open is the foregoing embodiment, in some embodiments, some parts, such as the magnetic scanner, may be fixed to the main case 2 so long as it would not interfere with removing the process media.
[0074] Although the invention is described as a check processing device 1 in the foregoing embodiments, one of skill would appreciate that the present invention may include other types of image processing devices, including but not limited to printers for printing receipts, page scanners, and other types of optical scanners.
[0075] Given the embodiments and principles described herein, it is appreciated that the present invention may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be appreciated by one skilled in the art are included within the scope of the present invention, which is limited only by the following claims
|
An image processing device allows for easy removal of a process medium stuck in the conveyance path while protecting the image processing unit from the outside. In many embodiments, the device includes a conveyance path for conveying process media in a specific conveyance direction, an image processing unit having an ejection surface (process surface) disposed facing the conveyance path, and a first cover and a second cover disposed along the conveyance path and covering the conveyance path. Typically, the first and second covers open and close by pivoting on first and second pivot pins disposed in a direction intersecting the conveyance direction, and the first and second pivot pins are disposed adjacent the conveyance path upstream and downstream of the portion of the conveyance path facing the ejection surface.
| 1
|
FIELD OF THE INVENTION
The present invention relates to endermic application kits for external medicines, with which drugs can be administered into a human body through the skin thereof with high absorption efficiency by the utilization of the function of ultrasonic oscillation.
BACKGROUND OF THE INVENTION
Means for administration of medicines to human bodies for remedy and prevention of human diseases include a method of peroral or parenteral administration by the use of an injection, a pill, a capsule, a suppository, etc. and a method of endermic administration by the use of an ointment, a drug-containing adhesive plaster, etc. Among them, the endermic administration method has almost been disregarded up to the present except the direct application of external medicines, since the endermic absorption of a drug is extremely low. (This is especially because a skin physiologically has a biological barrier function against microorganisms, chemical substances, radioactive substances, heat, etc.) Recently, however, various external medicines for endermic application are being developed through recent progress of pharmaceutical technique.
In the conventional drug-administration method by the use of peroral medicines, injections, suppositories, etc., in general, the drug concentration rapidly achieves its peak and then decreases with the lapse of time, and therefore, it is difficult to maintain a constant concentration of the drug in the blood. Even the most conventional peroral medicines have various difficult problems including the induction of gastroenteric disorders, the inactivation of the drug during the initial passage through liver after the absorption thereof from the intestine, the induction of hepatopathy, etc., and the drugs which may fully satisfy the conditions for use as a medicine are extremely limitative. In addition, the injection also has various difficult problems including the use of a needle, the induction of immunoreaction which would be caused by the direct injection of a foreign substance, etc. Furthermore, this may bring on shock or the like dangerous state, since the removal of the drug once injected into a body by injection is almost impossible.
Under the circumstances, particular attention is recently being riveted to an endermic application method, which is free from the above-mentioned defects in the case of peroral or parenteral administration methods and which can maintain the relatively constant drug concentration in blood without any dangerous immunoreaction, and an ointment or a drug-containing adhesive plaster is used for the endermic application method.
In the endermic application method by the use of such ointment, drug-containing adhesive plaster or the like, the drug is required to be transferred from the skin to the capillary bed. Since the possibility of the passage of the drug through the corneal layer or keratin layer of epidermis depends upon the various properties of the drug, including the oil-solubility, the water-solubility, the drug concentration, the pH value, the molecular weight, etc., it was difficult to maintain the sufficient drug concentration in blood by the endermic administration method. In order to solve these difficult problems, a study on the base compositions for introducing the drug into the inside of the skin by means of chemical techniques has predominantly been carried out, which resulted in success of limited base compositions for only several kinds of medicines.
SUMMARY OF THE INVENTION
The present inventors earnestly studied so as to attain the possibility of facilitating the introduction of a drug into the inside of a skin by the utilization of a physical energy in such extent that would not traumatize the skin treated, so that the drug thus introduced can pass through the corneal layer or keratin layer of epidermis with high efficiency and that the drug concentration in blood can be sufficiently maintained, and as a result, have found that the application of a drug to the surface of a skin in the presence of an ultrasonic oscillation can lead to the remarkable introduction of the drug through the skin whereby the thus-introduced drug can be absorbed into the capillary bed to cause the elevation of the drug concentration in blood. On the basis of such an unexpected discovery, the present inventors have achieved the endermic application kits for external medicines of the present invention with high endermic availability.
Accordingly, the object of the present invention is to provide an endermic application kit for external medicines, which is characterized by the provision of a drug-containing layer near an ultrasonic oscillator.
BRIEF EXPLANATION OF DRAWINGS
FIG. 1 shows a cross-sectional view of a fixed-type endermic application kit of the present invention.
FIG. 2 shows a cross-sectional view of a portable-type endermic application kit of the present invention.
FIG. 3 shows a cross-sectional view of a regular-type endermic application kit of the present invention.
FIGS. 4 (a) and (b) each show a cross-sectional view of an adhesive-type endermic application kit of the present invention.
FIG. 5 is a graph to show the results of the absorption test No. 2 in which the endermic absorption of various drugs was tested in the presence of an ultrasonic oscillation.
FIG. 6 is a graph to show the results of the absorption test in which the endermic absorption of a drug was tested by the use of the endermic application kit of the present invention.
In the drawings, (1) is an ultrasonic oscillator device, (2) an ultrasonic oscillator, (3) a drug-containing layer, (4) a battery, (5) an adhesive layer, (6) a protective film, (7) a terminal, (8) an ultrasonic oscillation collector, and (9) a sponge-like buffer.
In FIG. 5, (a) denotes the case of dipping in water only, (b) the case of dipping in water in the presence of an ultrasonic wave (5000 to 7000 Pa), (c) the case of dipping in water in the presence of an ultrasonic wave (3000 to 5000 Pa), (d) the case of dipping in 20 U/ml of insulin, (e) the case of dipping in 20 U/ml of insulin solution in the presence of an ultrasonic wave (3000 to 5000 Pa), and (f) the case of dipping in 20 U/ml of insulin solution in the presence of an ultrasonic wave (5000 to 7000 Pa).
In FIG. 6, (A) denotes the case of endermic application of an insulin gel in the presence of an ultrasonic wave (1750 Pa), and (B) the case of endermic application of an insulin gel in the absence of the ultrasonic wave.
DETAILED DESCRIPTION OF THE INVENTION
By selecting type of ultrasonic oscillator devices and the electric sources, various endermic application kits can be adopted with the present invention, including fixed-type, portable-type, regular-type and adhesive-type kits, etc.
The ultrasonic oscillator for use in the kits of the present invention is to be electrically insulated.
One embodiment of the fixed-type kit is shown in FIG. 1, where the ultrasonic oscillator device (1) as connected to a general alternating current source is connected to the ultrasonic oscillator (2) as equipped in the bottom of the cylindrical container via the leading wires, and the drug-containing layer (3) is arranged at the top end of the container. In this type, a general electric source is used as the electric power, and therefore, a high energy can be applied to the kit. As the ultrasonic oscillator can be used a general ceramic oscillator, for example, made of barium titanate, zircon, lead titanate, etc.
The fixed-type kit of this kind is suitable for hospital or household use, which can be applied to a skin for a short period of time.
One embodiment of the portable-type kit is shown in FIG. 2, where the battery (4) and the ultrasonic oscillator device (1) as connected to the ultrasonic oscillator (2) via the leading wires are housed in the cylindrical container, and the drug-containing layer (3) is arranged at the top end of the container. In this type, a battery is used as the electric power source, and therefore, a relatively high energy can be applied to the kit. The ultrasonic oscillator can be used with ceramic oscillator, like the above-mentioned fixed-type kit.
The portable-type kit of this kind is relatively small in size and compact and the electric source and the ultrasonic oscillator device are housed in one container, and therefore easy to carry for daily use. The portable-type kit can be used anywhere, when desired, by applying the same affected part on the skin thereby to administer the drug through the skin.
One embodiment of the regular-type kit is shown in FIG. 3, where the small battery (4) and the small-sized ultrasonic oscillator device such as IC oscillator device (1) as connected to the ultrasonic oscillator (2) via the leading wires are housed in the flat container, and the drug-containing layer (3) is arranged below the ultrasonic oscillator (2). In the kit of this type, both sides of the container are preferably provided with bands so that the drug-containing layer of the kit can usually be applied to the affected part of the skin by the function of these bands. Thus, the kit is especially suitably used for such diseases that require continuous administration of drugs.
One embodiment of the adhesive-type kit is shown in FIG. 4(a), where the drug-containing layer (3) is provided below the disc-like ceramic ultrasonic oscillator (2), with laminating the drug-permeable adhesive layer (5) below the said layer (3), and the whole is covered with a plastic cover. The oscillator (2) has the terminal (7) to be connected to an external oscillator device. In case the adhesive-type kit is required to be flexible or elastic, another embodiment is provided as shown in FIG. 4(b), in which the drug-containing layer (3) is provided on the flexible ultrasonic oscillator such as ultrasonic oscillator film (2), with laminating the drug-permeable adhesive layer (5) below the said film (2). The flexible ultrasonic oscillator (2) has the terminal (7) to be connected to an external oscillator device. For the formation of the kit of this type, an oscillator device can be applied to the conventional disc-type or tape-type drug-containing adhesive plaster which has generally been used in these days. Accordingly, the release rate of the drug from the kit can be controlled by the decrease or increase of the output energy of the ultrasonic oscillation and thus the drug concentration in the blood can freely be varied. The terminal (7) can be connected to a variable oscillator device with the possibility of the free control of the drug release rate and the drug concentration in blood, and the said ultrasonic oscillator device can be connected to a battery or a general electric source, and thus, the drug-containing layer of the kit is applied to the skin while the ultrasonic oscillation is imparted thereto. The kit being thus constituted, is suitable for application to such diseases that require an exact adjustment of the drug concentration in blood. In addition, the kit being flexible or elastic, the absorption of the drug from a fairly broad skin area is possible. A self-exciting system can also be adopted for these endermic application kits, in place of the use of the oscillator device.
Various kinds of drugs which have heretofore been used for external application, such as for ointments or drug-containing adhesive plasters, can be used in the kits of the present invention, including various slow-release drugs such as scopolamine, nitroglycerin, indomethacin, ketoprophene, calpronium chloride, etc. In addition, other drugs which were difficult to use in the form of ointments or drug-containing adhesive plasters for endermic application in the past can be used in the kits of the present invention, including, for example, a high molecular insulin, various kinds of hormones, antibiotics, carcinostatics, depressors, etc. Accordingly, the continuous slow release of the said drugs is possible by the use of the kits of the present invention. Moreover, the kits of the present invention can suitably be used for administration of a hypertensor to serious and emergent state patients who are difficult to ensure the blood vessel.
The administration of drugs by the use of the kits of the present invention is an endermic application by a physical technique and is therefore free from the problems in the endermic application by a chemical technique which would be limited because of the solubility and size of the molecules of the drug to be administered. Accordingly, the utility value of the kits of the present invention is extremely high.
As mentioned above, in the use of the kit of the present invention, the drug can be applied to the skin while an ultrasonic oscillation is applied thereto, and therefore, the introduction of the drug into the skin is good and the endermic administration of the drug through the skin can be carried out with extremely high efficiency. In addition, the control of the drug concentration in blood can rapidly be carried out by the control of the release rate of the drug from the kit.
Two experiments No. 1 and No. 2 were carried out, where the endermic absorption of various drugs was tested in the presence of an ultrasonic oscillation. The results are shown hereinafter.
Experiment No. 1
Experiment with calpronium chloride solution (MTB) for observation of the permeation-accelerating effect by ultrasonic oscillation to drug which is known to be adequate for endermic application:
Hairless mice were used as experiment animals. They were dipped in 0.5%, 1% or 2% MTB solution, whereupon no mice died even when dipped in the highest 2% solution for an unlimited long period of time. However, when the mice were dipped in the same MTB solution with the application of an ultrasonic oscillation of 48 kHz and 2000 Pa (Pa means Pascal unit) thereto, they died in 160 minutes in the 0.5% solution, in 39 minutes in the 1% solution, and in 15 minutes in the 2% solution. The results indicate the extreme reduction of the survival time in proportion to the increase of the concentration of the solution. In addition, when the ultrasonic oscillation was intensified three times up to 6000 Pa, the time to death was further reduced such that the mice died in 19 minutes when dipped in the 0.5% solution, in 11.5 minutes in the 1% solution, and in 7.6 minutes in the 2% solution. Accordingly, the results further indicate the acceleration of the endermic absorption of the drug with the increase of the output power of the ultrasonic waves.
Experiment No. 2
Effect by the application of ultrasonic oscillation to drug which is known to be quite difficult in absorption from skin by endermic administration:
Hairless mice were used like the above-mentioned Experiment No. 1 and the endermic application of insulin to the same mice was tried. The determination of the insulin absorption effect was carried out by the use of a dextrometer and the tail venous blood was measured for the determination. The mice were dipped in a 20 U/ml aqueous-insulin solution (novoactorapit MC) for 5 minutes while an ultrasonic oscillation was imparted thereto. After taken out from the solution, the state of the decrease of the blood sugar value of the thus dipped mice was observed for 240 minutes so as to evaluate the insulin effect by the endermic application of the insulin solution for 5 minutes. As control, mice were dipped in the 20 U/ml aqueous-insulin solution for 5 minutes in the absence of the ultrasonic oscillation, or mice were dipped in an insulin-free water in the presence of an ultrasonic oscillation for 5 minutes. These control mice were also observed, after taken out from the solution, in the same manner as above, to obtain the blood sugar value variation up to 240 minutes. The results obtained are shown in FIG. 5.
The blood sugar variation curve obtained by the 5 minutes endermic absorption of the 20 U/ml insulin solution in the presence of the 3000 to 5000 Pa and 48 kHz ultrasonic oscillation was almost the same as that obtained by the intradermal injection of the same insulin solution in an amount of 4 U/kg. The blood sugar values in FIG. 5 are shown by the term of the percentage on the basis of the 100 percentage of the value just before the experiment.
In this experiment, mice which had been fasting for 8 hours were used, and these were fed after 16 hours. Accordingly, the blood sugar value of the tested mice after 24 hours was higher than the time at the beginning of the experiment.
Experiment No. 3
Experiment with antibiotics ABPC ointment (ampicillin phthalidyle HCl ointment)
2 g of antibiotics ABPC (10%) ointment was applied to the shaved portion of rabbits which had been shaved on their backs (7×7 cm) with an electric shaver. They were treated by an ultrasonic oscillation (100 kHz, 5000 Pa) in 20 minutes after the application. Then, after 20 minutes without the ultrasonic oscillation, the second treatment by the ultrasonic oscillation for 20 minutes followed and the ointment was then removed. Afterwards, the blood of the rabbits was gathered in 0 minute, 20 minutes, 40 minutes, 60 minutes, 120 minutes, 180 minutes, 240 minutes and 24 hours intervals, and the concentration (μg/ml) of ABPC in the blood was evaluated.
Furthermore, using the same animals to which only ABPC applied without the treatment by the ultrasonic oscillation, the concentration of ABPC in the blood of the experimented animals (untreated) was evaluated. The results are shown in the following table 1.
TABLE 1______________________________________unit: μg/ml treated by the ultrasonictime oscillation untreated______________________________________0 (minutes) 0 020 0.10 1.1940 4.50 0.3060 2.84 0.48120 0.41 0.33180 0.46 0.25240 1.41 0.7124 (hours) 0.24 0.19______________________________________
As apparent from the results shown above, with the treatment by the ultrasonic oscillation, the concentration in the blood peaked 40 minutes after the application; the amount of absorption was four times greater than those untreated by comparison.
Experiment No. 4
Experiment with ethyl loflazepate (EL) ointment tranquilizer belonging to benzo diagepine group (1)
The five rates were employed in this experiment and had their backs shaved with an electric shaver. 0.3 g of EL (5%) ointment (100 mg/kg approximately) was applied to the shaved portion of the back of each rat.
Each rat was treated as follows:
A. After application of the ointment and the ultrasonic oscillation treatment for 10 minutes, the blood was gathered in one hour.
B. After application of the ointment and the ultrasonic oscillation treatment for 20 minutes, the blood was gathered in one hour.
C. After application of the ointment and without the ultrasonic oscillation treatment, the blood was gathered in three hours.
D. After application of the ointment without the ultrasonic oscillation treatment, the blood was gathered in one hour.
Metabolic concentration of EL in serums in the gathered blood of the rats was evaluated.
The ultrasonic oscillation treatment was carried out in 100 kHz 2000 Pa with the ceramic oscillator (diameter: 20 mm) on the ointment.
The results were shown in Table 2.
TABLE 2______________________________________ Metabolic concentration ofSamples EL in serums (ng/ml)______________________________________A 18.8B 28.2C 3.0D 1.0______________________________________
As apparent from the results shown above, with the treatment by the ultrasonic oscillation, the amount of absorption was eighteen times greater than those untreated when treated for 10 minutes and twenty-eight times greater when for 20 minutes.
Experiment No. 5
Experiment with EL ointment (2)
2 g of EL ointment was applied to inner sides of the rabbits' ears. They were treated by the ultrasonic oscillation (100 kHz, 6000 Pa) in 10 minutes after the application. Then, after 10 minutes without the ultrasonic oscillation, the second treatment by the ultrasonic oscillation for 10 minutes followed and the ointment was then removed. Afterwards, the blood of the rabbits was gathered from the other side of the respective ear in 105 minutes and 265 minutes intervals, and the metabolic concentration of EL in the blood was evaluated.
Furthermore, as contrast, using the same animals from which the ointment was removed 30 minutes after application without the treatment by the ultrasonic oscillation, the concentration of EL in the blood of the experimented animals (untreated) was evaluated in 120 minutes and 290 minutes intervals. The results are shown in the following table 3.
______________________________________treated by the ultrasonicoscillation untreated concentration concentration in the blood in the bloodtime (minute) (ng/ml) time (minute) (ng/ml)______________________________________105 662.6 120 11.9265 100.7 290 28.7______________________________________
As apparent from the results shown above, the sufficient concentration of EL was evaluated such as 662.6 ng/ml with the treatment by ultrasonic oscillation although little amount of concentration such as 28.7 ng/ml in the absence of the treatment.
As mentioned above, it is apparent that the absorption of the drug into blood is improved when the endermic application of the drug is carried out in the presence of an ultrasonic oscillation.
The following examples are intended to illustrate the present invention but not to limit it in any way.
EXAMPLE 1
As shown in FIG. 1, this is a fixed-type endermic application kit for external medicines. In the cylindrical holder made of a synthetic resin, which has the drug-containing layer (3) at the top end thereof, the ceramic ultrasonic oscillator (2) is arranged above the drug-containing layer (3) via the bugle-shaped ultrasonic oscillation collector (8) by the aid of the holder inner wall and the sponge-like buffer (9), and the terminal (7) which is connected to the said oscillator (2) via the leading wires is provided at the other end of the holder. The terminal (7) is connected to the variable ultrasonic oscillator device (1) to be connected to a general electric source in use.
EXAMPLE 2
As shown in FIG. 2, this is a portable-type endermic application kit for external medicines. In the pencil-shaped holder made of a synthetic resin, which has the drug-containing layer (3) at the top end thereof, the ceramic ultrasonic oscillator (2) is arranged on said drug-containing layer (3), and the ultrasonic oscillator device (1) is arranged above the said oscillator (2) and the battery (4) is further above the oscillator device (1), these parts being connected to each other via leading wires.
EXAMPLE 3
As shown in FIG. 3, this is a regular-type endermic application kit for external medicines. In the flat container made of a synthetic resin, which has the drug-containing layer (3) at the bottom thereof, the ceramic ultrasonic oscillator (2) is arranged on the said drug-containing layer (3), and the IC ultrasonic oscillator device (1) and the battery (4) are arranged in parallel above the said oscillator (2), these parts being connected to each via leading wires.
EXAMPLE 4
(a) As shown in FIG. 4(a), this is an adhesive-type endermic application kit for external medicines. The drug-containing layer (3) is arranged below the disc-like ceramic oscillator (2) having the terminal (7), and the drug-permeable adhesive layer (5) is laminated below the said layer (3), and the whole is covered with the protective film (6). The terminal (7) of this kit is connected to a variable ultrasonic oscillator device to be connected to a general electric source in use.
(b) As shown in FIG. 4(b), this is an adhesive-type endermic application kit for external medicines. The drug-containing layer (3) is arranged on the flexible ultrasonic oscillator film (polyvinylidene fluoride film) (2) which has a number of pores, the terminal (7) being arranged at one side of the film, and the surface of the said layer (3) is covered with the protective film (6). In addition, the drug-permeable adhesive layer (5) is laminated below the said flexible ultrasonic oscillation film (2). The terminal (7) of this kit is connected to a variable ultrasonic oscillator device to be connected to a general electric source in use.
Next, one experimental example to show the endermic absorption effect of the drug by the use of the kit of the present invention is described hereinafter.
Experimental Example
Novoactorapit MC (40 U/ml purified neutral porcin insulin injection) was gelled with sodium polyacrylate, and the resulting gel was incorporated into the drug layer (3) of the kit of FIG. 4(a). The kit was applied to a Wistar rat at the groin (diameter: 15 mm) for 10 minutes, while an ultrasonic wave (1750 Pa, 20 kHz) was applied thereto for 5 minutes. Afterwards, the kit was removed and the variation of the blood sugar value of the tested rat was observed. As a control, the kit was applied to a control rat in the same manner for 120 minutes without the application of the ultrasonic wave thereto, and the variation of the blood sugar value was also observed. The results obtained are shown in FIG. 6.
The results apparently prove that in the case of the application of the kit of the present invention in the presence of the ultrasonic oscillation only for 5 minutes, the 25% blood sugar value depression lasted 120 minutes, and afterwards, the value gradually recovered to the original value in 180 minutes. On the contrary, in the case of the application of the same kit in the absence of the ultrasonic oscillation, the blood sugar value increased after having once somewhat decreased.
The effect of the present invention can be summarized as follows: According to the endermic application kits of the present invention, the drug as incorporated in the kit can surely be absorbed into the capillary bed through the surface of the skin, while the drug-release rate from the kit can be controlled by the control of the variation of the ultrasonic wave output from the kit. The endermic application kits of the present invention, which are characterized by such novel drug-delivery system, are advantageous for practical use.
|
Disclosed is an endermic application kit for external medicines, which comprises a drug-containing layer as provided near an ultrasonic oscillator. The kit includes a cylindrical fixed-type or portable-type and a flat regular-type or adhesive-type, and the adhesive-type may be flexible and elastic. The drug absorption is ensured by the action of the ultrasonic waves from the oscillator and the drug release can be controlled by varying the ultrasonic wave output from the oscillator.
| 0
|
CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit of the filing date of U.S. Provisional Application No. 61/485,122, titled PROMPT HOT WATER SYSTEM AND METHOD. Filed May 11, 2011.
TECHNICAL FIELD
The invention is in a convection hot water system that provides prompt delivery of hot water from a central water heater for use at one or more remote locations and conserves water.
BACKGROUND OF THE INVENTION
The hot water system in many homes, offices and other facilities includes a hot water heater that receives cold water from a water source, heats the water and delivers the heated water through pipes to a location where heated water is needed. The hot water heater is often located on a lower level of such facilities near where potable water is received. Kitchens and bathrooms are generally located on upper levels and may be remote from the hot water heater.
A hot water faucet is opened to obtain hot water from a hot water heater. Unless hot water was obtained from the faucet a short time earlier, water must run from the faucet for a sufficient time to remove all the cold water from the pipe between the faucet and the hot water heater plus heating the pipe. The cold water discharged from the hot water faucet passes into a drain pipe and to a sewer system. The quantity of water that is lost can be significant. Insulation on the pipe can keep hot water in the pipe and the pipe at least warm for some period of time. However, insulation will not keep the water and pipe hot for an extended period of time.
Potable water is generally pumped from a water source by pumps. The pumps also maintain pressure in a water system or elevate water to a storage tower. The water is generally filtered and treated with some chemicals to insure that water born organisms do not make people sick. In a few areas, salt water is evaporated and then condensed to provide potable water. This pumping, filtering and chemical treatment of water is expensive. The heat required to distill salt water is also expensive. Sanitary sewer systems, where available, are constructed and operated by fees added to water bills thereby further increasing the cost of water.
Instant or nearly instant hot water may be obtained by adding a flow through heater to the hot water pipe near the hot water faucet. These electric heaters work well to heat a relative small quantity of water for making a hot drink or some food products. Such heaters have relatively low capacity. The purchase, installation and operation of an instant or nearly instant hot water heater is expensive. However, such heaters may reduce water usage. Such reduction of water usage is probably more significant than most home owners believe. However installation and operating costs of a flow through heater are significant and may exceed the cost savings due to water use reduction.
Instant or nearly instant hot water may also be provided by a pump or pumps that circulate water through a hot water supply pipe and back to the hot water heater. Such pumps run constantly and require a significant amount of electricity. These water circulating systems are generally reliable. The water that is returned to the water heater has cooled somewhat in the hot water supply line. The return flow of water by the pump is through a cold water supply pipe in some pump systems. After the pump runs for a period of time, there is hot water in a portion of the cold water supply pipe. Opening a cold water faucet will in some cases result in the discharge of hot water. Hot water in the cold drinking water is undesirable. Some chemicals employed to treat potable water will become gases at an elevated temperature and atmospheric pressure. The gases will separate from the water. The separated gases may be harmful to people and animals. Although the need for hot water may only occur a few times each day, the pump circulates water continuously.
Pumps employed to return cooled hot water to a hot water heater produce pressure changes in a pipe system that may result in vibrations and noise. Noise generated by a pump resonates throughout the plumbing system and often is objectionable. Although the need for hot water may only occur a few times each day, the pump cycles, as required, 24 hours per day.
A recent innovation used to provide hot water is the high flow, point of use water heaters that can be placed adjacent to areas such as showers and laundries that require a large quantity of hot water in a very limited time. They produce hot water almost instantly by the rapid infusion of large quantities of energy. They work well, and reduce the amount of cooled hot water discharges to the drain. Often they are secondary serving only a portion of the building, the main source being a standard hot water heater. The purchase price may be two to three times the cost of a standard hot water heater. Infrastructure is expensive due to the required capacity of 180,000 B.T.U.s of energy at an instant as need basis. If the high capacity point of use heater is selected, there is additional cost to provide venting of exhaust gas, and a larger gas meter to provide that fuel.
To overcome the delay in obtaining hot water, people often increase the thermostatic control on the hot water heater to the maximum or near maximum setting, thereby increasing the output temperature of water from a relatively safe one hundred and thirty degrees (130°) Fahrenheit to a potentially scalding temperature of one hundred and sixty degrees (160°). Skin exposure to 160° water can result in serious scalding in as little as one second. New regulations in some areas limit delivered water temperature through a faucet to 110 degrees Fahrenheit. The majority of grandfathered faucets in use today do not provide this protection, predictably resulting in many serious injuries. It will be years before all of the grandfathered faucets are replaced to prevent delivery of hot water above a regulation temperature.
SUMMARY OF THE INVENTION
The natural resource conserving prompt hot water system reduces potable water usage by reducing the quantity of cooled hot water discharged from a hot water faucet. The water conserving prompt hot system returns hot water that has cooled in a hot water pipe to the bottom of a hot water storage tank or hot water heater through a dedicated line without a pump and also limits the flow of cold water into the hot water supply system. The reduction in the quantity of cold water entering the hot water heater can reduce the energy required to heat water entering a home or building.
The natural resource conserving prompt hot water system, as described above operates without a pump with a normal temperature change in the hot water supply pipe and the return pipe and an elevation change as low as the distance between the hot water discharge opening and the drain pipe in a standard upright hot water heater. A two story building with a basement will have a substantially larger pressure change urging water flow in the return pipe. The return flow rate may be reduced by partially closing the metering valve.
The natural resource conserving prompt hot water system minimizes the quantity of water that is discarded, through a drain, before water at a desired elevated temperature is available. The system minimizes the energy required to reheat water returned to a hot water tank with partially cooled hot water. Energy is also reduced by substituting the quantity of cold water added to the hot water tank with partially cooled hot water. Energy is also reduced by insulating the hot water supply pipe and at least a portion of a return pipe.
The hot water tank includes a tank body, a tank top end and a tank bottom end. A water inlet opening in the hot water tank is connected to a water supply pipe. The water supply pipe generally supplies cold water from a water utility or a private water well. The water received from the water supply pipe is under pressure.
A hot water supply pipe has an inlet end connected to a hot water discharge opening in the hot water tank. The hot water supply pipe extends away from the hot water tank to a supply pipe remote end. This hot water supply pipe functions as a manifold. Pipe inside diameter depends on a number factors include maximum expected flow, pressure drops in the system and government ordinances. A manifold, for hot water in most residential construction in North America, employs half inch inside diameter pipe or three fourths inch inside diameter pipe. In some hot water systems there can be a change in the diameter of the hot water supply pipe between the inlet end and the remote end.
A plurality of point of use pipes are connected to the hot water supply pipe. A discharge faucet is connected to each point of use pipe and controls the flow of hot water from one of the point of use pipes. One or more discharge faucets can be open at a given time. In some hot water systems there may be only one point of use pipe.
A return pipe includes a return pipe inlet end that is connected to the hot water supply pipe or a nearby convenient branch. The connection is generally adjacent to the supply pipe remote end. However, the connection may be located in any chosen location where the connection can be made. A return pipe discharge end is connected to the drain opening in the tank body. Hot water tanks are provided with a drain opening near the tank bottom. The drain opening is provided for removing sediment from the tank. The drain opening is also used to empty the hot water tank if necessary. The return pipe discharge end may be connected to the drain valve. Drain valves have a threaded end for connecting a hose. It is generally possible to replace the drain valve and valve pipe with a short nipple. The return pipe discharge end may be connected to the nipple by suitable couplers if desired.
The hot water supply pipe, the return pipe and the hot water tank form a water circulation system. The water entering the return pipe from the hot water supply pipe is returned to the bottom of the hot water tank. Water removed from the hot water supply pipe, through the return pipe is replaced by hot water from the hot water tank. Water is circulated from the hot water discharge opening in the hot water tank, through the hot water supply tank, through the return pipe and back into the hot water tank. None of the recirculated water is lost. This water circulation results from the increase in water density as the temperature decreases as the hot water moves through the hot water supply pipe and return pipe and the decrease in elevation as the cooled water moves downward to the circuit bottom and into the drain opening. A pumpless circulation system is created that maintains hot water in the hot water supply pipe. The return pipe may have a return pipe inside diameter that is substantially the same or less than the supply pipe inside diameter to the hot water supply pipe. The relative large inside diameter of the return pipe is desirable to limit impedance to flow in the return pipe. However, an inside pipe diameter that is about sixty seven percent of the supply pipe inside diameter has been found to function well in some buildings.
A directional flow control device is provided any place between the hot water supply pipe connection to the return pipe and the drain opening in the tank body. The directional flow control device substantially limits the flow of cold water through the return pipe and into the hot water supply pipe in response to the opening of one or more of the discharge openings from the hot water supply pipe.
The directional flow control device includes a body. The body includes an inlet bore that receives return water. A conical bore portion in the body includes an inlet end with an inlet bore that joins a small diameter end of the conical bore portion. A cylindrical bore portion in the body joins a large diameter end of the conical bore portion. A plug includes a plug tubular portion. An outlet bore passes through the plug tubular portion. A cylindrical plug portion is received in the cylindrical bore portion and fixed to the body to form a chamber. An axis of the directional flow control device is coaxial with the inlet bore, the conical bore portion, the cylindrical bore portion and the outlet bore through the plug.
A sphere positioned in the chamber of the directional control device is movable by water flow in a first direction toward at least one projection in the chamber. The projection limits movement of the sphere toward the outlet bore and permits free flow of water through the chamber. The sphere is movable by water flow in a second direction generally parallel to the axis and into the conical bore portion in response to opening one of the hot water discharge faucets. The sphere is moved, by water in the second direction, toward the small diameter end of the conical bore portion and substantially blocks the flow of water through the inlet bore and into the hot water supply pipe.
The conical bore portion includes a conical wall surface that extends from the small diameter end to the large diameter end of the conical bore portion at an angle relative to the axis of more than twenty degrees (20°).
There sphere may be a glass member with a high density. With the high density sphere, the inlet bore is at the same elevation as the outlet bore and the axis of the chamber is horizontal. Substantial water flow from a hot water discharge faucet may be required to move a high density sphere into the conical bore small diameter end.
A low density sphere made of a material such as nylon will move with water flow into the directional flow control device from the drain opening in the hot water tank or from the hot water supply pipe. The axis of the flow control device may be vertical, horizontal, or any position between horizontal and vertical.
A low density sphere may stick in the conical portion of the chamber due to the minimal density change with liquid water temperature change. The low density sphere remains free to move into and out of the conical bore portion by increasing the angle of the conical wall surface of the conical bore portion relative to the axis from twenty degrees to thirty degrees or more.
Cold water entering the chamber from the drain opening in the hot water tank may increase the pressure in the chamber and hold the sphere in the conical small end. A fluid bypass between the sphere and the conical bore portion equalizes pressure or the downstream side and the upstream side of the sphere.
The fluid bypass between the sphere and the conical bore portion is provided by three ridges on the conical bore portion surface. The ridges extend radially inward toward the axis a distance of up to thirty thousands of an inch. These ridges may extend only a portion of distance to the large diameter end of the conical bore.
A valve is provided to limit the quantity of cool water passing through the return pipe and into the hot water tank.
The device operates within a pressurized environment, and functions by sensing direction of flow, not pressure. The low convective pressure (0.006 PSI) generated is too low to reliably open, shift, or close a check valve. The natural resource conserving hot water device is never totally closed.
The function to be encouraged is from the hot end of the hot water supply to the cold end. Very low impedance is applied in this direction of flow. Flow from the cold side to the hot side, such as when a supply faucet is opened disrupts this balancing process; a small flow is permitted by higher impedance. Check valves are not used, as they do not operate reliably at the low convective pressure, and eventually cause the system to fail.
Thermal change is self-regulation. As the cooled hot water in the return line cools, the density of that water in the vertical component increases, slightly increasing the convective pressure moving additional hot water from the hot water line into the return line, and eventually back into the hot water heater. As the temperature of the water in the vertical component warms, its density becomes less, thus decreasing the convective pressure slowing the flow. The Low Impedance Directional Flow Control Device senses and restricts backflow. As demonstrated in the prototype system that has operated for an extended time, the temperature in the vicinity of the metering valve is virtually constant with a variance of a few degrees.
The natural resource conserving prompt hot water system is installable by a professional plumber or by a home owner. The system conserves water and may also conserve energy for heating the water. The system conserves water by reheating water in the water supply pipe that would be discharged to a drain pipe and sewer system without the reheating system. Energy may be saved by reducing the quantity of cold water entering the hot water heater from a source outside the home or other structure. If the hot water system is not to be used for an extended period of time, the reheating system and the primary water system can both be turned off.
The method for conserving water in a prompt hot water system includes connecting a return pipe inlet end of a return pipe to a hot water supply pipe in a position remote from a hot water discharge opening in a hot water tank. A return pipe discharge end of the return pipe is connected to a drain opening in the hot water tank. The drain opening of the hot water heaters is in a bottom portion of the hot water tank. Water is forced to flow from the return pipe and into the hot water tank through the drain opening entirely by an increase in water density due to a decrease in water temperature at the return pipe discharge end.
A sphere is moved in response to water flow through a direction flow device toward a position in which flow of water, in the return pipe, through the drain opening and into the hot water tank is unimpeded.
A faucet is opened to discharge water from the hot water supply pipe. Water moves the sphere, in response to water flow from the hot water tank through the drain opening and into the return pipe, into a position in which reverse flow of water through the directional flow device is substantially reduced.
Closing the faucet to block discharge of water from the hot water supply pipe results in returning the sphere, by water flow from the hot water supply pipe and into the return pipe, to the position in which flow of water through the directional flow device is unimpeded.
The maximum water flow rate of water through the return pipe is controlled to control the minimum temperature of water entering the hot water tank through the drain opening. The flow rate through the return pipe is controlled by a valve. A minimum temperature, of water returned to the water tank for reheating, that is twenty degrees Fahrenheit below the temperature of hot water discharged from the hot water tank through the hot water discharge opening provides satisfactory operation in most residential systems.
BRIEF DESCRIPTION OF DRAWINGS
The presently preferred embodiment of the invention is disclosed in the following description and in the following drawings, wherein:
FIG. 1 is a perspective view of a water return connection to a hot water heater with parts broken away;
FIG. 2 is a sectional view of an injection molded plug of the directional flow control device;
FIG. 3 is a sectional view of an injection molded body of the directional flow control device;
FIG. 4 is an enlarged expanded sectional view of a low back pressure mono directional flow control device;
FIG. 5 is a schematic view of the prompt hot water system; and
FIG. 6 is a sectional view of an injection molded low back pressure mono directional flow control device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A typical home or office hot water system 10 includes a hot water heater 12 . The hot water heater 12 includes a tank 14 with a cylindrical body 16 , a top end 18 and a bottom end 20 . The top end 18 includes a water inlet opening 22 and a hot water discharge opening 24 . The water inlet opening 22 is connected to a water supply pipe 26 that supplies unheated potable water under pressure from a remote water source or from a nearby well. An internal pipe 28 , in the tank 14 , is connected to the water inlet opening 22 and discharges water through an open end 30 near the bottom end 20 . A heater 32 heats water near the bottom end 20 of the tank 14 . A temperature control 33 , for adjusting maximum water discharge temperature is usually provided. Construction of the heater depends upon the heat source. An electric heat source would include a heater coil 21 inside the tank 14 . A natural gas source would include a burner in the heater 32 under the bottom end 20 and a fire tube or tubes (not shown) extending upward from the burner and through the bottom end 20 and through the top end 18 . Products of combustion discharged from a fire tube would be connected to a chimney by a pipe (not shown). A drain pipe 34 and valve 36 shown in FIG. 3 is provided near the bottom end 20 of the tank 14 . The valve 36 is opened to drain water from the tank 14 and to remove any sediment collected in the tank.
The tank 14 , of hot water heater 12 , is substantially encased in insulation 38 as shown in FIG. 5 . The cylindrical body 16 is generally fully encased in insulation 38 when water is heated electrically. The top end 18 is encased in insulation except for the water inlet opening 22 and the hot water discharge opening 24 . A metal cover 40 encases the insulation.
Hot water in the tank 14 tends to migrate toward the top end 18 . Cold water in the tank 14 tends to descend toward the bottom end 20 where it is heated.
A hot water supply pipe 42 is attached to the water discharge opening 24 in the top end 18 of the tank 14 . In homes and offices the supply pipe 42 is often copper. Pipes made from other material are also used.
The hot water supply pipe 42 for hot water may extend upward to the bottom of floor joists for an upper floor and then extend to a far end of the building. The hot water supply pipe 42 is supported by the floor joists and pipe hangers. Point of use pipes 44 , 46 and 48 are connected to hot water supply pipe 42 . Pipes 44 and 48 supply water from the hot water supply pipe 42 to a floor directly above the hot water heater 12 . Pipe 46 supplies hot water from the hot water supply pipe 42 to a point of use at the same elevation as the hot water heater 12 .
A faucet 50 on the point of use pipe 44 may for example supply water to a kitchen sink or a dish washer. A faucet 52 on the point of use pipe 46 may for example supply water to a laundry washing machine on the same floor as the water heater 12 . A faucet 54 on the point of use pipe 48 may for example supply water to a bathroom on the same floor as the kitchen.
A building with a second floor above the floor directly above the hot water heater 12 may be supplied with water through a vertical extension 56 to the hot water supply pipe 42 and a point of use pipe 58 as shown in FIG. 5 . A faucet 60 on the point of use pipe 58 can for example supply water to a bathroom on the second floor.
The pipe 42 may have a diameter of one half inch (0.5 inch), however the plumbing code in many states requires a diameter of three fourths of an inch (0.75 inch). The larger three fourths inch diameter is often used in the hot water supply pipe 42 that becomes a manifold, to reduce the pressure drop when a faucet 50 , 52 , 54 or 60 is opened.
The water in the hot water supply pipe 42 cools over a period during which there is no demand for hot water. To obtain hot water from the hot water heater 12 after a period of non use, it is necessary to drain the water between the faucet from which hot water is desired and the hot water discharge opening 24 in the hot water heater 12 . These pipes hold a significant quantity of water. The quantity of water in the supply pipe 42 is increased if the pipe diameter is larger than one half inch.
Water contracts and becomes denser from a temperature at which there is a change from steam to a temperature at which water becomes ice. A return pipe 64 connected to the hot water supply pipe 42 , at a location near a remote end of the hot water supply pipe, and the bottom end 20 of the hot water tank 14 will create a natural return flow of cooled water to the tank 14 through the return pipe. The rate of return flow through the return pipe 64 depends on water temperature differences and the change in vertical elevation between the return pipe inlet end 66 and the return pipe discharge end 68 . A temperature decrease increases water density. A vertical drop in elevation increases the pressure at the discharge end 68 of the return pipe 64 .
A vertical column of water that is ninety six inches long loses 0.000288 pounds per square inch (PSI) for each degree centigrade of temperature increase. The convective system head change is 0.00576 pounds per square inch with a twenty degree centigrade temperature change. This pressure change is relatively small. The pressure change is however sufficient to create convective fluid flow due in part to the inside diameter of the return pipe 64 providing low flow impedance.
The rate of return flow through the return pipe depends on water temperature differences and the change in vertical elevational changes as stated above. There are a number of other factors that change the rate of return convection flow. These factors include the flow restrictions in the hot water supply pipe 42 and in the return pipe 64 . Temperature changes in the convective fluid due to friction in the pipes 42 and 64 also change flow rates. The movement of relatively cold water from the point of use pipes 44 , 46 and 48 and movement of hot water from the hot water supply pipe 42 into the point of use pipes also changes the temperature of water entering the return pipe 64 . These other factors have a less significant affect on water flow in the return pipe 64 than water temperature differences and elevation changes between the inlet end 66 and the discharge end 68 of the return pipe 64 . The elevation change between the hot water discharge opening 24 and the drain pipe 34 in the hot water heater 12 is sufficient to provide some return flow.
The return pipe 64 is a flexible Chlorinated Poly Vinyl Chloride (CPVC) water conveying plastic pipe, commonly called PEX. PEX is resistant to scale and chlorine, doesn't corrode or develop pinholes, can be installed quickly, and has a maximum service temperature of 200 degrees Fahrenheit. However, the return pipe 64 could also be copper or other material. The return pipe 64 may have the same inside diameter as the hot water supply pipe 42 . A return pipe 64 with an inside diameter of one fourth of an inch will provide adequate flow in some hot water systems 10 .
Two different plumbing assemblies exist for connecting the return pipe 64 to the bottom portion of tank 14 . The plumbing assembly shown in FIG. 1 would most likely be used by the home owner or a semi skilled installer. The plumbing assembly shown in FIG. 5 would probably be used by the professional plumber.
The return pipe inlet end 66 of the return pipe 64 is connected to the hot water supply pipe 42 by a T-coupler 70 shown in FIG. 5 . If there is a vertical extension 56 to the hot water supply pipe 42 , the T-coupler 70 may be moved to a position adjacent to the point of use pipe 58 . The vertical extension 56 in some buildings may be inside walls and not available for connection to the return pipe 64 . The pipe discharge end 68 of the return pipe 64 is connected to the drain valve 76 . The metering valve 130 is connected to the hot water input end 88 of the directional flow device 82 . The discharge end 84 of the directional flow device 82 is connected to the coupler 91 . The coupler 91 is connected to the T-coupler 78 . The T-coupler 78 is connected to the drain valve 80 . The drain valve 80 is also connected to the return valve 76 . The drain valve 36 as shown in FIG. 1 is connected to the hot water discharge drain pipe 34 of the hot water heater 12 . Adequate flow rate in the return pipe 64 insures that the water in the hot water supply pipe 42 is nearly the same as the temperature of hot water leaving the hot water heater 12 through the hot water discharge opening 24 . Significant heat loss can occur in the hot water supply pipe 42 and in the return pipe 64 . To limit heat loss it is desirable to insulate the hot water supply pipe 42 and the return pipe 64 . The insulation reduces heat loss and reduces the load on the heater 32 of the hot water heater 12 . The hot water heater 12 maintains the temperature of water passing through the water discharge opening 24 . Heat is added, by the heater 32 or the heater coil 21 , to water returned by the return pipe 64 to maintain the temperature of water entering the hot water supply pipe 42 from the hot water heater 12 . It is therefore desirable to return water to the hot water heater 12 from the return pipe 64 with a relatively high temperature. A decrease in the temperature difference between hot water passing through the discharge opening 24 and the water entering through drain pipe 34 or nipple 74 will decrease the pressure drop and the flow rate.
The return pipe 64 can be connected to the drain pipe 34 and drain valve 36 of the hot water heater 12 as shown in FIG. 1 . The drain pipe 34 is a return water entry port. However, the drain valve 36 and the drain pipe 34 may be removed if desired. A short nipple 74 , shown in FIG. 5 , is screwed into the tank 14 where the original drain valve 36 and drain pipe 34 were located. A return valve 76 is attached to the nipple 74 . The nipple 74 is a return water entry port. The return water entry port is a drain opening 75 in the hot water tank. A T-coupler 78 is connected to the return valve 76 . A drain valve 80 is connected to the T-coupler 78 . The drain valve 80 is connectable to a hose 81 with a female hose connector 83 . The return pipe 64 is also connected to the T-coupler 78 . The return valve 76 permits the flow of water from the return pipe 64 to be opened or closed. The drain valve 80 can be opened to drain water from the tank 14 when the return valve 76 is also open. The drain valve 80 is also opened to discharge air from the return pipe 64 when the return valve 76 is closed.
The return pipe 64 is connected to the hot water supply pipe 42 through the T-coupler 70 inserted into the hot water supply pipe 42 in a selected position as described above. A directional flow control device 82 may be connected to the supply pipe T-coupler 70 . However, the return pipe 64 is connected to the T-coupler 78 as shown in FIG. 1 . An inlet end 88 of the directional flow control device 82 is connected to a metering valve 130 and to the return pipe 64 . The discharge end 84 of the directional flow control device 82 is connected to the short nipple 74 through a coupler 91 the T-coupler 78 and the return valve 76 shown in FIG. 5 or the drain valve 36 shown in FIG. 1 . A stem elbow 126 and a female hose connector 128 connect the T-coupler 78 to the drain valve 36 as shown in FIG. 1 . The drain valve 36 is also a metering valve as shown in FIG. 1 .
Without the directional flow control device 82 the water supply pipe 42 and the return pipe 64 would both supply water to an open faucet 50 . The water passing through the open faucet 50 , or any other open faucet in a hot water supply system, could pass a mixture of hot water from the top end 18 of the tank 14 and cold water from the bottom end 20 of the tank. Cold water entering the bottom end 20 of the tank 14 through the internal pipe 28 would reduce the temperature of water flowing through the return pipe 64 . The flow rate through the hot water supply pipe 42 would most likely be different than the water flow rate through the return pipe 64 . The two flow rates would most likely change relative to each other depending upon which faucet 50 , 52 , 54 and 60 in the system is open and the number of faucets that are open.
Check valves are used in some systems to control the flow of water between two flow paths. Check valves will not work in the hot water system described above. The pressure differentials due to the changes in water temperature and water elevations are too small to reliably open or close a check valve in a pumpless system.
The directional flow control device 82 includes a device body 86 made of CPVC or other suitable material. The directional flow control device 82 , as shown in FIG. 4 is machined from blocks. The directional control device 82 , as shown in FIGS. 2 , 3 and 6 , is injection molded. An inlet end 88 of the device body 86 includes an inlet bore 90 in a tubular portion 89 and a cylindrical outer surface 93 . The interior of the device body 86 includes a conical bore portion 96 and a cylindrical bore portion 98 . The tubular portion 89 joins the small diameter end 97 of the conical bore portion 96 . The large diameter end 95 of the conical bore portion 96 joins the cylindrical bore portion 98 . A plug 100 has a cylindrical portion 102 with a diameter that is the same as the diameter of the cylindrical bore portion 98 in the device body 86 . The cylindrical portion 102 of the plug 100 is telescopically inserted into the cylindrical bore portion 98 until a radial surface 104 on a flange 106 engages an end surface 108 on the device body 86 . An outlet bore 110 through a plug tubular portion 100 is coaxial with the inlet bore 90 in the inlet end 88 of the device body 86 . The conical bore portion 96 , the cylindrical bore portion 98 and the bore 110 through the plug 100 have a common central axis 111 .
A sphere 114 of a material such as nylon is inserted into the conical bore portion 96 and the cylindrical bore portion 98 before the plug 100 is telescopically inserted into the cylindrical bore portion 98 as explained above. An adhesive may be employed to hold the plug 100 in the cylindrical bore portion 98 and retain the sphere 114 in the device body 86 . If the plug 100 and device body 86 are made from a material that cannot be joined by adhesives, a different joining system is employed.
The sphere 114 has a diameter that is larger than the inlet bore 90 , the small diameter end 97 of the chamber 116 defined by the conical bore portion 96 , and the outlet bore 110 . The sphere 114 also has a sphere diameter that is smaller than the large diameter end 95 of the conical bore portion 96 . A plurality of projections 118 on the end surface 120 , of the plug 100 facing the conical bore portion 96 , are adjacent to the outlet bore 110 , and extend away from the end surface 120 . These projections 118 contact the plastic sphere 114 and prevent the sphere from closing the outlet bore 110 . The projections 118 are spaced apart and extend axially toward the chamber 116 so that the sphere 114 does not impede the flow of water through the return pipe 64 and into the lower portion of the water tank 14 . The cross section area of the cylindrical bore portion 98 is at least two times the cross section area of the sphere 114 to insure that the sphere does not impede flow through the cylindrical bore portion. The projections 118 have sphere engaging surfaces 119 that maintain sufficient space between the sphere 114 and the outlet bore 110 to insure that the sphere does not impede flow into the outlet bore through the plug 100 . There may be two projections 118 separated by a slot 121 as shown in FIG. 2 . The slot 121 has a slot width normal to the central axis 111 that nearly as large as the diameter of the outlet bore 110 .
The return pipe 64 has a capacity that insures there is return water flow to the tank 14 due to temperature changes in the hot water supply pipe and the return pipe. A ¾ inch diameter hot water supply pipe 42 and a ½ inch diameter return pipe 64 work well. Pipes with other inside diameters will most likely work if they provide adequate flow rates. When one or more of the faucets 50 , 52 , 54 and 60 are opened, to dispense hot water for use, water flows out of the system and cold water flows into the system through the water inlet 22 . The water in the tank 14 of the hot water heater 12 tends to be forced out of the tank through both flow passages including supply pipe 42 and return pipe 64 connected to the hot water heater 12 . As a result cold water tends to exit the tank 14 through the return pipe 64 . Flow through the return pipe 64 is reversed. Flow through hot water discharge opening 24 and into the hot water supply pipe 42 is reduced. The dual flow paths could result in cold water and hot water mixing and warm water passing through one of the faucets. The dual flow paths could also result in cold water flowing through one of the faucets and hot water flowing through another one of the faucets. The sphere 114 of nylon is moved toward the inlet end 88 by back flow from the tank 14 . The sphere 114 engages the conical bore portion 96 and restricts flow through the directional flow control device 82 including the chamber 116 .
Three ribs 140 , 141 and 143 are provided on the conical bore portion 96 . The ribs 140 , 141 and 143 are spaced apart 120° from each other about the axis 111 as shown in FIGS. 3 and 6 . Each rib 140 , 141 and 143 is radially spaced from the axis 111 and parallel to one of three planes that include axis 111 . The conical bore portion 96 has inside surfaces that extend from the device bore 90 at an angle 150 of thirty degrees from the axis 111 as shown in FIG. 3 . Each rib 140 , 141 and 143 has a radial height of less than 0.030 inches. The ribs 140 , 141 and 143 permit some water to bypass the sphere 114 when one of the faucets 50 , 52 , 54 and 60 is opened. The ribs 140 , 141 and 143 insures that a pressure differential does not lock the sphere 114 in the small diameter end 97 of the conical bore portion 96 . The angle 150 of the conical bore portion 96 shown in FIG. 3 , insures that friction does not hold the sphere 114 is the small diameter end 97 of the conical bore portion. The slight leakage between the sphere 114 and the conical bore portion 96 when a faucet 50 , 52 , 54 or 60 is open has minimal effect on the temperature of hot water passing through open faucets. One or more grooves 146 may provide the same function as the ribs 140 , 141 and 143 . The groove 146 is shown in FIG. 4 .
Closing the open faucets 50 , 52 , 54 and 60 will stop the flow of potable water through water inlet opening 22 . The force of water equalized on both sides of the sphere 114 by water will permit the sphere 114 to move to an open position with the assistance of gravity or water flow.
The sphere 114 made of nylon or a similar plastic member is relatively light weight and can be moved by water with a low flow rate. As a result, the low impedance directional control device 82 may be in a vertical position, a horizontal position or a position between horizontal and vertical. The low impedance directional control device 82 may also be mounted in any position in the return pipe 64 .
A sphere 114 may also be made from a material such as glass. With a glass sphere, the central axis 111 of the directional flow control device 82 should be nearly horizontal. A glass sphere 114 will require somewhat more water flow to be moved into a flow reducing position adjacent to the small diameter end 97 of the conical bore portion 96 than a lighter weight sphere.
The angle 150 can vary from thirty degrees. However, a sphere 114 has stuck in the position adjacent to the small diameter end 97 of the conical bore portion 96 when the angle 150 was twenty degrees. The angle 150 should therefore be larger than twenty degrees. There is a maximum angle 150 . A sphere 114 may not move to a position coaxial with the central axis 111 if the angle 150 is ninety degrees.
A metering valve 130 , shown in FIG. 5 is connected to the inlet and 88 of the directional flow control device 82 and the return pipe 64 as shown in FIG. 5 . The metering valve 130 is preferably a CPVC valve with integral connectors for connection to the return pipe 64 and to the directional flow control device. The metering valve 130 is employed to control the rate of water return flow through the directional flow control device 82 and into the bottom end 20 of the hot water heater 12 . The return flow rate is self regulating to some extent in that as the temperature of return water to the bottom of the tank 14 increases the pressure difference decreases. If the temperature of water returned to the tank 14 is the same as hot water passing out through the discharge opening 24 , the flow of water through the return pipe 64 will stop. However, an attempt to hold the return water close to the hot water discharge temperature from the hot water tank 14 will require the addition of substantial heat. In most homes, maintaining a water flow rate that maintains a water temperature drop of 20° F. between the return pipe inlet end 66 and the return pipe discharge end will provide satisfactory results. If a home owner is to be away for some time the return valve 76 or metering valve 130 can be closed. The metering valve 130 is positioned in a relatively easy place to reach. The return valve 76 is close to the bottom of the hot water heater 12 and may be more difficult to adjust or close. The metering valve 130 can be closed to prevent the entry of air into the return pipe 64 when discharging water from the bottom end 20 of the hot water heater 12 through the open return valve 76 and the open drain valve 80 .
The directional flow control device 82 can be located anyplace in the return pipe 64 . It is however generally desirable to mount the flow control device near the hot water heater 12 where most of the system components are located.
The water conserving prompt hot water supply system 10 can be added to most existing home, office and other facilities. These systems 10 can be sold as kits. Each kit might contain a hot end assembly including one T-coupler, and a cold end assembly, including one metering valve 130 connected to one directional flow control device 82 , connected to one elbow 126 , connected to one T-coupler 78 , to which is connected one drain valve 80 , and either one female hose connector 128 or one ¾ inch male NPT threaded connector. Additional fittings and pipe can be added to the supply system if desired.
|
The prompt hot water and water conservation system includes a hot water supply pipe connected to a hot water heater outlet. A discharge faucet is connected to the supply pipe. A return pipe is connected to the supply pipe and to a hot water tank drain. The return pipe carries cooled water to the drain for reheating. Reheated water circulates into the supply pipe. A flow control device, in the return pipe, includes a chamber that houses a sphere. Return water flow moves the sphere toward a stop and permits unimpeded movement of water into the tank drain for reheating. When the faucet is opened, water flows from the tank drain into the flow control device. The sphere is moved to contact a small end of the chamber and substantially stop flow through the return pipe. Water is circulated through the system by increased density of cooled water.
| 5
|
TECHNICAL FIELD
[0001] The present invention relates to a pole grip, in particular for walking sticks, trekking poles, downhill ski poles, cross-country ski poles and Nordic walking poles, having a grip body and having a device for the adjustable fastening of a hand-retaining device in particular in the form of a hand strap or of a glove.
PRIOR ART
[0002] Such a device may be configured, for example, such that a hand strap is fastened on the pole grip via a screw or via a wedge, and the screw or the wedge provides a straightforward option for adapting the length of the hand strap, as far as possible without using any tools, to the user's requirements. Such mechanical devices should be as reliable as possible, and should not allow any undesirable adjustment of the length of the strap during use. In addition, it should allow adjustment without any complicated manipulation and, in order to keep costs low, it should be of extremely straightforward design. On the other hand, such fastening mechanisms, and this is very important in particular in downhill skiing, should be capable of performing this releasable arresting function over the widest possible temperature range.
[0003] Such a design is known, for example, from German Utility Model DE 681 01 226 U1. In the latter document, a strap is fastened in an adjustable manner on the pole by the strap band being guided around two pins in the fastening region of the pole. Adjustment is carried out via a tiltable element which is arranged on the head of the pole grip and in which these two pins are arranged. If this tilting element is swung upward out of a recess in the pole grip, then the length of the hand strap can be adjusted. If the tilting element is swung at least partially downward again into the pole grip, then the length of the hand strap is fixed.
[0004] There are also solutions in which, with the aid of a slotted region of the strap band, adjustability is achieved when the hand strap is moved upward whereas, when the hand strap is directed downward, the length of the hand strap is fixed. Such options are described, for example, in DE 19632718, DE 29906612 U1, and similarly EP 1118362.
[0005] The problem with these known solutions, inter alia, is the fact that, although straightforward adjustment is provided, secure fixing is very difficult if not impossible. In other words, these known solutions often have the disadvantage that during use, for example if the hand strap is accidentally pulled upward, they allow the length of the hand strap to be adjusted at an undesirable point in time.
DESCRIPTION OF THE INVENTION
[0006] This is where the invention comes in. The object of the invention is thus to provide an alternative pole grip to those in the prior art. The concern here in particular is to improve a pole grip for walking sticks, trekking poles, downhill ski poles, cross-country ski poles and Nordic walking poles, this pole grip having a grip body and a device for the adjustable fastening of a hand-retaining device in particular in the form of a hand strap or of a glove.
[0007] This object is achieved in that, for fastening on the pole grip, the hand-retaining device has, at least in a fastening region, a fastening element in the form of a band, of a belt or of a woven-fabric strand, and in that the device has an eccentric element which can be rotated and/or pivoted about an axial member, which eccentric element, in the fastening region, has a surface of which the radius, in relation to the axial member, increases in the arresting direction of rotation, in which case, by virtue of the eccentric element being rotated or pivoted in the arresting direction of rotation, the fastening element guided, in the fastening region, between this surface of the eccentric element and a stationary abutment is clamped between the eccentric element and abutment. The radius of the surface of the eccentric element here can increase continuously and, as it were, smoothly; however, it may also increase at least in sections, or in ribbed or stepped fashion.
[0008] An essential part of the invention is thus the use of an eccentric element for fixing the fastening element. This extremely straightforward design element proves to be surprisingly efficient for the releasable fixing of a fastening element in the form of a band, or of a belt or of a woven-fabric strand, since, on the one hand, it can be released without an excessive amount of force being applied in order adjust the length of the hand-retaining device on the pole grip, and since, on the other hand, it preferably makes it possible for the length of the hand-retaining device actually to be fixed, essentially irrespective of the position of the hand-retaining device. An eccentric element can be integrated to good effect in the pole grip and is very reliable, and the orientation of the eccentric element may preferably be selected such that, when the hand-retaining device is subjected to pulling, the eccentric element is pulled into its fixed position, that is to say, when the hand-retaining device is subjected to pulling, the fastening mechanism is fastened to an even more pronounced extent. As an alternative, however, it is also possible, in the manner of a safety-activation means, for the eccentric element to be arranged precisely the other way around, in which case, if the hand-retaining device is subjected to accidental pulling, for example in the event of a fall, it is possible for the hand strap, for example, to be released.
[0009] A first preferred embodiment of the invention is characterized in that the axial member of the eccentric element is arranged essentially perpendicularly to the pulling direction of the fastening element and in particular preferably essentially perpendicularly to the pole axis. If the eccentric element is arranged in this way, then the forces occurring on the hand-retaining device can be optimally absorbed by the eccentric element, and it is possible, at the same time, to release the eccentric element without any great amount of force being applied, in order to alter the distance between the hand-retaining device and the pole grip.
[0010] The eccentric element can be basically of any form where its radius, in relation to the axial member, increases in the arresting direction of rotation at least in sections. It is thus possible to use, for example, an eccentrically mounted ball or an eccentrically mounted cylinder, or also crosses between these two types of element or the like. Use of an eccentrically mounted cylinder is preferred in particular since this makes it possible to achieve optimum interaction with a strip-like or band-like hand-retaining device, located in the fastening region, against an abutment over the width of the cylinder.
[0011] According to a further preferred embodiment, the eccentric element has a lever or swing-action handle which can be manipulated from the outside and by means of which the eccentric element can be rotated or pivoted in order to clamp the hand-retaining device. As an alternative, however, it is also possible to provide, for example on the eccentric element, a ribbing arrangement or even (step-up) transmission means, which are accessible from the outside of the pole grip. It is typically possible here for the swing-action handle, for the purpose of releasing the fastening of the hand-retaining device to be swung upward and, for the purpose of clamping the fastening of the hand-retaining device, to be swung over forward or rearward in which case the lever is arranged essentially horizontally in the arresting position. The swing-action handle is thus least obtrusive in the fixed position on the pole grip and is barely noticeable during use of the pole. This can be achieved, in particular, by the lever or the swing-action handle being arranged on the top side of the pole grip, and preferably in the arresting position being integrated at least partially, or in particular more or less entirely, within the outer contour of the grip body. At least the tip should be exposed, in order to be freely accessible for release purposes (this, for example, also being the case with gloves).
[0012] A further preferred embodiment is distinguished by particularly practical integration in the pole grip, namely by, from the hand side, the grip body having, at the top end, a recess which, in the direction of the top side of the pole grip, has a through-opening in which the eccentric element is mounted in particular preferably by way of an axial pin guided in the grip body on both sides. The eccentric element rather than being arranged entirely in this opening, preferably projects into the recess. It is also possible to arrange the eccentric element in the recess and to allow only the swing-action handle to pass through the opening. The abutment is preferably formed in the recess in the manner of a crosspiece or pin which is arranged beneath the eccentric element, is supported in the grip body on both sides and is arranged in particular preferably parallel to the axial member of the eccentric element. It is also possible for two or even more such abutments to be present. The entire arresting device is thus integrated more or less completely within the pole grip as long as the swing-action lever is in its arresting position, that is to say essentially horizontal. It is also possible to arrange the swing-action lever on the front edge, in which case it is also conceivable for a swung-in position to be vertical.
[0013] The recess has, for example, a height in the range of 12-15 mm, and a width of 10-15 mm, but may also be configured to be smaller, for example in the case of cross-country ski poles or Nordic walking poles, which in some cases are of somewhat narrower design.
[0014] As has already been mentioned above, the hand-retaining device, for the purpose of clamping between the eccentric element and the abutment, has at least one portion (fastening element) in the form of a band, of a belt or of a woven-fabric strand. This portion is preferably flexible. It may be, for example, a plastic strip, although it is preferably a flexible portion of a band or belt, and, in the case of a hand strap, this entire strap can also form the hand-retaining device. Use is preferably made of materials for hand straps such as, for example, woven-fabric bands, preferably made of plastic. This portion, starting from the hand-retaining device, is initially guided through between the eccentric element and abutment, is then guided downward around the abutment and is subsequently guided out of the recess. A free end remains and it is possible for the length at which the hand-retaining device is attached to the pole grip to be adjusted via this free end. The free end can pass out of the pole grip either in the downward direction or else in the upward direction.
[0015] Corresponding to a further preferred embodiment, the hand-retaining device is a strap with its top end fastened in a fixed or releasable fashion, in the manner of a safety-activation means, on the grip body, in particular preferably on the base of the recess. This strap is guided around the hand and has a region guided into the recess of the pole grip, in which case the free end projects out of the pole grip in the downward direction. Analogously, it is, of course, possible to fasten the fastened end of the hand strap at the bottom of the recess and to guide it in an equivalent manner from bottom to top through the fastening device, in which case the free end projects out of the recess of the pole grip in the upward direction. It is also possible, if the strap is fastened on the top side to fasten the fastened end of the hand strap on the swing-action lever, for example, from beneath. Movement of the strap in the upward direction, in this case, can release the eccentric element and thus render the strap adjustable. Equally, the eccentric element can be fixed by moving the top portion of the hand strap.
[0016] As already mentioned, the hand-retaining device may be a hand strap or else a glove or a strap-like device which can be fastened on the hand, the latter two options having, essentially between the thumb and forefinger, at least one band which is guided into the recess of the pole grip and via which, correspondingly, the hand-retaining device can be fixed in an adjustable manner on the pole grip.
[0017] Further preferred embodiments are described in the dependent claims.
BRIEF EXPLANATION OF THE FIGURES
[0018] The invention will be explained in more detail below with reference to exemplary embodiments, in conjunction with the drawings, in which:
[0019] FIG. 1 shows sections through a pole grip with an eccentric element, a) illustrating a central section, and b) likewise illustrating a central section, this time taken perpendicularly to the section according to FIG. 1 a ); and
[0020] FIG. 2 shows sections through an alternative pole grip with an eccentric element, a) illustrating a central section, and b) likewise illustrating a central section, this time taken perpendicularly to the section according to FIG. 2 a ).
WAYS OF IMPLEMENTING THE INVENTION
[0021] The exemplary embodiments illustrated in the figures should serve to illustrate, and support, the idea of the invention, but should not be used to limit the scope of the idea of the invention as formulated in the claims.
[0022] FIGS. 1 a ) and b ) illustrate different sections of a first exemplary embodiment of a pole grip according to the invention. The pole grip 1 comprises a grip body 3 , which is usually produced from a plastic material by injection molding. As seen from beneath, the grip body 3 has a recess or a cavity 5 into which the pole, which is formed, for example, from an aluminum shaft, can be pushed and fastened.
[0023] At its top end, the pole grip 1 has a recess 4 which is designed from the hand side 6 a in the first instance, as it were, as a blind hole. The hand strap 2 is fastened in this recess 4 , which typically has a height in the range of 12-15 mm, and a width of 10-15 mm. For fastening purposes, the recess, in the direction of the top side of the pole grip has an opening in which an eccentric element 11 is mounted. This is essentially a plastic cylinder (a cylinder made of metal is also conceivable) which is mounted eccentrically, that is to say, rather than being mounted along its center-of-gravity axis, it is mounted in an offset manner in relation to the same. In the case of the exemplary embodiment according to FIG. 1 a , the axial member 12 is displaced somewhat upward and to the left in relation to the center-of-gravity axis, since the eccentric element is intended, via rotation in the clockwise direction, to fix a band located beneath it. The eccentric element 11 has a swing-action handle 13 , which is either formed integrally with the eccentric element 11 or fastened on the same. The swing-action handle is oriented in the direction of the front side 6 b of the grip. When it is located in the fixing position, as is illustrated in FIG. 1 a ), the swing-action handle 13 is at least partially recessed in a groove which is made in the pole grip 3 from above. The eccentric mounting of the eccentric element 11 gives rise, in relation to the axial member 12 , to radii which differ depending on rotary position. These different radii are depicted by the arrows a (short radius), b (radius in typical fixing position) and c (large radius).
[0024] The axial member 12 is mounted in the pole grip 3 , as can be seen in particular in FIG. 1 b ). The lateral surface of the cylinder of the eccentric elements may have an essentially unmodified surface; it is also possible however, in particular in the downwardly directed region, where the fixing action is to be effected, to provide a special surface for increasing the friction in relation to the hand strap, for example a roughened surface or one with ribs transverse to the loading direction, or the like.
[0025] Directly beneath the eccentric element 11 , a pin 14 is arranged coaxially in relation to the axial member 12 . This pin 14 forms the abutment or the surface on which the strap is fixed. It is also the case that the pin 14 , as can be seen in FIG. 1 b ), is incorporated in corresponding recesses or bores in the grip body 3 . The pin 14 may also be provided with a special surface structure in order to increase the friction between the pin 14 and the strap. Here too, in other words, it is possible to have a roughened surface or ribs parallel to the axis of the pin 14 or the like.
[0026] In this exemplary embodiment, a hand strap 2 has its fastened end 8 screwed or riveted to the top wall of the recess 4 . The hand strap is guided around the hand, and the other end is then guided, in the region 9 , into the recess 4 and is guided between the pin 14 and the eccentric element 11 . Subsequently, the strap is guided downwardly around the pin 14 and guided out of the recess 4 again. A free end 7 of the hand strap forms as a result.
[0027] It should be pointed out, in this context, that it is not absolutely necessary for the free end to be guided out of the pole grip 3 in the direction of the hand side 6 a again. It is likewise readily possible for the free end 7 to be guided out of the pole grip in the forward direction, through a hole provided for this purpose, toward the front side 6 b . It is also possible to allow the free end 7 to pass out of the pole grip 1 in the upward direction or even to guide the free end downward through the grip body 3 , in which case it only passes out of the pole grip at the bottom, for example at the bottom edge, and therefore does not get in the way at all here.
[0028] In the case of each of these embodiments, when the fastening device is released, the strap 2 can be shortened by virtue of the free end 7 being subjected to pulling.
[0029] It is also possible to configure the fastening on the pole grip in the region 8 as a safety-activation means. In other words, the fastening may be configured such that, in the case of a force above a defined level, it releases the strap at its fastening. This can be achieved in a variety of different ways, for example by the strap being attached, in its region 8 , in the first instance to a plastic element which is fitted into a corresponding recess in the pole grip and can be released from this recess via material deformation in the event of pronounced pulling. The activation force here may even be defined, in some cases, via the material of the plastic element. However, more complex mechanisms, which may be adjustable via springs or the like, are also possible.
[0030] The actual fastening takes place, as already explained, by the clamping between the eccentric element 11 and pin 12 . FIG. 1 a ) illustrates the clamped state, that is to say the state in which the length of the strap cannot be changed. In this state, the swing-action handle 13 is recessed, in the forward direction, essentially within the pole grip.
[0031] If the hand strap 2 is then adjusted, the swing-action handle 13 is gripped at the front, from beneath, and pulled upward and/or rotated in the counterclockwise direction. In this case, the eccentric element 11 rotates about the axial member 12 . Whereas, in the fixing position, the large radius b was oriented in the direction of the pin 14 , this rotation then causes the radius to become gradually shorter, as a result of the eccentricity, until, for example, the position illustrated by the arrow a is reached. In this position, the swing-action handle 13 is oriented almost entirely in the upward direction, and the interspace between the eccentric element 11 and the pin 14 , then, has been widened such that the band located therebetweeen is released to the full extent and either the hand strap 2 can be shortened, by being pulled at the free end 7 , or lengthened, by being pulled at the region 9 .
[0032] Once the length of the strap has been changed, the strap can be fixed in the new position by virtue of the swing-action handle 13 being swung down in the clockwise direction (arresting direction of rotation F). Since the radius gradually increases during rotation, the clamping between the eccentric element 11 and the abutment 14 is defined, as desired, in accordance with the force on the swing-action handle 13 .
[0033] Using the eccentric element 11 thus has, inter alia, the advantage that the arresting force can be defined in adaptation to requirements. Moreover, tolerances in the range of the thickness of the band guided between the eccentric element and abutment 14 do not have any great effect, as is the case with other fastening mechanisms. Such tolerances can readily be absorbed, and if, for example, a band region which is somewhat thicker is pushed between 11 and 14, then the lever 13 has to be swung down to a somewhat lesser extent in the clockwise direction F, and if for example, a band region of the strap which is somewhat thinner is pushed therebetween, then the lever 13 is simply swung down somewhat further in the clockwise direction. In order for the latter to be possible, rather than a stop being provided for the swing-action handle 13 , preferably on the pole grip the groove in the grip body 3 is provided with sufficient clearance for movement to allow the swing-action handle 13 to be used for arresting purposes even in the case of a thin band or in the case of the eccentric element 11 being worn.
[0034] This gives the advantage, on the one hand, that relatively large tolerances are possible in respect of the thickness of the strap material and, on the other hand, that even regions which may already be partially damaged, or have been subjected to pronounced compression as a result of intensive use, can readily be fastened. The latter in particular often poses problems in the case of the conventional fastening mechanisms.
[0035] Moreover, the wear caused by the fastening mechanism is kept to a minimum as a result of the surface pressure of the strap material between the pin 14 and the cylinder surface of the eccentric element 11 .
[0036] FIG. 2 shows an analogous exemplary embodiment, although in this case, rather than being arrested in the clockwise direction, the swing-action handle 13 is arrested in the counterclockwise direction (arresting direction of rotation F). Whereas, in the exemplary embodiment according to FIG. 1 , the eccentric element 11 is fixed yet further under the loading caused by the hand strap being subjected to an exceptional pulling force, this is not the case in the exemplary embodiment according to FIG. 2 . On the contrary, it is even possible here, in some cases, for the strap band to be released when subjected to pronounced loading since pulling at the region 9 results in a torque counter to the arresting direction of rotation F, and can thus rotate the swing-action handle upward. This may be expedient, for example, as a safety-activation means.
[0037] In the case of an exemplary embodiment according to FIG. 2 , it is also possible for the end 8 of the strap, rather than being fastened on the grip body 3 , to be fastened on the top side, or preferably the underside, of the swing-action handle 13 or to be fixed in a slot in the swing-action handle. This makes it possible to release the eccentric as a result of the strap 2 being pulled upward, either as a safety function or, quite simply, in order to release the fixing for the purpose of adjusting the length of the hand strap.
[0000] List of Designations
[0000]
1 pole grip
2 hand strap
3 grip body
4 recess in 3
5 cavity in 3 for pole shaft
6 a hand side of the grip
6 b front side of the grip
7 free end of the hand strap
8 fastened end of the hand strap
9 hand-strap region guided into the pole grip
10 opening of 4
11 eccentric cylinder
12 axial member of 11
13 swing-action handle
14 pin
a,b,c radii of eccentric element for different rotary positions
F arresting direction of rotation
|
The invention relates to a stick/pole grip ( 1 ), particularly for walking sticks, trekking poles, alpine ski poles, cross-country ski poles and Nordic walking poles, with a grip body ( 3 ) and with a device ( 11 - 14 ) for adjustably fastening a hand-retaining device, particularly provided in the form of a hand strap ( 2 ) or a glove. The inventive stick/pole grip is characterized in that the hand-retaining device has, at least in a fastening area, a fastening means provided in the form of a strip, a strap, a belt or a rope for fastening to the stick/pole grip ( 1 ), and that the device has an eccentric element ( 11 ) that can rotate and/or pivot about an axis ( 12 ), this eccentric element ( 11 ) having a surface in the fastening area whose radius (a, b, c) increases toward the axis ( 12 ) in a fixing direction of rotation (F) at least in a step-by-step, continuously, ribbed or stepped manner so that the fastening means guided in the fastening area between this surface of the eccentric element ( 11 ) and a fixed abutment ( 14 ) is clamped between the eccentric element ( 11 ) and the abutment ( 14 ) by rotating or pivoting the eccentric element ( 11 ) in the fixing direction of rotation (F). This design makes possible an extremely simple and reliable variable fastening of a hand-retaining device on the stick/pole grip.
| 0
|
CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
Not applicable
BACKGROUND OF THE INVENTION
It is generally known to provide money changers for coin-operated machines with so-called coin tubes which receive coins of certain denominational values in an upright position. The coin tubes stack the coins in columns, and a pay-out device associated with the lower ends of the coin tubes delivers coins from the tubes in correspondence to the small change which is to be given out. Prior to this, a coin testing device tests the coins for genuineness. Coins which are found to be genuine either get into a cash-box or sorting device which sorts the coins into the individual tubes according to their denominational values. More recent money changers have a maximum of six coin tubes for coin storage.
From EP 0 957 457 B1, the entire contents of which is incorporated herein by reference, a sorting device for coin-operated machines has become known in which coin tubes arranged in a row are allotted the coins via four sorting flaps. From EP 0 622 763 B2, the entire contents of which is incorporated herein by reference, a sorting device has become known in which sorting gates are provided in three superposed planes to route coins to four coin tubes.
From EP 0 576 436 B1, the entire contents of which is incorporated herein by reference, a sorting device has become known which also feeds four coin tubes. A first V-shaped gate element leads incoming coins to one side or the opposite one. For this purpose, the two legs of the V-shaped gate element are either in the plane of the arriving coins or outside the same. The first gate element is operated by a first solenoid. Either side of the first gate element has disposed thereon gate portions which can be pivoted about a vertical axis. When in one position, they pass arriving coins on to another runway and, when in the other position, they direct the coins to a coin tube which is disposed underneath. Here, the disadvantage is that the coins require to be deflected in a vertical direction from the plane in which they drop into the sorting device.
It is the object of the invention to provide a device for sorting coins in which the coins are moved and deflected in one plane only.
BRIEF SUMMARY OF THE INVENTION
In the inventive device, the axes of the coin tubes are located in a common plane. A first gate element and a second gate element have runways each associated therewith above one of the middle coin tubes. Two runways are oriented towards the outer coin tubes each, the two runways also allow a downward passage to the middle coin tubes when the second gate element is inoperative and the runways are retracted. The coins are routed towards the outer coin tubes when the second gate element is operated.
In the inventive sorting device, the coins will always remain in one plane and will not be deflected, which has a very favourable effect on the wear and the rapidity of forward motion of the coins.
In an aspect of the invention, the second gate element has coupled thereto barrier portions which extend into the common plane when the second gate element is inoperative, and are retracted from the plane when the second gate element is operated. The barrier portions take care that the coins are able to enter the coin tube, which is located underneath, in a substantially vertical position when the second gate element is inoperative.
Another aspect of the invention provides that the first gate element has a first runway which is oriented towards a fourth runway located in the dropping path of the coins with the first runway extending into the common plane when the first gate element is inoperative and being retracted from the plane when the first gate element is operated. Coins which arrive from the coin tester, after passing the reception gate, drop onto the fourth runway of a so-called cash-box gate. If the cash-box gate is not being operated all coins will drop into the cash-box disposed underneath. On the other hand, if the cash-box gate is being operated the coins arriving from the coin tester drop onto the fourth runway and are deflected to the first runway.
In another aspect of the invention, the first gate element, at the end of the third runway, has a first barrier portion which has a passage for the coins when the first gate element is not being operated, and directs arriving coins towards the second or third runway of the second gate element when the first gate element is being operated. The passage which is defined by the second and first runways or the first barrier portion is limited by the wall of the sorting device in which the first and second gate elements are slidably mounted.
According to a further aspect of the invention, it is advantageous for the sorting procedure if the outer coin tubes have their upper ends disposed lower than the middle coin tubes.
To achieve a larger storage capacity or allow the coin tubes to accommodate coins of more denominational values an aspect of the invention provides that a fifth and a sixth coin tube be provided the axes of which are located approximately in a joint second and third plane with the axes of the matching outer coin tubes, the first and second planes being nearly perpendicular to the first plane. Above the outer coin tubes, further gate elements each can be operated by a solenoid provided and allow the coins to pass to the outer coin tubes when the third or fourth gate element is not being operated, and directs the coins to the fifth or sixth coin tube when the third or fourth gate element is being operated.
The second gate element preferably constitutes a unit with the second and third barrier portions. According to an aspect of the invention, arms for the barrier portions and the barrier portions can define a first component and the runways of the second gate element can define a second component, which are combined into a unit. Since those components preferably are formed from a plastic it is advantageous to provide one component with a latch pin and the other one with a detent aperture which are of a non-releasable snap-in configuration.
An embodiment of the invention will be described in more detail below with reference to the drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 shows a plan view of a tube cassette for a sorting device of the invention.
FIG. 2 shows the upper portion of the tube cassette of FIG. 1 with the sorting device of the invention in a perspective view.
FIG. 3 shows the sorting device of FIG. 2 with a coin tester disposed there above in a perspective view.
FIG. 4 shows the back of the sorting device of FIG. 3 in a perspective view.
FIG. 5 shows another portion of the sorting device for the outer coin tubes of FIGS. 1 and 2 in a perspective view.
FIG. 6 shows a first gate element of the sorting device of the invention in a perspective view.
FIG. 7 shows a second gate element of the sorting device of the invention in a perspective view.
DETAILED DESCRIPTION OF THE INVENTION
While this invention may be embodied in many different forms, there are described in detail herein a specific preferred embodiment of the invention. This description is an exemplification of the principles of the invention and is not intended to limit the invention to the particular embodiment illustrated.
FIG. 1 illustrates a plan view of a coin tube cassette 10 where the individual coin tubes 12 are designated A, B, C, D, E, and F. The axes of coin tubes B to E are located approximately in a common first plane. The axes of coin tubes A and B and F and E are also located approximately in a common second and third plane each. The two planes mentioned last are approximately perpendicular to the first plane.
From FIG. 2 , it can be seen that the upper ends of inner coin tubes C and D are located higher than the upper ends of the outer coin tubes B and E and coin tubes A and F each. The tube cassette 10 is placed in an apparatus casing which is not shown and, as illustrated in FIG. 2 , also houses the assembly units of the sorting device and coin tester that are described below.
The sorting device comprises two superposed sorting modules here in a casing ( 14 ).
The upper sorting module shown in FIG. 4 is joined together with the coin testing module as is shown in FIG. 3 and can be inserted as a unit into the apparatus casing.
The second sorting module shown in FIG. 5 is inserted directly below in the apparatus casing in the portion as is depicted in FIG. 2 . When so inserted, it is guided by a slot in the casing and is snapped into place in the end position.
FIG. 3 shows the way a casing portion 16 of a coin tester is placed on top of the casing 14 . The casing 16 has an insertion hopper 18 and a return lever 20 . The construction of the coin tester in the casing 16 is conventional and will not be described in more detail. A coin gate 22 is pivotally supported about an approximately horizontal axis in the casing portion 14 of the sorting device. The coin gate 22 has mounted thereon an actuation shaft 24 which is pivotally supported at 26 and is pivoted by a portion 28 which is operated by a solenoid not recognizable in FIG. 3 . Below the acceptance gate 22 , there is a cash-box gate 30 which is also actuated by a solenoid which is not shown. The cash-box gate has a runway portion 32 .
A first gate element 34 is slidably supported perpendicularly to the plane of the drawing in a wall 36 of the casing 14 . A second gate element 38 also is slidably supported perpendicularly to the plane of the drawing in the wall 36 . The gate elements 36 , 38 are illustrated in FIGS. 6 and 7 .
The gate element 34 has a runway portion 40 and a first upwardly extending arm 42 with a recess 44 . Another arm 44 parallel thereto on the opposite side of the runway portion 40 defines a barrier portion. A pin-type anchor (not shown), which forms part of a solenoid for operating the first gate element 34 , is snapped into the recess 44 .
The second gate element 38 has a first component 48 and a second component 50 which are combined together into a unit. The first component has two runway portions 52 , 54 each, which are slantingly oriented downwards, on opposed sides. In the middle, they are joined to a pin-like trunnion 56 which extends obliquely to the plane in which the runway portions 52 , 54 are arranged.
The second component 50 has a bushing-shaped middle portion 58 into which the trunnion 56 may non-releasably be snapped. However, the connection described is not rigid, but allows of a certain pivoting motion of the two components 48 , 50 relative to each other. Arms 60 , 62 at the ends of which a barrier portion 64 and 66 each is mounted extend on opposite sides of the bushing 58 . The bushing 58 further has joined thereto a metallic pin 68 which leads to a solenoid for actuating the second gate element 37 .
FIG. 4 shows the other side of the casing 14 . Two upper solenoids 70 , 22 can be recognized. The solenoid 70 operates the cash-box gate 30 and the solenoid 72 operates the acceptance gate 22 . The operating portion 28 of FIG. 3 thus belongs to the solenoid 72 . However, the operation mechanism will not be described in detail since it is conventional.
FIG. 4 allows recognizing a further solenoid 74 which serves for operating the first gate element 34 . A further solenoid 74 serves for operating the second gate element 38 .
In FIG. 3 , the first and second gate elements 34 , 38 are in an inoperative position of the solenoids 74 , 76 . When the cash-box gate 30 is operated this causes genuine coins which are passed by the acceptance gate 22 to get onto the runway 32 of the cash-box gate 30 and, subsequently, onto the runway 40 of the first gate element 34 . The coin rolls down the runway 40 and passes the barrier portion because this portion leaves a distance from the wall 36 of the casing 14 . As a result, the coin gets into the area of the runway 54 . This runway, however, also is at a distance from the wall 36 when the solenoid 76 for the second gate element 38 is inoperative. This implies that the coin drops down in front of the barrier portion 66 . The barrier portion 66 , which extends from the plane in which the arriving coin is rolling, takes care that the coin is deflected downwards. With regard to FIG. 2 , this means that the coin drops into tube C.
An activation of the solenoid 74 causes the first gate element 34 to be operated and the runway 40 to get outside the plane in which coins roll from runway 32 to runway 54 , causing the coin to drop down. The barrier portion 34 , which now does not present a passage any longer for the coin, takes care that the coin be deflected downwards. Since the runway 52 forms a gap with the wall 36 the coin will drop down vertically, which means in FIG. 2 that the coin drops into the tube D.
If only the second gate element 38 is operated a coin will run along the runway 40 through the barrier portion onto the runway 54 because this one no longer forms a gap with the wall 36 . Hence, the coin runs along the runway 54 and, thence, into the tube disposed underneath, which is tube B in FIG. 2 .
If the two gate elements 34 , 38 are operated by an activation of the two solenoids 74 , 76 the coin, when behind the runway 32 , gets directly onto the runway 52 because the runway 40 is retracted from the coin plane. Since the runway 52 has ceased to form a gap with the wall 36 the coin will run rightwards into the tube which is disposed underneath and is tube E in FIG. 2 .
It can be seen that if the deflections described exist the coin will always remain in the same plane and need not be deflected to any place.
FIG. 2 allows recognizing that further gate elements 78 , 80 are laterally disposed below the gate elements 34 , 38 . When activated, they serve to direct arriving coins into coin tubes A or F, respectively. The gate elements 78 , 80 are supported in casing portions 84 , 86 of the casing part 82 of the second sorting module and can be pivoted about an axis which approximately is horizontal. Their operation is performed by means of solenoids 88 or 90 . The pivoting mechanism is not shown in detail.
It can be seen from FIG. 2 in conjunction with FIG. 5 that if the third or fourth gate element 78 , 80 is inoperative the coins arriving from the runway of the second gate element 38 are directed each into tube B or E. On the other hand, if a solenoid 88 or 90 is operated a coin arriving from one of the two runways will be routed to the coin tube A or F.
In FIG. 3 , a sorting sensor is arranged at 92 and a further sensor is disposed at 96 or 98 . They detect that a coin is passing on the runways 52 , 54 or runway 40 and enable the coins to be counted.
As is outlined at 100 the casing 14 has hinged thereto a flap (not shown) which closes the open side of the sorting device. The flap contains prisms, not shown, for the sensors 92 , 96 , and 98 . One of the two small circles pertaining to the sensors shown denotes a pass of a light beam which is reflected in a prism in the flap, not shown, into the other aperture behind which a light-sensitive element is disposed. Sensors of this type are known as such in coin testers and sorting devices.
The flap further includes a return channel towards which the coins are led by the acceptance gate 22 if the coin tester identifies a counterfeit coin. Coins will also get out through the return channel if the return lever 20 of the coin tester is actuated.
A printed-circuit board for operating the solenoids and activating the sensors 92 , 96 , 98 is located at the back of the casing 14 that is shown in FIG. 4 . This printed-circuit board is also connected, via a flat cable, to a printed-circuit board which performs the control of the coin tester which was not described in detail.
|
A device for sorting coins in at least four coin tubes of a coin changer that leave a coin testing device, the coin tubes being located in a common plane, the device comprising a housing having a substantially vertical wall, a first gate element including a first runway inclined relative to a horizontal level and a barrier portion at the lower end of a first runway, the first gate element being supported for movement approximately perpendicular to wall and actuable by a first electro magnet between two positions, in the first position the first runway projecting from wall and the first barrier portion together with wall forming a passage whereby a coin may roll along the first runway through the passage while in the second position the runway extends into wall and the first barrier portion is adjacent to wall.
| 6
|
BACKGROUND OF THE INVENTION
The invention relates to a method for detecting a state of engagement of a pinion with a corresponding gearwheel, in particular a state of engagement of a starter pinion with a starter.
The invention also relates to a method for starting a starter motor.
Furthermore, the invention relates to a computer program.
The invention also relates to a computer program product.
Moreover, the invention relates to a device for detecting a state of engagement of a pinion with a corresponding gearwheel, in particular a state of engagement of a starter pinion with a starter.
The invention likewise relates to a device for starting a starter motor.
Last but not least, the invention relates to a starter having a pinion which is to be engaged.
The invention is based on a starter having an associated relay which controls engagement of a pinion in a corresponding toothing arrangement. In particular, the invention is based on start/stop systems, in particular start/stop systems which have an expanded functionality and in which engagement occurs in an internal combustion engine which is coasting to a standstill, with subsequent positioning of the crankshaft. In such solutions it is necessary to ensure that the pinion is engaged before the starter turns.
In known solutions, the pinion position is not detected but instead waiting occurs for a predetermined time period in which engagement of the pinion has taken place with a high degree of probability. In this context it is ensured that the starter pinion has engaged in the ring gear of the internal combustion engine before the starter motor turns, by virtue of the fact that a certain lag time is maintained between the energization of the relay and that of the starter. This lag time must be selected such that under all circumstances the starter does not begin to turn before the pinion is securely engaged in the ring gear. Failure to engage, loud noises or even aborted starts are the result of excessively early turning. However, in most cases this configuration takes into account a time loss which leads to prolonged starting times, and in the case of engagement in the internal combustion engine which is coasting to a standstill and has subsequent positioning of the crankshaft leads to intermediate deactivation and/or swinging back of the internal combustion engine.
EP 960 276 B1 discloses a circuit arrangement for an engagement relay, which engages two gearwheels, of a starter device of an internal combustion engine, having a switching element which, after a first time period before the two gearwheels are brought into engagement with one another, reduces a relay current to a specific current value during a second time period. The switching element is embodied as an open-loop and closed-loop control device which increases the relay current to a predetermined value in a third time period, wherein the third time period starts when the one gearwheel reaches the other.
SUMMARY OF THE INVENTION
The methods according to the invention, the computer program according to the invention, the computer program product according to the invention, the devices according to the invention and the starter according to the invention have, among other advantages, the advantage that the detection of the pinion position permits faster turning of the starter since there is no need to wait for a fixed time period. Particularly in the case of start/stop systems with an expanded functionality, such as engagement in the internal combustion engine which is coasting to a standstill and has subsequent positioning of the crankshaft, it is advantageous, for reasons of comfort and service life, to start positioning the internal combustion engine as quickly as possible after the engagement process. In this way it is possible to prevent or at least minimize intermediate deactivation of the internal combustion engine and/or swinging back. According to the invention, of at least one energization parameter of the energization is sensed, the sensed energization parameter is placed in relation to possible pinion positions and an associated pinion position with respect to the sensed energization parameter is selected and therefore detected. The detection of the pinion position ensures that starting does not take place too early, that is to say before the complete engagement of the pinion, and a malfunction with loud noises or aborted starting due to incorrect engagement does not occur. Since an energization parameter is sensed for the purpose of detection, there is no need for an additional sensor which, for example, visually senses the position, which also minimizes a risk of faults. By reference to a repeatedly recurring typical characteristic curve profile of the energization parameter it is possible to unambiguously infer the position of the pinion, with the result that failure during the engagement is reliably prevented.
It is advantageous that a plurality of pinion positions are stored in a data memory in relation to energization parameters which can be sensed. In particular, various discrete energization parameters and associated pinion positions are stored. In this way, not every intermediate position between pinion positions which are relevant for the engagement is recorded, as a result of which there is a reduction in memory space and a computational speed or processing speed is optimized. Accordingly, in other embodiments further positions, for example of an armature, of a fork lever or the like, are also stored, with the result that a plurality of positions of different components can be detected. Since the movement of the pinion is dependent on the positions of other components, it is therefore possible to implement redundancy which further increases the detection accuracy and therefore prevents incorrect detections.
It is particularly advantageous that the sensed energization parameter is placed in relation to possible pinion positions and an associated pinion position is selected with respect to the sensed energization parameter, and therefore detected. Since the pinion positions are assigned, in a memory, to corresponding characteristic curves of various energization parameters, by sensing the energization parameter it is possible to reliably determine and detect a pinion position. For example, a sequence of current rise-current fall-current rise-current fall-current rise-current fall can be assigned, as a profile of an energization parameter embodied as a current, to a pinion position pinion starts to engage in ring gear. Other profiles or sequences are assigned to further positions. In addition to the sequence of current rise or current fall, a relationship is dependent as a function of the gradient of a profile curve or on a magnitude of a sensed energization parameter. For example, a current fall can also be assigned to a corresponding current level of a specific pinion position.
Another advantage of the present invention is that a plurality of pinion positions are stored in a data memory in relation to energization parameters which can be sensed. The pinion can assume a plurality of positions in a starter, in particular a non-engaged position, an engaged position and a position of the start and/or end of engagement. In one embodiment of the invention, a plurality of positions are assigned to corresponding energization parameter profiles, so that not only the position of the pinion which is relevant for the engagement but also further positions can be detected. It is therefore possible, by monitoring further pinion positions, to avoid further incorrect switching operations and to initiate maintenance in good time.
In one particular preferred embodiment there is provision that the sensing comprises the sensing of a chronological profile of the energization parameter. The energization parameter changes over time during the engagement process. As a result, sensing depends not only on specific current values but also on a sequence of current values over time. A certain position of the pinion cannot be inferred solely from a current drop. Instead, the energization level and the preceding sequence of the energization parameter over time are relevant here, in particular also the change in the energization parameter over time. As a result of the relationship of the energization parameter with time, a higher level of reliability of the detection probability is provided.
Furthermore, it is advantageous that a differentiated profile is generated from the sensed chronological profile by means of differentiation. In particular the change in the profile of the energization parameter, i.e. the gradient of the profile, is particularly advantageous for the detection of a pinion position. It is therefore possible to define boundaries for a gradient which provide exclusion via the pinion positions. If a sensed energization parameter or the gradient thereof is not within the boundaries, there is, for example, no engagement switching time. In this way, a malfunction due to fluctuations in voltage or other influences which do not relate to the engagement process can be avoided. Accordingly, tolerance values are provided around the limiting values, renewed measurement or time-sequence-controlled engagement being carried out, for example, when said tolerance values are reached.
In particular, it is advantageous that various sections of the profile are classified in order to generate a profile with discrete sections with corresponding jumps. The classification takes place, for example, as current rise, current fall and constant current. Subclassifications are also defined, for example current rise to a high current level, current rise to a low current level, strong current rise with a large gradient, small current rise with a low gradient etc. On the basis of this classification it is possible to assign unambiguous pinion positions, for example in the case of stops of the pinion or in the initial position or final position thereof. In this way, only the positions of the pinion which are relevant for starting are assigned, which provides a saving in terms of computing capacity and brings about a better performance.
In addition it is advantageous that the relation comprises a comparison of the profile with a corresponding predefined characteristic curve. Characteristic curves for various energization parameters have been obtained from various trials. Said curves are correspondingly stored or saved together to form a characteristic curve, if appropriate with a tolerance range. The characteristic curve storage is not rigid in advantageous embodiments but it is instead implemented in a self-learning fashion so that the characteristic curve is regularly adapted on the basis of further empirical values and measured values. In particular even if characteristic curves change as a function of a service life, this change is taken into account in advantageous embodiments.
In particular it is advantageous that a pinion position profile is assigned to the characteristic curve. A corresponding pinion position profile is assigned to the characteristic curve or the characteristic curves with the result that each point on the characteristic curve corresponds to a pinion position. Inflection points of the characteristic curve, which stand for correspondingly relevant pinion positions, are of particular importance here. The points on the characteristic curve are only theoretically representative of a certain pinion positions here. Instead, regions of points are assigned to a pinion position region. In this way less computing power is necessary for the determination process since only certain discrete pinion positions have to be detected for the starting process.
A further preferred embodiment of the present invention provides that at least one further parameter selected from the group comprising time, current strength, voltage strength, current fluctuation, voltage fluctuation and the like is taken into account in order to determine the pinion position. In particular, the current can be sensed simply and precisely, for example by means of the current strength, and the voltage can be sensed simply and precisely, for example by means of the level of the voltage, without complicated sensors being necessary. Corresponding connections are provided, with the result that the method according to the invention can also be easily retrofitted for existing starter systems.
Furthermore, it is advantageous that in a method for starting a starter motor, a method according to the invention for detecting a state of engagement of a pinion with a corresponding gearwheel, in particular a state of engagement of a starter pinion with a starter, is carried out, and further steps such as starting or positioning the crankshaft are carried out as a function of the detected position of the pinion, in particular after engagement of the pinion. The detection of the pinion position, in particular of the pinion position which is the optimum one for starting, permits the relay to be switched, that is to say the starting process to be begun, without a delay, which brings about an increase in effectiveness, in particular in start/stop systems.
The methods can advantageously be implemented as a computer program and/or computer program product. They include all computing units, in particular also integrated circuits such as FPGAs (Field Programmable Gate Arrays), ASICs (Application Specific Integrated Circuits), ASSPs (Application Specific Standard Products), DSPs (Digital Signal Processors) and the like as well as hard-wired computing modules. The method can be quickly and easily retrofitted by means of corresponding embodiments.
The method can particularly advantageously be implemented in suitable devices with means for carrying out the method. An advantageous embodiment of the invention therefore provides that in a device for detecting a state of engagement of a pinion with a corresponding gearwheel, in particular a state of engagement of a starter pinion with a starter, there is provision that an energization section for energizing a starter relay in order to switch the pinion and a sensing section for sensing at least one energization parameter of the energization are included. Particularly advantageously a control section is provided in order to form, on the basis of the sensed energization parameter, a relationship with possible pinion positions and to select an associated pinion position for the sensed energization parameter, and therefore to detect the pinion position. The individual sections can be embodied in different ways. For example, the control section can comprise control logics or control modules on which, for example, the method is implemented by software or as a circuit. The method can easily be implemented with a corresponding device.
In order to use the method in a starter, one advantageous embodiment of the invention provides that in a device for starting a starter motor there is provision that a device for detecting a state of engagement of a pinion with a corresponding gearwheel, in particular a state of engagement of a starter pinion with a starter, is provided. The device comprises, in accordance with the above, an energization section for energizing a starter relay in order to switch the pinion, and a sensing section for sensing at least one energization parameter of the energization, wherein a control section is provided in order to form, on the basis of the sensed energization parameter, a relationship with possible pinion positions and to select an associated pinion position for the sensed energization parameter, and therefore to detect the pinion position. In addition, the device according to the invention also comprises an actuator for starting the starter motor, which actuator brings about the starting as a function of the detected position of the pinion, in particular after engagement of the pinion. The starting is advantageously carried out by energizing a corresponding relay.
A further preferred embodiment of the invention therefore also provides that in a starter having a pinion which is to be engaged, a device according to the invention for starting a starter motor is provided. In this way, starters which can be engaged quickly and which are optimized, in particular, for a start/stop function can be implemented.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments of the invention are illustrated in the drawings and explained in more detail in the following description. In the drawings:
FIG. 1 is a schematic perspective view of a section through a starter 100 with a pinion 101 ,
FIG. 2 is a schematic diagram of two profiles of a sensed energization parameter plotted over time in an engagement process,
FIG. 3 is a schematic diagram of a characteristic-curve-like profile of one of the energization parameters according to FIG. 2 ,
FIG. 4 is a schematic circuit diagram of a starter control unit, and
FIG. 5 is a schematic diagram of a plurality of profiles of a sensed energization parameter plotted over time during an engagement process.
DETAILED DESCRIPTION
FIG. 1 is a schematic perspective view of a section through a starter 100 with a pinion 101 . The pinion 101 is switched by means of a relay 110 , so that, in the event of corresponding energization, the pinion 101 engages in a ring gear of the starter 100 . The engagement occurs roughly as follows: the relay—also press-in relay — 110 has a bolt which is an electric contact and which is connected to the positive pole of an electric starter battery, which is not illustrated here. This bolt is led through a relay cover. This relay cover closes off a relay housing, which is attached to the drive end plate by means of a plurality of attachment elements (screws). Furthermore, a draw-in winding or an engagement winding ENW and what is referred to as a holding winding HW are arranged in the engagement relay 110 . The draw-in winding ENW and the holding winding HW both respectively in the switched-on state give rise to an electromagnetic field which flows through the relay housing (made of electromagnetically conductive material), a linearly movable armature 102 and an armature return 103 . The armature 102 has a pushrod 104 , which is moved in the direction of a switching bolt 105 when the armature 102 is drawn in linearly. With this movement of the pushrod 104 with respect to the switching bolt 105 , the latter is moved out of its position of rest in the direction of two contacts, with the result that a contact bridge which is attached to the end of the switching bolt 105 which is positioned on the contacts connects both contacts electrically to one another. As a result, electrical power is conducted from the bolt via the contact bridge to the current feed and therefore to the carbon brushes. The drive motor or starter 100 is energized in the process.
The engagement relay 110 or the armature 102 also has the function of moving, with a pulling element 106 , a lever 107 which is arranged in a rotationally movable fashion the drive end plate. This lever 107 , usually embodied as a fork lever, engages, with two “prongs” (not illustrated here) on its outer circumference around two in order to move a driver ring 108 , clamped in between the latter, toward the freewheel counter to the resistance of a spring, and as a result to engage the starter pinion 101 in the ring gear.
During the engagement process described above, with the various steps at least one energization parameter of the relay 110 , in particular the relay current and the relay voltage, changes. In FIG. 2 , two profiles of an energization parameter are represented plotted against the time. The energization parameter according to FIG. 2 is the current profile of the relay 110 during energization of the engagement winding. One profile represents the sensed current profile, which is also schematically represented in FIG. 3 . The other profile represents the first derivation of the current profile. Various steps of the engagement process can be assigned to the current profile. The engagement process is roughly divided up into the following steps. In an initial state A, all the components which are involved in the engagement process are at rest. When energization occurs, a corresponding current rise 1 is found to occur. After a certain time, the armature 102 starts to move owing to the energization at B, and in the process it compresses the armature restoring spring 102 a . A current drop 2 is found to occur here. In addition, as a result of the movement of the armature 102 and therefore of the associated fork lever 107 , the driver 108 impacts on the fork lever 107 —C—wherein a current rise 3 can be observed. Subsequently, the pinion 101 —D—moves, initiated by the driver 108 , as a result of which in turn a current drop 4 can be observed. The current drop 4 can be observed until the pinion 101 impacts on the ring gear—E—, and the movement initially stops. In this context, a current rise 5 can be observed. After the pinion 101 impacts on the ring gear, the pinion 101 moves into the ring gear—F—, wherein a current drop 6 can be observed. At the end of the engagement, the armature 102 impacts on a stop—G—which limits the engagement process. Correspondingly, a renewed current rise 7 is then found to occur. This characterizing profile occurs to a greater or lesser degree during all engagement processes. In FIG. 2 , the first derivation of the current profile is given in addition to the current profile. On the basis of the two profiles, a simple assignment to the various pinion positions is possible.
FIG. 4 is a schematic view of a circuit diagram. According to the circuit diagram, a starter or starter motor 100 is provided with a start/stop function. The starter 100 also has the relay 110 . On one side, the relay 110 is connected to the positive pole of a battery 130 by means of terminals KL 30 . The negative pole of the battery 130 is grounded by means of the terminal KL 31 . On another side, the starter 100 is coupled by the relay 110 to a control unit—Starter Control Unit SCU. The control unit SCU has various inputs and outputs, including KL 87 , KWR, CANH, CANL, Emergency off, KL 31 , GND vehicle, GND, KL 30 p , KL 50 r , KL 50 s , KL 45 , KL 50 t . The control unit is grounded by means of a screwed connection to the motor. KL 31 is the battery ground. KL 30 therefore denotes a supply of the battery with a voltage of +12V. KL 50 denotes the direct energization of the holding winding HW and of the engagement winding ENW from the motronic unit. KL 30 p denotes the connection to the +12V battery supply in the control unit SCU. KL 50 r denotes the connection to the +12V supply to the holding winding HW, the engagement winding ENW and the switching winding STW. KL 50 s denotes the connection to the ground of the switching winding STW. KL 45 denotes the connection to the +12V battery supply from the control unit SCU, that is to say starter energization when the switching elements S 1 to S 3 switch, the latter being switched together or individually. KL 50 t denotes the connection to the ground at the holding winding HW and the engagement winding ENW. S 0 denotes a main switch of the control unit SCU. By this means, the control unit SCU, which is also referred to as a power component, is switched. S 1 -S 3 denote switches or switching elements for switching the starter current. For this purpose, the resistances R 1 to R 3 are connected in parallel. The switching element S 4 serves to switch the energization of the holding winding HW and of the engagement winding ENW by means of the control unit SCU. The switching element S 5 switches the energization of the switching winding STW. As a result, the various switching elements S 1 -S 4 , Süa/b, a shunt and other electrical components such as diodes and the like are contained internally. The control unit SCU is connected via the terminal KL 30 p to a common node by the starter to the positive pole of the battery 120 . Via the terminals KL 50 r , KL 50 s , KL 45 and KL 50 t , the control unit SCU is connected to the relay 110 of the starter 100 . In addition, a motronic unit 140 is provided which is coupled via a terminal KL 50 L by the line to the terminal KL 50 r between the control unit SCU and the relay 110 . The control unit SCU, the motronic 140 and the relay 110 are constructed as follows and function as follows. A power supply of the control unit SCU, that is to say the logic component, is implemented by means of the terminal KL 87 . KWR denotes a crankshaft reference signal for, inter alia, positioning the crankshaft. CANH denotes a CAN high signal and CANL a CAN low signal. These signals function as signals for a BUS system (controller area network) for performing further control.
A voltage can be sensed, alternatively or in combination, as further energization parameters. The corresponding profiles are illustrated in FIG. 5 . FIG. 5 shows the corresponding profiles. When the engagement winding is energized and the resulting movement sequence of the relay armature 102 occurs, a relay current (RS in FIG. 2 and FIG. 5 ) which changes over time is produced. The profile in FIG. 2 and that in FIG. 5 are similar. The changing relay current in turn brings about a change in the magnetic field of the coil of the engagement winding through which the current flows. The change in the magnetic field of the engagement winding ENW in turn induces a voltage in the switching winding STW, which voltage can be observed at the terminal KL 50 s as U 50 s . The unenergized switching winding STW is therefore used as a measuring sensor. During the chronological sequence, the voltage U 50 s exceeds the voltage U 50 r at the terminal KL 50 r once. At this time, engagement of the pinion has certainly occurred. This process is illustrated by the square wave curve ON. In order to reliably detect the engagement, the voltage U 50 r is therefore subtracted from the voltage U 50 s . If the value is above a corresponding limiting value and if a current rise occurs thereafter, it is therefore the case when this condition is met that the pinion has engaged. In addition, a safety redundancy can be taken into account. This may have as condition the fact that a predetermined time limit after the beginning of the energization of the relay is exceeded. The time limit can be adapted in accordance with earlier empirical values, for example in a self-learning adaptation process.
|
The invention relates to a starter ( 100 ), to a device for starting a starter motor, to a device for detecting an engaged state of a starter pinion, to a method for starting a starter motor, to a method for detecting an engaged state of a pinion ( 101 ) in a corresponding gearwheel, to a computer program and to a computer program product, wherein the method for detecting an engaged state of a pinion ( 101 ) in a corresponding gearwheel, in particular an engaged state of a starter pinion in a gear rim of a starter ( 100 ), comprises applying a current to a starter relay ( 110 ) for switching the pinion ( 101 ) and detecting at least one current flow parameter of the current flow, wherein the detected current flow parameter is set in relation to potential pinion positions and a pinion position associated with the detected current flow parameter is selected and is thus detected.
| 5
|
BACKGROUND OF THE INVENTION
This invention relates to a process and device for detecting the presence of insects or insect larvae in a solid substrate, e.g. wood, by observing their specific behavior (behavioral pattern).
Insects and insect larvae living in wood cause, in some cases, considerable damage to timber and artificial objects. The early detection of noxious organisms in wood is rendered difficult by the lack of effective tests operating free from interference, as is the establishment of the effectiveness of treatment measures. The standard specifications, which are associated with long exposure times of the test organisms, for the determination of the effectiveness of wood protection agents, serve, as a rule, also as a--time --intensive--basis for the testing of new active substances in the foreground of production. In this case, too, there is a lack of test processes with which changes in the behavior of test organisms can be detected rapidly and reliably.
In industrial practice, a determination of the behavior of insects (insect larvae) living in wood is
5 undertaken in accordance with the standards, DIN EN 20, DIN EN 21, DIN EN 22 and DIN EN 47. In this case, the number of surviving test organisms is employed to draw conclusions concerning changes in behavior; furthermore, these standards permit observations using X-ray systems. In basic biological research, since the invention of the carbon microphone, repeated use has been made of devices which make audible, or record in a nonspecific manner, the noises generated by insects (insect larvae) living in wood. Note A. E. EMMERSON and R. C. SIMPSON 1929 in Science, 1929, Vol. 69, pages 648-649.
The above indicated DIN processes for the determination of changes in behavior of insects or insect larvae living in wood require, in some cases, very long exposure times of the test organisms (between 6 and 52 weeks, depending upon the type of organism) and, in such a case, do not permit any guaranteed statements concerning the temporal progression of changes in behavior. An unambiguous determination of the current behavior of the test organisms is (without suspending the test), therefore, impossible.
The processes employed in basic biological research for a specific set of problems record noises and vibrations in an entirely non-specific manner. In the case of the construction of the test arrangement in low-noise and low-vibration chambers, it is possible to detect in a controlled manner the noises and vibrations generated by insects (insect larvae) living in the wood.
SUMMARY OF THE INVENTION
The object of the process, according to the invention, is to detect the presence and behavior of insects or insect larvae living in a solid substrate, preferably wood, with the aid of simple means, in a manner free from interference.
According to the invention, this object is achieved in that the substrate vibrations generated by the insects or insect larvae, or the sound generated by the insects or insect larvae, are measured and correlated with the behavior (behavioral pattern) causing the substrate vibrations or sound, and in that the result of this correlation is automatically displayed.
Before carrying out the process, according to the invention, in the first instance, the behavioral repertoire of the organism is established by observation under conditions which are as natural as possible. The recording of the substrate vibrations or sound phenomena generated by the organism takes place contemporaneously with the observations. After determination of the behavioral repertoire, the signals which are characteristic of each relevant behavior (behavioral pattern) are investigated for common features in duration, form and spectrum. Those signal properties which describe a behavior in a manner which is as far as possible unambiguous and thus delimit it optimally as against the signal properties of the other behavior patterns, are established as a "prescribed reference." The signal processing steps leading to the prescribed references are established as an "evaluation specification". Both a "prescribed reference" and also an "evaluation specification" are correlated with each relevant behavior from the behavioral repertoire of the organism.
The process according to the invention is implemented by quasi-simultaneous execution of the signal detection, of the "evaluation specifications", of the testing against the "prescribed references" and the resultant output is realized by means of the device claimed. In this manner (also in signal mixtures), patterns typical of behavior are detected with very great reliability and are correctly correlated with the causative behavior. The presence of an active organism can be detected immediately, and the current behavior of the organism can be interrogated at any time, since "on-line" results are available.
According to the invention, in place of the substrate vibrations generated by the organisms, the sound generated by them, preferably ultrasound, can be used for the detection of their behavioral patterns, in the event that a contact-free process is expedient.
For test environments with high interference levels or for signals which are very difficult to distinguish, according to the invention, both the substrate vibrations generated by the organisms and also the sound generated by them, preferably ultrasound, are used for the detection of their behavioral patterns. The simultaneous evaluation of both signals increases the reliability of the process according to the invention, and the susceptibility to interference is further reduced.
According to a preferred embodiment of the process claimed according to the invention, in the frequency range from 0.01 mHz to 150 kHz, the frequency signals of the substrate vibrations generated by the insects or insect larvae or of the sound generated by the insects or insect larvae, possibly together with the vibration or sound frequency signals (interfering frequency signals) originating from the environment, after possibly preceding amplification, are measured or recorded, are evaluated after filtering out the interfering frequency signals, and are subsequently compared with one or more prescribed references, preferably signal form or level frequency, which are obtained in the frequency range form 0.01 mHz to 150 kHz, preferably from 100 Hz to 15 kHz, and which are characteristic of the behavior of the pertinent noxious insects or insect larvae in the solid substrate, and the result is automatically indicated.
According to a particular refinement of the process according to the invention, behavioral patterns are evaluated, which take place as reactions of the organisms to special specific or alien vibrations or sound phenomena. In this case, in the first instance such signals are transmitted in an appropriate form into the substrate, preferably wood, and subsequently the reactions of the test organisms are evaluated. This particular refinement is predominantly used in the case of insects living in the wood which have available specifically associated communication mechanisms (e.g. knocking signals in the case of termites). In this case, vibration frequency signals or sound frequency signals situated in the frequency range form 1 mHz to 150 kHz, preferably form 1 Hz to 15 kHz, are preferably transmitted.
It is, accordingly, an object of the invention to provide a system for the detection of insects or insect larvae living in a solid substrate, usually wood.
It is a further object of the invention to provide a sound and vibration detecting system for determining the presence of insects or larvae in a wooden structure.
It is another object of the invention to provide a method for detecting the destruction of wooden structures by analyzing the sound and vibration patterns of wood-eating pests and comparing them to the sound and vibration patterns of on-going activity.
It is still another object of the invention to provide a method, using a microcomputer, to detect pest destruction in a wooden structure by analysis of insect damage and movement activity.
BRIEF DESCRIPTION OF THE DRAWINGS
Further details of the process according to the invention, as well as the device according to the invention, for carrying out the process, are described in greater detail with reference to the accompanying drawings.
In the drawings:
FIG. 1 shows the determination of valuation specifications and prescribed references as a basis for the implementation of the process according to the invention using the substrate vibrations or sounds generated by the organisms;
FIG. 2 shows the progress diagram of the process according to the invention, which is at the same time the functional principle of the device, according to the invention, for carrying out the process, and
FIG. 3 shows the device, according to the invention, for the automatic detection of insect and larval behavioral patterns.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows diagrammatically the progress of the preliminary operations typical of the process, which are required for an automatic detection of behavioral patterns.
In the first instance, the behavioral repertoire of the desired organism species is established by observation (the left hand side of FIG. 1a, dotted-line sequence). For this purpose, the organisms are, as a rule, observed in red light, and under optimal temperature and optimal humidity conditions, in glass-covered damage passages, and their activities are recorded in a protocol. Contemporaneously with these observations, the substrate vibrations generated by the organisms are measured, recorded and archived (the right hand side of FIG. 1a, dashed-line sequence).
After the behavioral repertoire of the organisms has been established (in FIGS. 1b, and 2 consisting, for example, of the two behavioral patterns "damage" and "movement"), the archived vibration signals are assigned to the behavioral patterns in accordance with the observation protocol. Thus, for each behavioral pattern a collection of vibration signals (FIG. 1b) is created, which represents the basic data material for the further process steps.
The object of the process step (FIG. 1c), which now follows, is the ascertainment of signal processing specifications with which the signals of a behavioral pattern, on the one hand, can be perfectly detected and, on the other hand, can be optimally delimited against the signals of the other behavioral patterns (and against interfering noises). In order to ascertain such signal processing specifications, a great variety of courses can be adopted, as described in literature, e.g. W. WEHERMANN in "Correlation Technology", Ernst-Verlag 1980; H. SPATH in "Cluster Analysis Algorithms", Oldenburg-Verlag 1977. Within the context of the present invention, the following procedure has proved to be effective:
1. Frequency analysis of all vibration signals of a behavioral pattern.
2. Selection of a frequency band which is represented in all signals of this behavioral pattern.
3. Determination of the "typical" signal form in this frequency band by filtering, and communication of all signals of this behavioral pattern.
4. Establishment of criteria for the detection of the signal commencement and the signal end (H. NEY in "AUTOMATIC VOICEPRINT COMPARISON BY COMPUTER. Int. Conf. Security through Science and Engineering, 1980, 121-130).
5. Signal comparison of all (filtered) signals of this behavioral pattern against the "typical" signal form according to the process of dynamic optimization (dynamic programming), and determination of the (permissible) similarity coefficients within the behavioral pattern (H. SPATH 1977 Loc. cit., H. SAKOE & S. CHIBA in "Dynamic Programming Algorithm Optimization for spoken word recognition. IEE Trans. on Acoustics, Speech and Signal Processing, 1978, Vol. ASSP-26, 43-49).
6. Signal comparison of all (filtered) signals of the other behavioral patterns against the "typical" signal form in accordance with the same process, and determination of (impermissible) similarity coefficients as compared with the other behavioral patterns.
7. Establishment of the confidence interval of the similarity coefficient for the signal comparison with respect to the "typical" signal form.
8. In the event that no clear delimitation of the confidence interval should be possible, either the "typical" signal form can be modified (elimination of "outliers"), or another frequency band can be evaluated.
9. Repetition of points 1 to 8 for the other behavioral patterns.
After the completion of this process step, precisely defined specified processing references and processing specifications (FIG. 1d) are established, by means of which a vibration signal is either correlated with one of the behavioral patterns or rejected as unknown. The reliability of the signal detection is dependent upon the specified processing references and processing specifications employed.
The last process step according to the invention (FIG. 2) is, in particular, the automatic execution of signal detection (in accordance with the prescribed processing references and processing specifications of FIG. 1d) and the result output.
FIG. 2 shows the sequence of the process according to the invention and, at the same time, the functional principle of the invention, for the detection of behavioral patterns with reference to the example of a practice-related application (detection of attack by noxious organisms in the roof truss).
A mixture of "interfering" signals (from the environment) and of "useful" signals (generated by the organism) passes out of the wood to the vibration recorder and is in the first instance amplified (FIG. 2a).
This signal mixture is fed to an analog/digital converter, which measures the analog input signal and converts it into a (digitally usable) sequence of numbers (FIG. 2b).
A microcomputer system (FIG. 2c) detects this sequence of numbers and in the first instance executes signal filtering in accordance with the prescribed details of FIG. 1d. To the extent that the computing power of the hardware employed is not sufficient for a digital signal filtering, this signal filtering takes place already before the analog/digital converter.
The signal preprocessed in this manner is (in accordance with the prescribed details of FIG. 1d) evaluated and compared with the prescribed references (see FIG. 1d). If it was possible to discover a behavior-typical pattern in the signal mixture, then the behavior (in this case: "DAMAGE" or "MOVEMENT") is output as the result, otherwise "UNKNOWN" or the like.
In this way, in the case of the above indicated practice-related application (detection of attack by noxious organisms in the roof truss), it is possible to make rapidly, reliably and in a manner free from destruction, the statement as to whether attack by noxious organisms is present; over and above this, it is also possible to determine the nature of the noxious organism (by multiple tests or process modifications).
The device according to the invention can be fitted or secured as a complete unit on the object to be tested. According to another embodiment, the recorders and preamplifiers can be secured to the test object separately from the microcomputer and analog/digital converter. In this case, the collected signals are passed via connecting lines to the microcomputer.
With the aid of the process, according to the invention, the temporal progression of the effectiveness of a treatment with wood protection agent may be established in a simple manner and without great expenditure of time, whether it be in the case of a preventive wood protection treatment or in the case of wood already attacked by noxious insects or insect larvae. The decline of the activity of noxious insects or insect larvae may be ascertained by means of a plotted time-action curved.
It is accordingly not necessary, as previously, to undertake a splitting of the small pieces of wood attacked in the course of test experiments, in order to be able to examine the number of noxious insects or insect larvae killed.
Over and above this, it is possible, with the aid of the device according to the invention, to carry out a permanent monitoring of valuable wooden objects set up in premises or regions which are particularly at risk.
According to an advantageous embodiment of the process, the position of the noxious insects or insect larvae in the substrate attacked, preferably wood, can also be established in anon-destructive manner, it is possible to undertake a controlled treatment of extended objects with wood protection agents.
FIG. 3 shows diagrammatically the assemblies of the device, according to the invention, for carrying out the process; in this connection, not all assemblies and recorders or transmitters which have been represented need necessarily to be present; the existence or omission of individual components will be decided by the requirements which (depending upon the type of organism and of wood in each instance) are placed on the signal detection.
Over and above this, for example, the assembly for the signal filtering can be dispensed with if the computing power of the microprocessor permits a digital signal filtering or if this filtering is executed by a specific signal processor.
According to a particular embodiment of the process according to the invention and of the device according to the invention, it is possible to establish the position of insects or insect larvae, living in a solid substrate (wood), in their substrate, preferably wood. The process utilizes the substrate vibrations or sound, generated by these organisms themselves, for the determination of position. Using two or more vibration recorders or sonometers, these vibrations or sound are picked off at least two opposite sides of the substrate, and the time difference with which the signals reach the recorders is measured. The location of the organism in the wood may be precisely determined from the time differences and having regard to the speed of propagation of the signals in the wood. A quasi-passive "echo sounding" principle is used for the determination of position.
|
The process of detecting the presence of insects or insect larvae in a solid substrate, e.g. wood, in which the behavioral patterns of the insects to be detected are established. These behavioral patterns are compared to actual noise and vibration patterns detected in the substrate, after extraneous noise is filtered from the actually detected information and the data has been converted to analog form. The actual analysis is performed by a microcomputer. The microcomputer analysis yields an output indicative of damage or movement activity or lack of such activity.
| 0
|
This application claims the benefit of U.S. provisional patent application No. 60/491,709, filed on Aug. 1, 2003, the entire disclosure of which is incorporated herein by this specific reference.
BACKGROUND OF THE INVENTION
The present invention relates to systems for vacuuming, blow nozzle cleaning, or extracting fumes from mass transit vehicles, and more particularly to any such system which employs festooned hoses.
Commonly, public transit systems, having a large number of passenger buses, employ vacuuming, blow nozzle cleaning stations, or fume extracting systems for such buses which comprise one or more lanes or service bays into which the bus is driven, adjacent to vacuuming, fume extracting, or cleaning equipment. The vacuuming, fume extracting, or cleaning equipment typically comprises a motorized or pneumatically driven vacuum pump or blower, additional vacuum pump (if needed), material collection system, and dumpster container, from which one or more lengthy hoses extend. At the distal end of each hose, which may be one or more inches in diameter, is provided a lance and nozzle. As is well known in the art of vacuuming, blow nozzle cleaning, or fume extraction systems, the hose functions to communicate the vacuum or blow nozzle air flow generated by the motorized vacuum pump or blower to the nozzle. Dirt, paper, or fumes are either picked up or blown away, as the case may be, by the nozzle, when being removed from the area being vacuumed or cleaned. Vacuumed material moves through the hose, ducting, and appropriate collector, and are deposited into a dumpster container to be emptied later, when full. Fume extraction systems do not require a collection system and dumpster container, but are usually exhausted to atmosphere directly. In prior art vacuuming, blow nozzle cleaning, and fume exhaust stations for vacuuming, cleaning or extracting fumes from mass transit buses and the like, an operator enters the bus for cleaning or goes to the bus engine exhaust pipe for fume extraction, which is parked in the cleaning station or service bay, carrying the lance end of the vacuum equipment for the purpose of vacuuming, cleaning, or extracting fumes from the bus.
A problem in such prior art vacuuming, blow nozzle cleaning, and exhaust extraction stations, is that the hose, because of its length, can be extremely unwieldy, making the vacuuming, cleaning, or fume extraction function difficult. Such hoses are most often deployed on hose reels, or manual counterbalance festoons. Hose reels include a large mounting structure system and a strong retraction mechanism to ensure that the hoses remain coiled about the reel, typically suspended from an adjacent wall or ceiling, except when extended for use. The pull forces exerted by the retraction mechanism makes hose manipulation by an operator difficult, can be a safety problem, because of the employment of large and powerful moving parts, and can also cause hose damage over time. As a practical matter, because of the retraction mechanism, hose reels typically require a remote control system at the distal (lance) end, so that the operator can alleviate the pulling force of the retraction mechanism when hose extension and manipulation are required. Such systems, however, are expensive and unreliable. Existing hose reel systems often fail or are more costly because of vacuum system plugging, are aesthetically displeasing, and are expensive to install or relocate. Manual counterbalance festoons utilize a counterweight that pulls the hose back to the fully retracted position. The “pull-back” force is greatest when the hose is fully extended and least when the hose is fully retracted. The hose operators must exert a continuous force against the counterweight “pull-back” while manipulating the extended hose and therefore becomes a burden to use.
What is needed, therefore, is a system for retaining lengthy hoses which eliminates the need for hose reels or manual counterbalance festoons, but permits the hoses to be retracted to a neat, attractive, and out-of-the-way disposition when the system is not in use, and permits the hoses to be readily deployed and manipulated, without “pull-back” during system usage.
SUMMARY OF THE INVENTION
Accordingly, there is provided an automatic hose festooning system constructed in accordance with the principles of the present invention which meets the foregoing objectives.
More particularly, in one aspect of the invention, there is provided a festoon hose handling system for mass transit vehicles such as buses, or the like, which comprises a motorized vacuum or fluid pressure (blower) source, an additional motorized vacuum pump (if needed), a hose connected to the vacuum source, a distal end of the hose, through which fluid can pass, and a festoon assembly for suspending the hose from a suitable support, such as a ceiling or wall, wherein the hose is pneumatically extendable and retractable.
In a preferred embodiment, as just noted above, a control switch is disposed in proximity to the hose distal end, such as on the lance portion of the hose, or some other stationary remote location, for pneumatically extending and retracting the festooned hose. The festoon assembly preferably comprises a festooning tube having a movable piston disposed therein, and a chamber disposed adjacent to the piston. The chamber has a flow passage connected thereto for permitting the pressure in the chamber to be changed, in order to move the piston in a desired direction. Preferably, the flow passage includes a valve therein for controlling flow, which is selectively actuatable between a closed and an open position. In one embodiment, this valve comprises a three-position valve which is selectively actuatable between the closed position, an open to vacuum position, and an open to atmosphere position. Alternatively, in another embodiment, the aforementioned flow passage comprises two connected flow passages, wherein the valve is disposed in one of the flow passages, and a second valve, also selectively actuatable between a closed and an open position, is disposed in a second one of the flow passages.
A cord is attached to the piston on one end, and to the festooned hose on a second end, wherein when the piston moves in a first direction, the cord moves with the piston in the first direction to extend the hose, and when the piston moves in a second direction, the cord moves with the piston in the second direction to retract the hose. A brake is preferably disposed adjacent to the cord at a predetermined location, and is selectively actuatable between a set position, wherein the cord is prevented from moving, and a released position, wherein the cord is free to move. A plurality of pulleys are provided about which the cord is arranged to travel when moving in the first or second directions. Advantageously, because the system does not employ a hose reel, which would necessitate fully coiling the hose thereabout, a control wire may be disposed along the festooned hose along a substantial length thereof, electrically connecting the control switch to a control unit, rather than having to use a wireless remote control system.
In another aspect of the invention, there is provided a festoon hose handling system for mass transit vehicles such as buses, which comprises a motorized vacuum or fluid pressure source and a hose connected to the vacuum or fluid pressure source, and a festoon assembly for suspending the hose from a suitable support. The festoon assembly comprises a cord attached to the festooned hose on one end and to a movable member on a second end, wherein the movable member is actuatable to selectively retract and extend the hose. A control switch is preferably disposed in proximity to a distal portion of the festooned hose, such as on the lance portion thereof, or in a suitable remote location adjacent thereto, for actuating the movable member, which is preferably pneumatically driven.
Also provided in the inventive system is a festooning tube in which the movable member is disposed, and a chamber located adjacent to the movable member. The movable member, or piston, is arranged to reciprocate within the festooning tube responsive to changes in pressure in the chamber.
A flow passage is connected to the chamber for permitting the pressure in the chamber to be selectively changed, and a valve is disposed in the flow passage which is selectively actuatable between a closed and an open position. The flow passage connects the chamber to the vacuum or fluid pressure source, through the valve.
In operation, the system has a stowed configuration, wherein the hose is stowed in a retracted condition, and an extended configuration, wherein the hose is extended in an operational condition. The system further has a retracted configuration, in which configuration the hose is permitted to retract to the retracted condition from the extended condition, but it is not stowed away.
In still another aspect of the invention, there is disclosed a method of vacuuming, cleaning, or extracting fumes from a mass transit vehicle such as a bus or the like, using a system having a festooned hose which is suspended from a suitable support using a festoon assembly comprising a cord attached to the hose on one end, and to a movable member on a second end. The disclosed method comprises steps of actuating a control switch to cause the movable member and connected cord to move in a first direction toward the festooned hose, thereby extending the festooned hose to a desired cleaning location, and maneuvering the festooned hose as desired to vacuum, clean, or extract fumes from the desired location and any other desired locations within a range of travel of the vacuum hose and connected cord. A third step is disclosed, which comprises actuating the control switch to cause the movable member and connected cord to move in a second direction opposite to the first direction, thereby retracting the festooned hose to a storage position.
The inventive festooning system functions to advantageously provide immediate hose availability, reduce the time and motion needed to press control buttons, eliminates the need for remote control transmitter handset handling, and simplifies and eases hose handling by keeping the hose off the vehicle floor during cleaning operations.
The invention, together with additional features and advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying illustrative drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a is a schematic view of one embodiment of a festooned vacuuming, blow nozzle cleaning, or fume extraction system constructed in accordance with the principles of the present invention, wherein the hose and associated lance are disposed in a fully retracted position;
FIG. 1 b is a schematic view similar to FIG. 1 b , showing a second embodiment of the invention;
FIG. 2 a is a schematic view of the embodiment of FIG. 1 a , wherein the hose and lance are in an extended position for vacuuming, blow nozzle cleaning, or extracting fumes from a mass transit vehicle or the like;
FIG. 2 b is a schematic view, similar to FIG. 2 a , of the embodiment of FIG. 1 b;
FIG. 3 a is a schematic view, similar to FIGS. 1 a and 2 a , wherein the system is in a retracting orientation for the purpose of retracting the extended hose and nozzle to the stowed position shown in FIG. 1 a ; and
FIG. 3 b is a schematic view, similar to FIG. 3 a , of the embodiment of FIGS. 1 b and 2 b.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now more particularly to FIGS. 1 a - 3 b , there is shown an automatic festooned vacuuming, blow nozzle cleaning, or fume extraction system 10 which is constructed in accordance with the principles of the present invention. The system 10 comprises a motorized vacuum blower source 12 and, optionally, a motorized vacuum pump 13 , both of known construction. In a preferred embodiment, the vacuum blower 12 and the vacuum pump 13 have a combined negative pressure rating of approximately 40″ to 200″ water column. In certain applications, other vacuum or pressure fluid sources, such as, for example, a compressed air powered venturi vacuum pump, may be used. Compressed air powered venturi vacuum pumps of this type, which are small (about 1″×6″), inexpensive, easy to install, have no moving parts, and are excellent for on/off applications, may be particularly suitable for certain applications, particularly those where compressed air is available, one festoon is being installed, and the vacuum source must be a substantial distance away from the festoon system. An upright cylinder or festooning tube 14 includes an air-tight or close tolerance fitting piston 16 which is free to reciprocate vertically within the festooning tube 14 . Proximally of the piston 16 , at a lower end of the festooning tube 14 , is disposed a cylinder chamber 18 , from which extends a main flow line 20 , so that fluid (air) may flow through the main flow line 20 into and out of the cylinder chamber 18 .
Referring now more particularly to FIGS. 1 a , 2 a , and 3 a , a first embodiment of the present invention is illustrated. In this embodiment, the main flow line 20 branches into two flow lines, namely first branch line 22 and second branch line 23 . The first branch line 22 extends from the main flow line 20 , and leads to a first valve 24 , the function of which will be described hereinbelow. The second branch line 23 extends from the main flow line 20 , and leads to a second valve 26 , the function of which will also be described hereinbelow. A third flow line 28 extends from a downstream end of the second valve 24 to a low pressure side of the vacuum pump 13 (if one is desired). A fourth flow line 29 extends from the high pressure side of the vacuum pump 13 and leads to the low pressure side of the vacuum blower 12 .
The piston 16 is connected to a cord and pulley system comprising a cord 30 disposed about pulleys 32 , 34 , and 36 . The pulley 32 is optional and is attached to the piston 16 . One end of the cord 30 extends through the pulley 32 , out of the upper end of the festooning tube 14 , about the pulley 34 , and then about the pulley 36 , which is suspended from an overhead location, such as the ceiling. When pulley 32 is used, the other end of the cord 30 extends out of the upper end of the festooning tube 14 and is attached to an overhead support 37 . Pulley 34 and the overhead support 37 are both centered over the festooning tube 14 so as to keep the piston 16 in vertical orientation while it reciprocates in the festooning tube 14 . When pulley 32 is not used, one end of the cord 30 is attached directly to the piston 16 , and the other end of the cord 30 extends out of the upper end of the festooning tube 14 , about the pulley 34 , and then about the pulley 36 . The other end of the cord 30 is attached to a hose 38 . A brake 40 is associated with the cord 30 , for a purpose to be described hereinbelow.
The brake 40 functions between set and released configurations, as will also be described hereinbelow. A lance portion 42 is disposed on a distal end of the hose 38 , and the proximal end of the hose is attached to the motorized vacuum pressure or blower source 12 mounted in a suitable location. The low pressure side of the source 12 is connected to the high pressure side of the vacuum pump 13 (if present). The lance portion 42 may include a handle, of known construction in the art, for convenient vacuuming, or cleaning operation. A suitable filter (not shown), known in the prior art, such as a cyclone collector assembly or dust collector, is employed to collect the dirt and debris recovered by the lance portion 42 , metal ducting 43 , and the associated hose 38 when vacuuming dust, paper, or material.
In FIG. 1 a , the system 10 is illustrated in its stowed configuration. In this configuration, the piston 16 is fully retracted to the bottom end of the festooning tube 14 , and both two-position valves 24 and 26 are closed. Because the piston 16 is retracted, the cord 30 , attached thereto, is fully retracted as well, meaning that the hose 38 , to which it is attached, is drawn upwardly to a suspended position adjacent to the pulley 36 , as shown. If desired, the lance portion 42 may be raised to the roof by means of additional optional pulleys such as pulley 44 , for convenient storage, using a provided hook 46 or the like, and a cord 47 , the other end of which is fastened to a cleat 48 on the wall or other convenient location.
The embodiment of FIG. 1 b is similar to that of FIG. 1 a , also illustrating the system 10 in a fully retracted condition. The primary difference between the two embodiments is that, in the embodiment of FIG. 1 b , a single three-way valve 49 is employed, rather than the first and second valves 24 and 26 employed in the FIG. 1 a embodiment. Thus, in FIG. 1 b , the main flow line 20 leads to an upstream side of the three-way valve 49 , and the third flow line 28 extends from the downstream side of the valve 49 . The valve 49 is in a closed position in the FIG. 1 a (fully retracted) configuration.
Now with reference to FIGS. 2 a and 2 b , the system 10 is shown in an extended or “fed out” configuration, for the purpose of vacuuming, cleaning, or extracting fumes from one or more mass transit vehicles or the like. To extend the hose 38 to an operable position, the operator actuates a control switch 50 which is preferably conveniently disposed on the lance handle portion 42 , as shown, although it may alternatively be disposed in any desired location. One advantage of the present invention over prior art hose reel systems is that the control switch need not be a relatively expensive remote wireless actuator, which uses RF control features known in the art, but may rather be a simple and relatively inexpensive hard-wired actuator, wherein the control wire 52 connecting the switch 50 to a control unit 54 is looped about the length of the hose 38 , from the lance handle portion 42 back to the control unit 54 , which may be mounted on the wall 55 or other suitable location. The use of a hard wire looped about the hose is feasible because the hose is not stored in a coiled configuration about a hose reel, which would twist and damage the wire as the hose reel rotates.
Now referring particularly to FIG. 2 a , when the control switch 50 is actuated, valve 24 opens, while valve 26 remains closed, thereby directing air from the atmosphere into the system through the valve 24 , as shown by arrows 56 . Because the valve 26 remains closed, the air is directed through the second branch line 23 and main flow line 20 into the cylinder chamber 18 , thereby causing the piston 16 to move upwardly within the festooning tube 14 . Movement of the piston 16 upwardly in turn causes the cord 30 to move upwardly.
In the FIG. 2 b embodiment, actuation of the control switch 50 causes the valve 49 to move to an open to atmosphere position, as shown, thereby directing air from the atmosphere into the system through the valve 49 , as shown by arrows 57 . Because the valve 49 is in its open to atmosphere position, the air is directed through the flow line 20 into the cylinder chamber 18 , thereby causing the piston 16 to move upwardly within the festooning tube 14 . Movement of the piston 16 upwardly in turn causes the cord 30 to move upwardly, as is the case also with the FIG. 2 a embodiment.
Thus, in both the FIGS. 2 a and 2 b embodiments, actuation of the control switch 50 ultimately causes the cord 30 to move upwardly. This action, in turn, causes the brake 40 to be released, thereby permitting the cord 30 to play outwardly from the pulley 36 , as shown in both FIGS. 2 a and 2 b , thus releasing the hose 38 and permitting the operator to utilize the lance handle portion 42 for desired cleaning operations. A slide gate valve 41 , forming a part of the vacuum source 12 , is also opened by actuation of the control switch 50 , thereby delivering vacuum pressure or blow nozzle air to the lance portion 42 .
Now with reference to FIGS. 3 a and 3 b , at the conclusion of vacuuming or cleaning operations, when it is desired to retract the hose 38 to its storage position, the control switch 50 may be depressed in order to actuate the system to a retract mode. In the FIG. 3 a embodiment, initiation of the retract mode causes valve 26 to close and valve 24 to open, thereby permitting a flow of air from the cylinder chamber 18 through flow lines 20 and 22 , then through the valve 24 , to the flow lines 28 and 29 , which lead to the vacuum blower 12 . Arrows 58 illustrate the direction of airflow. Since the valve 26 is closed, no air flows through the second branch line 23 . The pressure drop in the cylinder chamber 18 , due to the open valve 24 , causes the piston 16 to retract downwardly within the festooning tube 14 , as shown, thus causing, in turn, the cord 30 to retract toward the pulley 36 , in the direction of arrow 58 . Ultimately, this action permits the hose 38 to be stowed in the manner shown in FIG. 1 a . When the cord 30 reaches its fully retracted position, as shown in FIG. 1 a , the brake 40 becomes set once again, holding the cord 30 in its retracted position.
In the FIG. 3 b embodiment, at the conclusion of the cleaning operation, when it is desired to retract the hose 38 , the control switch 50 is actuated, thus initiating the retract mode. This mode is initiated by causing valve 49 to move to the open to vacuum position, as shown in FIG. 3 b , thereby permitting a flow of air from the cylinder chamber 18 through flow line 20 and the valve 49 , as indicated by arrow 58 , to flow lines 28 and 29 , which lead to vacuum pump 13 (if needed) and the vacuum blower 12 . Since the valve 49 is in the open to vacuum position, no air flows through the valve to the atmosphere. The pressure drop in the cylinder chamber 18 , due to the valve 49 being in the open to vacuum position, causes the piston 16 to retract downwardly within the festooning tube 14 , as shown, thus causing, in turn, the cord 30 to retract toward the pulley 36 , in the direction of arrow 58 . Ultimately, this action permits the hose 38 to be stowed in the manner illustrated in FIG. 1 b . When the cord 30 reaches its fully retracted position, as shown in FIG. 1 b , the brake 40 becomes set once again, holding the cord 30 in its retracted position.
Regarding the optional pulley 32 , discussed above, it should be noted that the diameter of the festoon piston 16 and the use or non-use of pulley 32 determines the festooned hose lifting force. The usage of pulley 32 permits the festoon tube piston to travel one-half of the distance that the hose travels, and thereby allows longer lengths of festooned hose in areas of low head room. However, using pulley 32 causes the festoon piston to have one-half the lifting force. Thus, there is a design trade-off which dictates the employment or non-employment of the piston 32 , depending upon individual application.
Thus, the resultant system comprises a festoon hose 38 which is suspended from the ceiling or other suitable overhead support to create a convenient mechanism for storing and maneuvering the hose during use. The inventive system 10 may be installed in an existing bay of a transit vehicle facility, such as a fueling or service station or the like. The advantages of such a system include:
a) the provision of an easily available hose to the operator;
b) the ability to use a reliable, hard-wired, customized lance handle for controlling the hose feed, retract, and vacuum functions, thereby eliminating the need for relatively unreliable, expensive, and fragile remote control handsets;
c) greater air flow and elimination of plugging of the vacuum or cleaning system caused by hose reel elbows and turns;
d) retraction of the hose with a user friendly pneumatic, rather than gear-driven, retraction force;
e) suspension of the hose by the cord 30 at the entry door of the transit vehicle, or near the bus engine exhaust tail pipe, thereby making it much easier to manipulate the hose in or around the vehicle, relative to alternative hose reel systems or hose brackets, wherein the hose must be dragged along the floor surface of the facility;
f) creation of a less congested, aesthetically pleasing fuel island and cleaning area;
g) a simplified duct system;
h) energy efficient, requiring very little electrical power to operate;
i) extremely reliable and easy to maintain; and
j) can be furnished and installed for substantially less cost than prior art hose reel systems.
The apparatus and method of the present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
|
An automatic festoon hose handling system for mass transit vehicles such as buses or the like, includes a vacuum or pressurized fluid source, a hose connected to the source, and a lance portion disposed on a distal end of the hose. A festoon assembly is positioned for suspending the hose from an overhead support. The hose is pneumatically extendable and retractable.
| 1
|
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. patent application Ser. No. 11/685,814 filed Mar. 14, 2007, which claims the benefit of U.S. Provisional Application No. 60/782,458, filed Mar. 15, 2006, which is incorporated herein by reference as if fully set forth.
FIELD OF INVENTION
[0002] The present invention is related to wireless communication systems. More particularly, the present invention is related to a method and system for switching operating modes of a receiver.
BACKGROUND
[0003] Equalizer based receivers typically provide enhanced performance over other types of receivers in many situations. For this reason, equalizer based receivers are often preferred over other types of receivers, such as RAKEs or matched filters (MFs). Unfortunately, this enhanced performance sometimes comes at a cost.
[0004] For example, equalizer based receivers are more complex and may have performance degradation under certain conditions. Additionally, equalizer based receivers typically consume more power than other types of receivers. In fact, in some cases the equalizer consumes more power than any other components.
[0005] It is not necessarily advantageous for a receiver to be always operating in an equalizer mode. Therefore, it would be beneficial if a method and apparatus existed that would switch a receiver from an equalizer operating mode to a different mode when the conditions warranted.
SUMMARY
[0006] The present invention is related to a method and apparatus for switching operating modes of a receiver. The method comprises determining whether a criteria is met to switch the operating mode of the receiver. The operating mode of the receiver is switched from the first mode to a second mode if the criteria is met.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] A more detailed understanding of the invention may be had from the following description of a preferred embodiment, given by way of example and to be understood in conjunction with the accompanying drawings wherein:
[0008] FIG. 1 is a functional block diagram of a receiver in accordance with the present invention; and
[0009] FIG. 2 is a flow diagram of a method for switching operating modes of the receiver of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0010] When referred to hereafter, the terminology “wireless transmit/receive unit (WTRU)” includes but is not limited to a user equipment (UE), a mobile station, a fixed or mobile subscriber unit, a pager, a cellular telephone, a personal digital assistant (PDA), a computer, or any other type of user device capable of operating in a wireless environment. When referred to hereafter, the terminology “base station” includes but is not limited to a Node-B, a site controller, an access point (AP), or any other type of interfacing device capable of operating in a wireless environment.
[0011] FIG. 1 is a functional block diagram of a receiver 100 in accordance with the present invention. The receiver 100 includes a channel estimate (CHEST) block 110 , having M taps, a complex conjugate block 120 , a delay spread estimate block 130 , a selection block 140 (or selection algorithm block), an equalization (EQ) tap update block 150 , having L taps, a switch 160 , having inputs (designated In 1 and In 2 ) and an output, a tapped delay line (TDL) block 170 having L taps, a multiplier 180 , and a summation (SUM) block 190 .
[0012] In the present example, the CHEST block 110 receives the input data sequence (Rx Data) and performs an operation on it to produce a vector “M” elements long that is as estimate of the channel impulse response (CIR), a channel estimate. There are various methods of performing a channel estimate including, but not limited to, linear techniques such as correlations with a known pilot sequence, non-linear techniques such as squelching small path estimates to reduce noise or decision directed methods, and adaptive techniques such as normalized least mean square (NLMS) or recursive least square (RLS) based channel estimates. The CHEST block 110 outputs a signal (h) to the EQ tap update block 150 , the complex conjugate block 120 and delay spread estimate block 130 .
[0013] The complex conjugate block 120 receives a vector of complex numbers as an input, and outputs a vector with each element being the complex conjugate of the corresponding input. The complex conjugate of the CIR may be used to realize a matched filter (MF) method and may be somewhat similar to that of a RAKE receiver, depending on the detail of the channel estimate. For example, if the elements of the channel estimate that do not correspond to a channel path location are squelched, the MF is very similar to a RAKE in performance. The complex conjugate block 120 outputs an MF signal to input In 2 of the switch 160 .
[0014] The delay spread estimate block 130 receives the channel estimate M length vector and computes a delay spread estimate. In one example, the delay spread may be calculated in accordance with the following equation:
[0000]
delay_spread
=
∑
m
=
1
M
d
m
p
m
2
;
Equation
(
1
)
[0000] where d m is the delay corresponding to the m th element of the channel estimation vector and p m is the value of the m th element in the channel estimation vector. The delay spread estimate block 130 outputs its signal to the selection block 140 .
[0015] The selection block 140 receives available data to determine if it is appropriate or acceptable to switch the receiver to the lower power MF receive. Such information may include, but is not limited to, Signal to Interference Ratio (SIR), the estimated channel delay spread received from the delay spread estimate block 130 , the aggressiveness of the transmission being received (computable from the transport format resource combination (TFRC) input, or from the data rate attempted), the energy left in the receiver's battery (power save input), and/or indication from the network that it is permitted to switch. The selection block 140 outputs a signal to the switch 160 . The switch 160 also receives the signal (w) in the input In 1 from the EQ tap update block 150 .
[0016] The equalizer tap update block 150 generates the taps for the equalizer that are used when the receiver 100 operates as an advanced receiver. The output (w) is a vector of L elements. The inner product of the generated taps, w, and the TDL produce the equalizer output.
[0017] The switch block 160 receives either the equalizer taps or the conjugate of the channel estimate and forwards it on to an input of the multiplier 180 . The multiplier 180 takes two vectors as inputs and computes the element-wise product to produce a third output vector. The elements of the output vector from 180 are all added up together in the SUM block 190 to produce either the equalizer or matched filter output, y, depending on which vector the switch 160 selected. In the case of adaptive equalizers, the output is fed back to the tap generation block. Where the MF is used and squelching was done in the channel estimate, the multiplications with zero elements may not need to be performed.
[0018] The TDL block 170 is preferably a shift register that receives the input data (Rx Data) and provides an output comprising a vector where the N elements of the vector are the last M values of the Rx Data signal. The TDL block 170 outputs a signal to the multiplier 180 and a signal (x) to the EQ tap update block 150 . The multiplier 180 outputs a signal to the SUM block 190 . The SUM block 190 outputs the receiver output signal (y), which is also a feedback to the EQ tap update block 150 .
[0019] FIG. 2 is a flow diagram of a method 200 for switching operating modes of the receiver 100 of FIG. 1 . In step 210 , the receiver 100 is operating in equalizer mode. The receiver 100 then determines whether a criteria for switching modes is met (step 220 ). These may include when conditions do not permit the performance advantage of the equalizer mode, when conditions may indicate a preference for the MF operation, or when higher performance is not required. Under those circumstances, it may be beneficial to switch from equalizer operation to MF operation to save power or possibly to improve receiver performance.
[0020] For example, if a high data rate is requested, the SIR is high, the delay spread is low, and the battery life of the receiver 100 is good, then the criteria for switching modes is considered to not have been met and the receiver 100 continues to operate in equalizer mode (step 210 ). However, if for example, the battery life of the receiver 100 is low and/or the channel quality is excessive for the required data rate, then the receiver 100 switches to operating in MF mode (step 230 ). In this example, the decision to switch to the MF mode is made to save power. However, the decision to switch modes to the MF mode may also be made for performance reasons as described above, for example if the delay spread indicated that the channel consisted of essentially a single path.
[0021] When the receiver 100 is operating in the MF mode, all the computation in the EQ tap update block 150 may be stopped. This saves a considerable fraction of the receiver power. The CHEST block 110 may be enlarged to cover a larger window of M taps than the equalizer window of length L taps so that larger delay spread channel may be accommodated in the MF mode. The enlargement may either be permanent and only enabled in the MF mode, or may be dynamic if resources are available from the EQ tap update block 150 and reassigned to the CHEST block 110 , without increasing gate-count complexity. The number of used taps in the TDL block 170 , N, will either be set to L or M depending on the mode. The output of the receiver 100 may then be expressed as follows:
[0000]
y
(
n
)
=
v
→
n
T
·
x
→
(
n
)
,
where
v
→
n
=
{
w
→
n
if
EQmode
h
→
n
*
otherwise
.
Equation
(
2
)
[0022] The EQ tap update block 150 only runs when in the equalizer mode and computes the weights to be used when generating the output. The update equation is as follows:
[0000]
w
→
n
+
1
=
α
·
w
→
n
+
Δ
→
n
;
where
Δ
→
n
=
μ
2
·
x
→
(
n
)
2
·
(
h
→
*
(
n
)
-
2
·
x
→
*
(
n
)
·
y
(
n
)
)
.
Equation
(
3
)
[0023] For equalizer structures that make use of a channel estimate (for example, channel estimation enhanced NLMS (CENLMS) or non-adaptive block equalizers), the mode switching can be done with little or no increase in design complexity. Although the aspects of the present invention have been described in terms of the CENLMS, they are also applicable to other compatible structures.
[0024] Although the features and elements of the present invention are described in the preferred embodiments in particular combinations, each feature or element can be used alone without the other features and elements of the preferred embodiments or in various combinations with or without other features and elements of the present invention. The methods or flow charts provided in the present invention may be implemented in a computer program, software, or firmware tangibly embodied in a computer-readable storage medium for execution by a general purpose computer or a processor. Examples of computer-readable storage mediums include a read only memory (ROM), a random access memory (RAM), a register, cache memory, semiconductor memory devices, magnetic media such as internal hard disks and removable disks, magneto-optical media, and optical media such as CD-ROM disks, and digital versatile disks (DVDs).
[0025] Suitable processors include, by way of example, a general purpose processor, a special purpose processor, a conventional processor, a digital signal processor (DSP), a plurality of microprocessors, one or more microprocessors in association with a DSP core, a controller, a microcontroller, Application Specific Integrated Circuits (ASICs), Field Programmable Gate Arrays (FPGAs) circuits, any other type of integrated circuit (IC), and/or a state machine.
[0026] A processor in association with software may be used to implement a radio frequency transceiver for use in a wireless transmit receive unit (WTRU), user equipment (UE), terminal, base station, radio network controller (RNC), or any host computer. The WTRU may be used in conjunction with modules, implemented in hardware and/or software, such as a camera, a video camera module, a videophone, a speakerphone, a vibration device, a speaker, a microphone, a television transceiver, a hands free headset, a keyboard, a Bluetooth® module, a frequency modulated (FM) radio unit, a liquid crystal display (LCD) display unit, an organic light-emitting diode (OLED) display unit, a digital music player, a media player, a video game player module, an Internet browser, and/or any wireless local area network (WLAN) module.
|
In a wireless communication system, a method and apparatus switches operating modes of a receiver receiving data and operating in a first mode. The method comprises determining whether a criteria is met to switch the operating mode of the receiver. The operating mode of the receiver is switched from the first mode to a second mode if the criteria is met.
| 7
|
BRIEF DESCRIPTION
[0001] The present invention relates generally to the field of power electronic devices and their thermal management. More particularly, the invention relates to a technique for improving cooling and heat distribution in power modules.
[0002] Power electronic devices and modules are used in a wide range of applications. For example, in electric motor controllers, rectifiers, inverters, and more generally, power converters are employed to condition incoming power and supply power to devices, such as a drive motor. However, the power and signals transmitted within the electronic devices often contain undesirable characteristics that may require additional devices to reduce or filter the signals. For instance, in alternating current (AC) motor controllers, a rectifier may be used to covert the AC power to stable direct current (DC) power, and an inverter may be used to convert the stable DC power back to the AC power supplied to the motor.
[0003] In a standard three phase rectifier (e.g., input converter) that uses six silicon-controlled rectifiers (SCR's) or six diodes and a filter capacitor bank, the three phase input current may contain harmonic distortions. Often, an inductor, such as a reactor or choke, may be added to the system to reduce the harmonics. For example, a reactor may be included at the input of the circuit to reduce the harmonics. Similarly, a choke may be added to buffer the capacitor bank from the AC line to reduce the harmonics. Accordingly, inductors may be useful in circuits for motor drives and other applications where characteristics of inductors are beneficial to the system. However, the design of such inductors may include inherent limitations, including the potential to build up heat within the inductor.
[0004] An inductor usually includes a passive electronic device constructed of a conductive coil of material (e.g., wire or foil) wrapped around a core of air or a ferromagnetic material (magnetic core). Passing electrical current through the conductive coil generates a magnetic flux proportional to the current. The inherent resistance of this winding converts electrical current flowing through the conductive coils into heat due to resistive losses, causing a loss of inductive quality. This may be referred to as coil loss. Further, energy loss that occurs in inductors may include core losses. Core losses may be attributed to a variety of mechanism related to the fluctuating magnetic field, such as eddy loss currents and hysteresis. Most of the energy is released as heat, although some may be mechanical, potentially resulting in audible signals (“hum”). The build up of heat due to coil losses and core losses may reduce performance of the inductor, and lead to failure of the device. Similar problems may be experienced by similarly constructed devices.
[0005] Accordingly, there is a need for improved techniques and cooling systems for removing heat from electronic modules and power converters.
BRIEF DESCRIPTION
[0006] The invention provides a novel approach to power electronic device thermal management. The technique may be applied in a wide range of settings, but is particularly well-suited to inductors, and similar devices. The technique may be utilized with single coil or multiple coil inductors, such as those used in single phase alternating current power systems, three-phase alternating current systems, or direct current power systems. A presently contemplated implementation, for example, is with a reactor used in a three-phase alternating current power system.
[0007] The technique relies upon a biasing element adjacent to a magnetic core of an inductor. The element may be provided between multiple core elements or pieces. The biasing element provides a biasing force to urge at least one cooling element disposed within the inductor into contact with a coil, and, where desired, into good thermal contact with both the core and the coil. The contact may close this and reduce the thermal resistance at the interfaces of the components, and thus promote heat transfer from the magnetic core and the conductive coil to the cooling element. The cooling element is configured to extract the heat from the inductor, such as via the flow of a cooling fluid.
DRAWINGS
[0008] These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
[0009] FIG. 1 is a diagrammatical overview of an exemplary power electronic circuit implementing inductors, including a three-phase reactor and a choke, in accordance with aspects of the invention;
[0010] FIG. 2 is an illustration of an exemplary embodiment of the three-phase reactor of FIG. 1 ;
[0011] FIG. 3 is an illustration of an assembled magnetic core piece of the reactor of FIG. 2 ;
[0012] FIG. 4 is an illustration of assembled components of the reactor of FIG. 2 ;
[0013] FIG. 5 is an illustration of an exploded view of the a conductive coil, cooling element and support of the reactor of FIG. 4 ;
[0014] FIG. 6 is an illustration of an exploded view of the magnetic core and biasing element of the reactor of FIG. 2 ; and
[0015] FIG. 7 is an illustration of a top view of a portion of the reactor of FIG. 2 , including one conductive coil.
DETAILED DESCRIPTION
[0016] Various electronic circuits benefit from the use of inductors. Although inductors are useful for filtering, smoothing or otherwise conditioning power signals, inductors, including reactors, chokes, transformers, and the like, generally produce heat due to core and coil losses. Heat may degrade the performance of the inductor, or may cause degradation and premature failure of the device. Accordingly, the following embodiments provide a system and method to remove thermal energy from the core and the coils of an inductor. In certain embodiments, a cooling element is disposed adjacent to a core, such as between the core and the coil of an inductor such that it may absorb the heat generated by the inductor. In a presently contemplated embodiment, the core includes multiple core pieces that are urged outward by a biasing element disposed between the core pieces. Urging the core pieces outward promotes contact between the core pieces and a cooling element located proximate to the core. Contact between the surface of the core and the surface of the cooling element may reduce the thermal resistance across the interface to promote heat transfer between the core and the cooling element. Accordingly, the effectiveness of the cooling element may be improved. Similarly, the biasing element may also urge the cooling element into contact with surfaces of the conductive coil. This improved contact may reduce the thermal resistance between the conductive coil and the cooling element, and increase the effectiveness of the cooling element to remove heat from the conductive coil. The system and technique are generally applicable to similarly constructed systems that may benefit from improved surface contact between components.
[0017] FIG. 1 illustrates an exemplary embodiment of a power circuit 10 including two inductors. In the illustrated embodiment of FIG. 1 , the power circuit 10 may be provided as part of a power module, such as for a motor drive. The power circuit 10 is adapted to receive three-phase power from a line side 12 and to convert the input power to an output power delivered at a load side 14 . It should be noted that this particular circuit of FIG. 1 is merely one example of an environment that this invention may be usefully employed.
[0018] In the embodiment illustrated in FIG. 1 , the power circuit 10 includes a rectifier 16 defined by an array of six diodes 18 , although SCRs or other power electronic devices may be used in place of diodes. The diode array converts three-phase AC input power to DC power that is applied to a DC bus 20 . The power circuit 10 also includes a capacitive filter 22 formed from a capacitor bank. The capacitive filter may be desired to smooth ripple current on the DC bus, for instance. Further, an inverter 24 is formed by an array of switches 26 and associated fly-back diodes 28 . The inverter may include high-speed transistors as switches to apply a pulse width modulated (PWM) waveform to the load side 14 to power a motor, for instance.
[0019] Standard motor drives that are configured to draw from the power circuit 10 may include “six pulse” drives that have a non-linear load. These drives tend to draw current only periodically during positives and negatives during loses of input power. Because the current wave-form is not perfectly sinusoidal the current may contain undesired harmonics. For instance, with a standard three-phase rectifier using six diodes 18 , or SCRs, and a capacitive filter 22 , as depicted in FIG. 1 , the three-phase input current may contain an increased amount of harmonic distortion. The harmonic distortion may be reduced with the addition of inductors, such as reactors and chokes, to the power circuit 10 .
[0020] A reactor may be added at the line side 12 or DC bus of a power circuit 10 to reduce harmonics. This reactor or inductor reduces the rate of change of current. It may force the capacitive filter 22 to charge at a slower rate drawing current over a longer period of time. In one embodiment of the power circuit 10 , an inductor 30 , may be configured as an input reactor 32 to reduce the harmonics. As illustrated in FIG. 1 , the reactor 32 is located between the line side 12 and the rectifier 16 . In this embodiment, the reactor 32 includes three coils, wherein each coil is configured to receive power from one conductor of the three phase conductors of the line side 12 , and to transmit the power to a respective phase input of the rectifier 16 . In this configuration, the reactor 32 may reduce harmonics and limit the peak current into the rectifier 16 and the capacitive filter 22 .
[0021] In other configurations (not shown), the power circuit 10 may include a reactor 32 located between the inverter 24 and the load side 14 . In such a configuration, the reactor 32 may buffer the current at the load side 14 , such as the current input to a motor drive.
[0022] The illustrated embodiment of the power circuit 10 also includes a DC choke 34 . The choke 34 is located on the DC bus 20 , between the rectifier 16 and the capacitive filter 22 . The choke 34 may help to buffer the capacitive filter 22 from the AC line and to reduce harmonics. The choke 34 may protect the power circuit 10 against a current surge. However, the choke 34 may not protect the rectifier 16 from a voltage spike, as the choke 34 is located downstream of the rectifier 16 .
[0023] Embodiments of the power circuit 10 may include a single inductor, such as the reactor 32 at the line side 12 , the load side 14 , or the choke 32 . Other embodiments may include various combinations of the three, as depicted in FIG. 1 .
[0024] As mentioned previously, the reactor 32 and the choke 34 are both forms of inductors. Accordingly, the characteristics of such inductors may be critical to the operation in which they are installed, such as power circuit 10 . Such inductors generally include a passive electrical device that is employed in an electrical circuit for its property of inductance. Inductance (measured in Henries) is an effect which results from the magnetic field that forms around a current carrying conductor. An inductor typically consists of a coil of conducting material (e.g., conductive coil or wire or foil) wrapped around a core. The core typically comprises air or a ferromagnetic material (magnetic core). Electrical current passed through the conductive coil creates a magnetic flux field proportional to the current. A magnetic core is a key component of higher power inductors, as the magnetic core increases the strength and effect of the magnetic field produced by the electric current passed through the conductive coil.
[0025] Configurations and the design of inductors may vary based on specific applications. For example, inductors may include a single conductive coil disposed about a singe magnetic core. In other embodiments, inductors may include multiple conductive coils, each wound about a portion of the magnetic core. For example, the reactor 32 may include a total of three conductive coils (one for each conductor of three-phase power from the line side 12 ) wrapped about a magnetic core. Other inductors may include two or more conductive windings about a magnetic core, wherein the conductive coils are magnetically coupled to form a transformer.
[0026] The inherent resistance of inductor coils converts a portion of electrical current flowing through the conductive coils into thermal energy (heat), causing a loss of inductive quality. This may be referred to as coil loss. Further, an inductor may experience energy loss attributed to a variety of mechanisms related to the fluctuating magnetic field, such as eddy loss currents and hysteresis. This form of energy loss may be referred to as core losses. Most of the energy due to coil losses and core losses is released as heat. Accordingly, heat may build up within the inductor if it is not dissipated or removed. Unfortunately, the build up of heat within the inductor may reduce performance of the inductor, and/or lead to failure of the device.
[0027] Turning now to FIG. 2 , an inductor 30 in accordance with an embodiment of the present technique is illustrated. The inductor 30 has a magnetic core 36 , conductive coils 38 , and cooling elements 40 . More particularly, the inductor 30 includes the magnetic core 36 surrounded by three conductive coils 38 , with two cooling elements 40 disposed between each conductive coil 38 and the magnetic core 36 , resulting in a total of six cooling elements 40 for the particular embodiment illustrated.
[0028] The overall design of the inductor 30 may be varied to meet specific applications and the desired performance. For example, as illustrated in FIGS. 2 and 3 , the magnetic core 36 includes a “figure-eight” shaped geometry. In this configuration, each leg 42 of the magnetic core 36 may be surrounded by a conductive coil 38 to form the inductor 30 . However, the geometry of the magnetic core 38 may be varied depending on the application. For example, other embodiments of the magnetic core 36 may have “I”, “C,” “E,” toroidal, planar, or pot shaped geometries, and so forth. The magnetic core 36 may also include a geometry formed from a combination of shapes. For example, the figure-eight shape of FIG. 2 may include an “I” shaped piece and an “E” shaped piece, or two “E” shaped pieces, combined to for the single magnetic core 36 .
[0029] The magnetic core 36 may comprise various materials suitable for use in an inductor 30 . In one embodiment, the magnetic core 36 may be formed from copper, aluminum, or steel. For instance, the magnetic core 36 may include conductive “tape” wrapped to form the body of the magnetic core 36 . Other embodiments may include various materials as well as other techniques to form the core. For instance, iron may be used as to form a unitary magnetic core 36 . The magnetic core 36 may also include iron alloyed with silicon, for example. Other materials used to form the magnetic core 36 may include carbonyl iron, ferrite ceramics, and so forth.
[0030] Further, various forming techniques, such as lamination and the like, may be employed to form the magnetic core 36 . Laminating multiple pieces to form the magnetic core 26 may aid in the reduction of undesired eddy currents.
[0031] FIG. 4 is an illustration of an assembled conductive coil 38 and cooling element 40 . This is representative of one of the three conductive coils 38 and one of the three pairs of cooling elements 40 depicted in FIG. 2 . Similarly, FIG. 5 is an illustration of the assembly of FIG. 4 , exploded to provide an improved view of the conductive coil 38 and the cooling elements 40 .
[0032] The conductive coil 38 includes various features that may be desired for use within in the inductor 30 . In one embodiment, the conductive coil 38 includes a coil of material disposed about a central region 44 . As depicted, the central region 44 includes an opening configured to accommodate at least a portion of the magnetic core 36 . Further, the central region 44 provides a location to dispose the cooling elements 40 . For example, cooling element 40 may be disposed at both ends of the conductive coil 38 , as depicted.
[0033] The conductive coil 38 also includes leads 46 configured to connect to other conductors, such as one of the three conductors at the line side 12 , and one of the three conductors output to the rectifier 16 , as depicted in FIG. 1 . The leads 46 provide for the flow of current through the conductive coil 38 . Accordingly, the inductor 30 , as depicted in FIG. 2 , may include a total of six leads 46 (two at each of three conductive coils 38 ). Each lead is configured for connection to an input or an output of the three conductors in a three-phase power system. The conductive coil 38 may include any number of coil turns or wraps around the central region, as desired by a specific application.
[0034] The conductive coil 38 may be composed of various materials. In one embodiment, the conductive coil 38 may include copper, aluminum or steel windings. In other embodiments, the conductive coil 38 may comprise other conductive materials suitable for use in the inductor 30 .
[0035] The cooling element 40 , as depicted in FIGS. 2 , 4 , and 5 , may take a variety of shapes and configurations to provide for the removal of heat from components of the inductor 30 , including the magnetic core 36 and the conductive coil 38 . For instance, each of the depicted cooling elements 40 has a semicircular shape, including a curved surface 48 and a generally flat surface 50 . In a presently contemplated embodiment, a surface, such as the curved surface 48 , may have a shape configured to conform to a curvature at an end turn of the conductive coil 38 . For example, the cooling elements 40 may be disposed within a conductive coil 38 that has been formed prior to placement of the cooling elements 40 . In another embodiment, the conductive coil 38 may conform to the shape of the cooling element 40 . For instance, forming the conductive coil 38 may include fixing the cooling elements 40 in a position and subsequently wrapping the windings of the conductive coil 38 about the cooling elements 40 . The generally shared profile at each end turn may promote contact of the conductive coil 38 and the cooling element 40 such that thermal energy may be more efficiently transferred between the conductive coil 38 and the cooling element 40 . For example, disposing the conductive coil 38 and the cooling element 40 such that they are proximate to one another along the curved surface 48 may reduce thermal resistance across that interface, and, thus, promote the transfer of thermal energy (heat) between the conductive coil 38 and the cooling element 40 . Thus, heat from the conductive element 38 may be more efficiently removed by the cooling element 40 .
[0036] Similarly, a surface of the cooling element 40 may be configured to contact other heat generating components, including the magnetic core 36 . For instance, the flat surface 50 of the cooling element 40 is generally shaped to provide contact between the magnetic core 36 and the cooling element 40 . Contact between the flat surface 50 of the cooling element 40 and a surface of the magnetic core 36 may enable a more efficient transfer of thermal energy (heat) between the magnetic core 36 and the cooling element 40 . Thus, heat from the magnetic core may also be more efficiently removed by the cooling element 40 .
[0037] Further, the cooling element 40 may include various features configured to provide for the transfer of heat from components of the inductor 30 to the cooling element 40 . For instance, the cooling element 40 may comprise a thermally conductive material, such as aluminum. In certain embodiments, the body of the cooling element 40 may include various channels configured to circulate a cooling fluid through the cooling element 40 . The circulation of a cooling fluid may help to remove heat from the cooling elements 40 and, thus, promote heat exchange between the cooling element 40 and components of the inductor 30 . For example, the inductor 30 depicted in FIGS. 4 and 5 includes coolant inlets 52 and outlets 54 configured to receive coolant from an external source, such as a fluid pump (not shown.) In a diversely contemplated embodiment, coolant enters the cooling element 40 via the coolant inlet 52 , passes through cooling channels internal to the cooling element 40 , and exits from the cooling element 40 via the cooling outlet 54 . The circulation of cooling fluid through the cooling element 40 provide for an increased rate transfer of thermal energy from other components of the inductor 30 , such as the conductive coil 38 and the magnetic core 36 .
[0038] The cooling fluid may include any gas or liquid capable of being passed through the cooling element 40 and including thermal properties beneficial to absorbing heat from the body of the cooling element 40 . For example, the cooling fluid may include a water based liquid or an oil.
[0039] FIGS. 4 and 5 also depict a support 56 disposed between each of the cooling elements 40 . The support 56 may be included to provide for spacing of the cooling elements 40 . For example, the support 56 includes a plate of material fastened to each of the cooling elements 40 via fasteners 58 disposed through holes 60 in the support 56 . This illustrates each set of cooling elements 40 includes two supports 56 that are fastened to the sides of the cooling elements 40 . In this configuration, the conductive coil 38 may be wrapped around the cooling elements 40 , with the supports 56 acting to maintain the open central region 44 . Maintaining the central region 44 may provide a location to assemble the magnetic core 36 or other components of the inductor 30 , for instance. The size, shape, and method of fastening the support 56 may be varied to accommodate applications.
[0040] In other embodiments, the support 56 may be a temporary component. For example, the support 56 may be included for assembly and placement of the cooling elements 40 and removed during assembly or prior to use of the inductor 30 .
[0041] As mentioned previously, cooling of the inductor 30 may be provided via the cooling elements 40 . The cooling elements 40 may be disposed proximate to the magnetic core 36 and/or the conductive coil 38 to remove thermal energy from the inductor 30 . To promote the transfer of heat, the inductor 30 may include areas in which each cooling element 40 contacts the components to be cooled, such as the conductive coil 38 and the magnetic core 36 . Good thermal contact between the surface of the cooling elements 40 and other components reduces thermal resistance across the interface to enable more efficient conduction of thermal energy between the components to the cooling element 40 .
[0042] In design and assembly, components of the inductor 30 may generally include some surface contact with the cooling element 40 . Even with good manufacturing tolerance, each of the components may experience expansion and contraction due to fluctuations in temperature during operation. The expansion of contraction in size may reduce or eliminate contact between components and the cooling element 40 . This concern may become more prevalent due to use of different materials for each component and the differing coefficients of thermal expansion for each material.
[0043] In the illustrated embodiment, the inductor 30 includes a magnetic core 36 and a biasing element 62 configured to urge the components of the inductor 30 into good thermal contact with the cooling element 40 . As depicted in FIG. 6 , the magnetic core 36 includes a first piece 64 and a second piece 66 with the biasing elements 62 disposed between the two pieces 64 and 66 . The first piece 64 and second piece 66 may be configured to be positioned or mated together to form the magnetic core 36 , as depicted in FIG. 1 . The two pieces 64 and 66 may include two complementary pieces that are symmetrical or generally symmetrical, as depicted. In other embodiments, the first piece 64 and the second piece 66 may include any shape and design configured to accommodate a specific application. For example, the two core pieces 66 and 64 may be varied in thickness, or may include any of the core geometries described previously.
[0044] The biasing element 62 may include a component, mechanism or material capable of being disposed between the two pieces 64 and 66 of the magnetic core 36 , and providing a biasing force to the pieces. The biasing element 62 exerts a force on the core pieces 64 and 66 after completion of assembly and closes any gap between the core 36 , coil 38 and cooling element 40 due manufacturing tolerances. When the reactor is in operation and warms up, the biasing element 62 exerts a force between the core 36 and coil 38 and closes any gap that is developed between the core 36 , cooling element 40 and core 36 due to thermal expansion mismatch between the components. This ensures improved thermal contact between the core 36 , coil 38 and cooling element 40 . As depicted, the biasing element 62 may include one or a plurality of corrugated sheets of material disposed at various locations between the faces of the two pieces 64 and 66 of the magnetic core 36 . FIG. 6 illustrates two biasing elements 62 located symmetrically about the edges of the pieces 64 and 66 of the magnetic core 36 . Other embodiment may include a single biasing element 62 or a plurality of biasing elements 62 disposed between the two pieces 64 and 66 . In certain embodiments, the biasing element 62 may be pre-compressed during manufacturing. For example, the biasing element 62 may be compressed during assembly of the core 36 such that the biasing element 62 provides a constant reactive force against the pieces of the core 64 and 66 .
[0045] Further embodiments may include alternate forms of the biasing element 62 . For example, the biasing mechanism 62 may include a beveled washer, a linear spring, and the like. Other embodiments may include a mechanically flexible material that is configured to provide a reactive force. For example, the biasing element 62 may include a rubber or resilient material disposed on at least one of the faces of the two pieces 64 and 66 , such that the material provides a biasing force when the two pieces 64 and 66 are compressed together.
[0046] Turning now to FIG. 7 , the top view of a portion of the inductor 30 , including the magnetic core 36 , biasing elements 62 , a single conductive coil 39 , and cooling elements 40 is depicted. The biasing elements 62 are disposed between the first piece 64 and the second piece 66 of the magnetic core 36 . Accordingly, the biasing element 62 may provide a biasing force in the direction of the arrows 70 . The force may urge the first piece 64 and the second piece 66 in the direction of the arrows 70 to increase contact between the magnetic core 36 and the cooling elements 40 at a core/cooling interface 72 . Accordingly, the thermal resistance between the core/cooling interface 72 may be reduced, thereby, promoting the efficient transfer of thermal energy from the magnetic core 36 to the cooling elements 40 .
[0047] Further, the biasing force provided by the biasing element 62 may urge the cooling elements 40 and the conductive coil 38 into contact. For example, the force in the direction of arrows 70 may be transmitted from the core 36 to cooling elements 40 , and, thus, the cooling elements 40 may be displaced in the direction of arrow 70 . The force and displacement on the cooling elements 40 may act to create or increase the contact between the surface of the cooling elements 40 and the surface of the conductive coil 38 at a coil/cooling interface 74 . Accordingly, the thermal resistance between the coil/cooling interface 74 may be reduced, thereby promoting the efficient transfer of thermal energy from the conductive coil 38 to the cooling elements 40 .
[0048] In one embodiment, the inductor 30 may include the support 56 (See FIG. 4 ) configured to allow increased movement of the cooling element 40 . For example, if the support 56 remains in the inductor 30 , the holes 60 may be increased in diameter relative to the fasteners 58 , or may include a slot, such that the cooling element 40 is capable of displacing as the other components contract and expand. Further, such an embodiment may account for variations in the coefficient of thermal expansion for the support 56 relative to other components of the inductor 30 .
[0049] While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. For example, the described system may be employed for heating elements, and or may be employed in similar systems that desire urging components into contact. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.
|
Provided is an electrical apparatus comprising a magnetic core, a conductive coil wound around at least a part of the core, a cooling element configured to receive a cooling fluid to cool the core and the coil during operation, and at least one biasing element operatively associated with the core to urge the core and the coil into engagement with the cooling element despite differential expansion or contraction of the core and the coil and manufacturing tolerances. Further provided is a method for making an electrical apparatus comprising disposing a conductive coil wound around at least a part of a magnetic core, disposing a cooling element between the core and the coil, the cooling element configured to receive a cooling fluid to cool the core and the coil during operation, and urging the core and the coil into engagement with the cooling element despite differential expansion or contraction of the core and the coil and manufacturing tolerances.
| 7
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. patent application No. 60/324,044 filed Sep. 24, 2001 and Swedish patent application No.0103174-9 filed Sep. 24, 2001, all of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to an apparatus and a method for suction and discharge of material.
BACKGROUND ART
[0003] Apparatus for suction and discharge of material as mentioned above are used, for instance, when making excavations in areas where electricity cables, telecommunication cables and the like are buried in the ground, and where an ordinary excavator may cause damage by breaking such cables by mistake. The material sucked up consists of stones, macadam, gravel, sand, earth etc. Such apparatus can also be used to suck up material in liquid form, such as mud and wet clay. One field of application is to suck up ballast adjacent to the rail when reconditioning railroad lines.
[0004] In a prior-art procedure, the ballast is sucked through a hose into a vacuum container which is placed on a rail vehicle. When the container is full, doors in the sides of the container are opened, and the ballast is discharged along the vehicle sides. There is usually some kind of guide plates arranged at the side of the vehicle below the doors in the container sides to direct the discharge in the desired direction somewhat obliquely away from the container. This prior-art apparatus cannot be used in cases where the sucked-up material is to be discharged behind the vehicle, for example to be able to convey it onto a collecting vessel.
[0005] U.S. Pat. No. 5,709,270 discloses another apparatus arranged on a rail vehicle for drawing in ballast by suction, for example, when renovating railroad lines. The ballast is drawn up by suction to a vacuum container which, when being full, is opened via a door in the bottom of the container. The ballast is discharged onto a conveyor belt running under the vehicle and discharging the ballast at the rear end of the vehicle, optionally onto another conveyor belt and then onto another container.
[0006] A difficulty in this prior-art apparatus is that the conveyor belt for conveying material to the rear end of the vehicle is arranged under the container and the other parts mounted on the vehicle, such as drive means etc, which makes the space for the conveyor belt very limited in the vertical direction. This makes it difficult to reach the conveyor belt for maintenance and repair. Moreover, the belt may easily come to a standstill when material is pinched between the conveyor belt and the lower parts of the superposed devices.
[0007] In all these prior-art apparatus, problems arise when discharging wet material since this sticks to the inner walls of the container, thus making it difficult to entirely empty the container. Low temperatures will also cause inconvenience when discharging, for instance, blue clay. The same problem arises when discharging, for instance, macadam according to the prior-art technique, when the material is stopped at the opening of the container and is retained above the opening owing to so-called bridging in the material according to the principle used to build stone bridges in former times.
[0008] This problem has been solved by arranging vibrators to vibrate the container so as to make the material come loose from the walls. However, this easily results in all the material falling out of the container in an uncontrolled manner, which is unfavourable.
[0009] The fact that the discharging occurs in an uncontrolled manner, both with and without the use of vibrators, means that it is not possible to control the speed of the material flowing out of the container once the door in the bottom of the container or the doors in the sides of the container are open. Nor is it possible to interrupt a discharging process, for instance in the case of a near-accident.
[0010] The uncontrolled discharging may also give rise to great strain on the conveyor belt receiving the material flowing out. In many cases a ketchup effect occurs in discharging, which causes a momentarily very high load on the conveyor belt or other devices receiving the discharged material. Problems with build-up of dust may also arise when dry material is discharged too quickly from the container. Dust build-up may cause negative environmental and health effects.
[0011] In another known procedure, the container is instead tilted for discharging and the material is discharged behind the vehicle. Also in this case, the problems mentioned above in connection with quick emptying may arise. When tilting the container, problems will also arise when driving through tunnels having a limited height, where discharge can be made difficult or prevented by there not being sufficient space in the vertical direction for tilting of the container.
SUMMARY OF THE INVENTION
[0012] An object of the present invention is to obviate the above problems by providing a device for suction and discharge of material, where the discharging operation takes place in a controlled manner, said device being further suited for use in tunnels and for use both for solid and liquid materials.
[0013] According to the present invention, the above object is now achieved by an apparatus having the features stated in claim 1 . The object is also achieved by a method according to claim 16 . Preferred embodiments are defined in the appended claims.
[0014] The invention gives the advantage that discharge takes place in a controllable manner since the discharge speed can easily be controlled by regulating the speed of rotation of the container. Moreover, the discharge operation may be interrupted when necessary and may then be easily started again. Furthermore, both solid and liquid materials, as well as mixtures thereof, can be easily and safely discharged completely from the container. Further no tilting of the container is necessary in the discharge operation.
[0015] The conveying means are preferably at least partly helical. This gives the advantage of easily performing efficient transport of the material to the discharge opening. It also facilitates the manufacture of the apparatus.
[0016] The suction opening is connected to a suction duct preferably via a first connecting means. This gives the advantage of facilitating the supply of the material/air mixture to the container.
[0017] According to an embodiment of the invention, the first connecting means may allow disconnection of the suction duct from the container. This gives the advantage that the entire container can easily be rotated without the suction duct being affected.
[0018] The container can have an exhaust opening for letting out air. This is advantageous since it easily allows the generation of a negative pressure in the container, which ensures efficient drawing-in of material and air by suction.
[0019] The exhaust opening can via a second connecting means be connected to an exhaust duct which communicates with an extractor for air. This gives the advantage of easily generating a negative pressure in the container.
[0020] The extractor preferably comprises at least one vacuum pump. This gives the advantage of ensuring efficient drawing-in of material by suction to the container through the suction opening and also efficient extraction of air from the container through the exhaust opening.
[0021] According to an embodiment of the invention, at least one filter is arranged between the exhaust duct and the extractor, which gives the advantage of efficiently filtering away any entrained particles from the container and separating these before they reach the extractor so as not to interfere with the function of the extractor.
[0022] Preferably the extractor comprises a filter, which gives the advantage of ensuring that only a minimum amount of dust particles can be entrained to those parts, for instance pumps, in the extractor, whose function can be interfered with.
[0023] The second connecting means can, according to an embodiment of the invention, allow disconnection of the exhaust duct from the container. This gives the advantage that the entire container can easily be rotated without affecting the exhaust duct.
[0024] The discharge opening is preferably sealable, which gives the advantage of allowing the generation of a negative pressure in the container, which results in the above-mentioned advantages. It is particularly advantageous if the discharge opening is hermetically sealable.
[0025] The suction and exhaust openings are preferably sealable, which gives the advantage that no material can flow or fall out of the container through the exhaust or suction openings in particular when the container is rotated during discharge. It is particularly preferred to combine this with embodiments involving disconnectible connecting means.
[0026] According to an embodiment of the invention, a conveyor belt is arranged in the vicinity of the discharge opening outside the container for conveying material discharged from the container. This gives the advantage of easily being able to convey material from the apparatus, for instance to a storage container.
[0027] According to a preferred embodiment of the invention, a longitudinal axis of the container is inclined relative to a horizontal plane, the discharge opening being arranged at the upper end of the container. This gives the advantage of minimising the amount of material that possibly falls or flows out of the container at the moment when the discharge opening is opened. A further advantage is that the arrangement of a possible conveyor belt in the vicinity of the discharge opening for removing material is facilitated. This is particularly advantageous in the cases where a plurality of conveyor belts are used.
[0028] The above advantages are achieved also by a method according to the invention, by use of an apparatus according to the invention, as well as by a vehicle according to the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] The invention will now be described in more detail with reference to the accompanying schematic drawings which by way of example illustrate a currently preferred embodiment of the invention.
[0030] [0030]FIG. 1 is a schematic side view of a prior-art apparatus for suction and discharge of material.
[0031] [0031]FIG. 2 is a similar view of a preferred embodiment of the inventive apparatus when used on a rail vehicle.
[0032] [0032]FIG. 3 is a sectional view of a container in the apparatus in FIG. 2.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0033] [0033]FIG. 1 shows an example of a prior-art apparatus A for suction and discharge of material when used on a rail vehicle B. A conveyor belt C is arranged along the rail vehicle B for conveying material to a collecting tank D arranged at the rear end of the rail vehicle B.
[0034] With reference to FIGS. 2 and 3, an apparatus for suction and discharge according to the invention will now first be described. Then the suction and discharge function of the apparatus will be described.
[0035] [0035]FIG. 2 shows an apparatus 1 for suction and discharge which is used like in FIG. 1 in connection with a rail vehicle 2 . The apparatus 1 comprises an elongate and flexible suction hose 3 communicating with two vacuum pumps 4 connected in parallel. The vacuum pumps 4 are, as shown in FIG. 2, arranged one behind the other on the rail vehicle 2 . A first end 5 of the suction hose 3 is connected to a nozzle 6 . The nozzle 6 is moved along the rail R at the front end of the rail vehicle 2 , according to an imaginary direction of travel in the direction of arrow F, for drawing in material by suction. The nozzle 6 is controlled by an operator by means of an articulated control arm 7 arranged on the rail vehicle 2 . The suction hose 3 is arranged along the longitudinal direction of the rail vehicle 2 and its second end 8 opens in a suction opening 19 in a cylindrical container 9 . The connection between the second end 8 of the suction hose 3 and the container 9 takes place by means of a docking plate 10 detachable from the container 9 .
[0036] The container 9 also has an exhaust opening 20 which is arranged in the vicinity of said suction opening 19 . An exhaust hose 11 is, via the above docking plate 10 , at its one end connected to the exhaust opening 20 of the container 9 . The other end of the exhaust hose 11 communicates with two filters 12 which are connected in parallel and arranged one after the other on the rail vehicle 2 and communicating with the above-mentioned vacuum pumps 4 . Moreover each vacuum pump 4 is provided with an additional filter (not shown), a so-called safety filter. A duct 13 connects the filters 12 to the suction hose 3 .
[0037] The cylindrical container 9 is arranged at the rear end of the rail vehicle 2 and has a longitudinal direction corresponding to that of the rail vehicle 2 . The container 9 has three openings, the suction and the exhaust openings 19 , 20 which are mentioned above and which at a front end 9 a of the container 9 via a docking plate 10 connect the container 9 with the suction and exhaust hoses 3 , 11 , and a sealable discharge opening 14 in the tapering rear part 9 b of the container 9 . The container 9 is inclined so that its longitudinal axis is inclined to an imaginary horizontal plane. The rear end 9 b of the container is thus arranged at a higher level than its front end 9 a . A flange 15 is arranged along the circumference of the rear portion 9 b of the container. The flange 15 is in contact with rolls 16 on the rail vehicle 2 . The container 9 is thus at its rear end 9 b in contact with the rail vehicle 2 via said rolls 16 and at its front end 9 a in contact via a drive shaft 21 . The drive shaft 21 allows rotation of the container 9 .
[0038] The rail vehicle 2 has at its rear end, below the discharge opening 14 of the container 9 , a conveyor belt 17 .
[0039] The function of the apparatus 1 which has been described above can be divided into two phases, a suction phase and a discharge phase. In the suction phase, material is drawn in by suction from the area around the rail via the nozzle 6 to the suction hose 3 . The suction function in the suction hose 3 is generated by the vacuum pumps 4 via the exhaust hose 11 drawing in air from the container 9 . A negative pressure is therefore generated in the container 9 and an influx of material and air can therefore take place to the container 9 through the suction hose 3 . The material falls down in the container and is separated from the air which is extracted from the container 9 by the suction pumps 4 . Then the air passes the two filters 12 to ensure that particles do not reach the vacuum pumps 4 . Any particles that are collected in the filters 12 will, via the duct 13 , between the filters 12 and the suction hose 3 , be moved from the filters 12 to the suction hose 3 and then be discharged into the container 9 . In order to further protect the vacuum pumps 4 from any particles, the air passes, before it reaches the vacuum pumps 4 , safety filters which are arranged in connection with each vacuum pump 4 .
[0040] The suction phase continues as long as is desirable or until the container 9 is filled to a predetermined level. The discharge opening 14 is, during the entire suction phase, hermetically sealed. Also the connection between the docking plate 10 and the container 9 is hermetically sealed. These hermetic seals are necessary to generate the negative pressure in the container 9 that is necessary for a suction function in the suction hose 3 .
[0041] After the suction phase, the discharge phase takes place when the material collected in the container 9 is discharged onto the conveyor belt 17 . The vacuum pumps 4 are then switched off and the docking plate 10 is disconnected from the container 9 . The suction and exhaust openings 19 , 20 of the container 9 are sealed by a door each or by a common door, and the discharge opening 14 is opened. Rotation of the container 9 takes place by means of a drive shaft 21 which is connected to the front end 9 a of the container and arranged on the rail vehicle 2 . During rotation of the container 9 , the material is discharged via the discharge opening 14 onto the conveyor belt 17 .
[0042] The discharge of the material from the container 9 takes place by means of conveying means such as vane-shaped conveyors or flanges 18 which are helically arranged on the inside of the container 9 , as shown in FIG. 3. Thus the flanges 18 convey the material from the front end 9 a of the container to the rear end 9 b thereof and out of the discharge opening 14 . The discharge speed of the material from the container 9 is determined by the speed of the drive shaft 21 in connection with the front end 9 a of the container.
[0043] When the discharge phase is terminated, a new suction phase can be begun. The rotation of the container 9 is stopped, the doors covering the suction and exhaust openings 19 , 20 are removed, the docking plate 10 with the suction and exhaust hoses 3 , 11 is connected to the container 9 and the discharge opening 14 is sealed. Subsequently the vacuum pumps 4 can be started once more.
[0044] It will be appreciated that many modifications of the above-described embodiment of the invention are feasible within the scope of the invention, as defined in the appended claims.
[0045] For instance, the invention is not bound by the number of vacuum pumps or filters. Nor does the entire container 9 have to be rotatable. For instance, the container 9 may consist of two parts, the first end 9 a of the container 9 , which communicates with the suction and exhaust hoses 3 , 11 , being nonrotatable, while the rest of the container 9 is rotatable and is in rotational contact with the front end 9 a of the container. During rotation of the container 9 in the discharge phase, the suction and exhaust hoses 3 , 11 thus need not in this case be disconnected from the container 9 via the docking plate 10 .
[0046] The apparatus may also be used in other applications, such as arranged on a truck, a caterpillar vehicle, a ship or the like, or when placed in a stationary manner, such as in factory premises.
|
An apparatus for suction and discharge of material comprises a container ( 9 ) with a suction opening ( 19 ) for letting in a sucked-up air/material mixture and a discharge opening ( 14 ) for discharging material. The container ( 9 ) is rotatable and has inner conveying means ( 18 ) which upon rotation of the container ( 9 ) are adapted to convey the material to the discharge opening ( 14 ).
| 4
|
FIELD OF THE INVENTION
This invention relates to novel split seals and techniques for sealing around shafts without the need for disassembly of equipment.
BACKGROUND OF THE INVENTION
Wherever rotating shafts are present in machinery and other such equipment it is necessary to support the shafts by means of a bearing in a housing. The bearings typically used are roller bearings or ball bearings, for example. With either type of bearing it is necessary to maintain sufficient lubricant therein to minimize wear of the bearing and the shaft and to prevent seizing of the shaft within the bearing. For this reason a seal is used at the outside edge of the bearing housing to prevent loss of lubricant.
Not uncommonly the seal in the bearing fails. This may be due to a number of reasons but the result is that the lubricant is permitted to escape from the bearing. Unless this problem is corrected in a timely manner the bearing may be ruined, the shaft may become scored, and the remainder of the machine or the equipment supported by the shaft may become damaged.
Conventionally the failed or inoperative seal is removed entirely and replaced with a new seal. However, this procedure requires disassembly of at least a portion of the machine or equipment. Of course, this necessarily involves a great amount of time and expense. When the equipment or machine is very large the repair procedure will also require the use of large and high capacity tools such as hoists, cranes, etc. in order to lift and move certain portions of the machine which must be disassembled before the seal may be removed.
For example, when the equipment which must be repaired is an oil well pumping unit, the shafts are several inches in diameter and the crank arms supported on such shafts are several feet long and weigh hundreds or thousands of pounds. Accordingly, in order to replace failed seals in such a unit the repair process is very time-consuming and is very costly. Furthermore, heavy equipment is required to handle the disassembled components. Moreover, the lost production time can result in a considerable loss until the repairs are completed and the unit is placed back in service. There are many other types of machinery and equipment in use in various types of industries which present similar problems when seals fail.
Although there has been suggested one type of split seal which may be installed around a shaft, use of such seal does not overcome all of the problems normally encountered nor is it suitable for all applications. Such seal is available from Garlock under the tradename "Split Klozure" and is U-shaped in cross-section. A plurality of metal fingers molded into the rubber seal body maintain the desired U-shape. After the seal has been fitted over the shaft a separate cover plate assembly must be made which is then bolted onto the bearing housing to firmly secure the seal in the desired position. This requires that sufficient space be available in front of the face of the bearing housing to enable the use of drills, etc. to form and then thread the requisite holes in the bearing housing. It is also necessary to make a suitable cover plate for each installation.
Of course, there is not always sufficient available space at the seal location to enable holes to be drilled and threaded, for example. Nor is there always sufficient space to accommodate the required cover plate. Moreover, the Garlock seal does not have the capability to accommodate shafts of many different sizes. Rather, only minor variations in shaft sizes can be accommodated by an individual seal.
The present invention provides a seal design and sealing techniques which overcome the disadvantages associated with conventional seals and with the Garlock seals.
SUMMARY OF THE PRESENT INVENTION
In accordance with the present invention there is provided an elongated strip having two terminal ends. The strip forms a seal when it encircles a shaft and is adhered to a surface (e.g., a bearing mount or bearing housing) extending radially outwardly from the shaft. One edge of the strip is adapted to contact and conform to the shaft when the terminal ends overlap.
The seal of this invention can be installed without costly and time-consuming disassembly of the components of the machinery or equipment being repaired. Furthermore, there is no need for drilling holes or using cover plates to hold the seal in place. Moreover, the seal may be applied even in situations where there is very limited space to work in. The installation is not time-consuming or costly and does not require expensive or cumbersome tools or equipment. Also, the novel seal may be provided in any desired configuration, and the seal is adapted to conform to various shaft sizes.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in more detail hereinafter with reference to the accompanying drawings, wherein like reference characters refer to the same parts throughout the several views and in which:
FIG. 1 is a side elevational view of one embodiment of seal of this invention;
FIG. 2 is a top view of the embodiment of seal shown in FIG. 1;
FIG. 3 is a side view showing a seal of this invention installed on a shaft between a bearing housing and a crank arm;
FIG. 4 is an elevational view along line 4--4 in FIG. 3;
FIG. 5 illustrates one type of cross-sectional configuration for the seal of the invention;
DETAILED DESCRIPTION OF THE INVENTION
Thus, in FIGS. 1 and 2 there is shown one embodiment of seal 10 of this invention. The seal comprises an elongated strip 11 having two terminal ends 12 and 14. The strip 11 is flexible and has a length greater than its width.
The strip preferably has sloped or slanted ends 12 and 14 (as shown in FIG. 2) which are adapted to mate when the strip is encircled around a shaft. Thus, the end portions 12 and 14 are adapted to overlap and may slide past one another so that the seal may conform to shafts of different diameters.
The strip 11 generally forms an annular ring, as shown, which is easily opened so that the seal may fit over and around a shaft without disassembly of the machinery or equipment in which the shaft is located.
The strip is typically composed of a synthetic rubber (such as silicone rubber or a fluoroelastomer or any other type of durable, flexible rubber or elastomer). The strip is preferably oil and moisture resistant, weather-resistant and corrosion resistant. The strip should also be crack resistant at temperatures in the range of about -50° F. to 150° F.
The thickness of the strip may vary. Generally speaking the strip should be sufficiently thick to be durable and crack resistant but yet should not be so thick as to be non-flexible or non-conformable. A convenient and suitable thickness is about 0.2-0.4 inch at the thickest part.
The width of the strip (i.e., the distance between the inside 11A and outside 11B of the annular ring shape) may also vary. However, a width of about 0.5-0.8 inch is very suitable for most applications.
Various different types of cross-sectional configurations for the seal strip may be used. Thus, in FIG. 5 there is illustrated a cross-sectional configuration which may be referred to as a half teardrop shape. One side surface 52 is flat so that it may be readily and easily adhered to a flat surface, such as the flat outer surface of a bearing housing. The tip 54 is shown as having a thinner cross-section than the upper portions of the seal so that the tip can more easily conform to the surface of the shaft around which it will be positioned.
Installation of the seal of the invention is illustrated in FIGS. 3 and 4. A bearing housing 16 surrounds rotating shaft 18 which extends outwardly from housing 16. A crank arm 20 is securely fastened to shaft 18. Nut 19 is threaded onto the outer end of shaft 18. A seal 10 of the invention is applied around shaft 18 and is adhered to the face of housing 16. The ends 12 and 14 of the seal 10 are adapted to slide past one another as they overlap so that the lower edge of the seal conforms to the surface of the shaft. The gap between the housing 16 and the crank arm 20 may be less than one inch, for example.
The face of the seal 10 is flat and is adhered to the abutting face of housing 16 (which has been thoroughly cleaned) by means of an adhesive to hold the seal firmly in position. The adhesive which may be used may be a one-part, two-part, or other multi-part curable adhesive. For example, it may even be an anaerobic adhesive or a pressure-sensitive adhesive. It may also comprise two components, one of which is applied to the face of the seal and the other of which is applied to the face of the housing.
When a pressure-sensitive adhesive is used it may be applied to one face of the seal and then covered with a removable protective liner until the time of installation.
The seal strips of this invention may be made in a series of standard sizes which will accommodate shaft sizes within a wide range of diameters. For example, generally annular shaped seals of this invention having a diameter of 3 inches (inside diameter) will accommodate shaft sizes of 1.5-3 inches. A seal having a diameter of 4.5 inches will accommodate shaft sizes of 3-4.5 inches. A seal having a diameter of 6.5 inches will accommodate shaft sizes of 4.5-6.5 inches. A seal having a diameter of 9 inches will accommodate shaft sizes of 6.5-9 inches. Various other sizes may also be made (e.g., by a simple molding process) which will each accommodate a wide range of shaft sizes.
The seals of the invention may be applied to a bearing or seal housing easily and expeditiously without disassembly of the equipment. They may also be used in very narrow spaces.
If desired, the flat surface of the seal which is to be adhered to the bearing or seal housing may be slightly roughened to enhance bonding.
Other variants of the invention are possible without departing from the scope of the present invention.
|
A novel sealing technique for bearings from which a rotating shaft extends outwardly. The novel seal comprises an elongated flexible strip having two ends. The seal encircles the shaft and is adhered to the face of the bearing housing.
| 5
|
BACKGROUND OF THE INVENTION
The present invention relates to an improvement in a cloth feed device for blind stitch sewing machines.
In such a cloth feed device of the prior art a cloth feed rack is secured to a locking lever which is connected to a main driving shaft of a sewing machine body so as to allow the locking lever to reciprocate to vertical and transverse directions.
A brief description of the prior art and brief summary of the invention follows a brief summary of the drawings so that the deficiencies of a conventional cloth feed device can be discussed with reference to the drawings.
BRIEF DESCRIPTION OF THE INVENTION
Certain objects and advantages of the present invention will become apparent from the following description of embodiments with reference to the accompanying drawing in which:
1A is a plan view showing a cloth blind stitched in a conventional manner;
FIG. 1B is a longitudinal sectional view of the cloth of FIG. 1;
FIG. 2 is a view of a skirt cloth to be blind stitched;
FIG. 3 is an elevational view of a cloth feed device for blind stitch sewing machines according to the present invention;
FIG. 4 is a bottom plan view of the cloth feed device of FIG. 3;
FIG. 5 is an exploded view showing a speed adjusting device for cloth feed rack;
FIGS. 6 and 7 are elevational views showing the operation of the cloth feed device of FIG. 3, FIG. 6 showing its final feed and FIG. 7 showing initial feed, respectively; and
FIG. 8 is an elevational view showing an operational condition of the speed adjusting device shown in FIG. 5.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a lower cloth 2' having a turned up edge forming an upper cloth 1'. During blind stitching of the turned-up portion of the cloth edge, the cloth is fed in the direction shown by the open arrow. When conventional cloth feed devices are used, the upper cloth 1' tends to be pulled by the thread in a direction opposite to the cloth feed direction as shown by the dark arrows. Therefore, the upper cloth 1' lags to the rear forming a defect in the blind stitch. Consequently, a lower cloth or padding cloth cannot be stitched to the edge of a surface cloth because of the non-uniform feed between the two cloths.
Particularly, in the case of a turned-up cloth having its lower edge cut in a circular arc shape, such a cloth for a skirt shown in FIG. 1, stitching portions of the upper and lower cloth are necessarily twisted to get out of shape if they are fed in an identical manner. Accordingly, in the prior art, such a lower edge cut in a circular arc shape is pre-stitched by a conventional sewing machine to form gathers at places and then must fold back (a condition shown in FIG. 2) to blind stitch the upper and lower cloth (1') and (2'). There are troubles with such a performance, and also its efficiency is remarkably bad.
In order to solve the above mentioned defects in the prior sewing machine, one object of the present invention is to provide an improved cloth feed device for blind stitch sewing machines, thereby being capable of feeding the upper and lower cloth at the folded portions, respectively.
Another object of the present invention is to provide a cloth feed device for blind stitch sewing machines which can adjust properly a cloth feed speed of the upper and lower cloth folded back.
Referring now to FIG. 3, indicated by reference numeral 1 is a cloth feed lever which at its left end of the Figure is attached in a main driving shaft 2 of a sewing machine body in an eccentric relation and which at its central portion is attached by a pin 6 to a lever 5 pivotably mounted on a frame 3 by a pin 4. Indicated by reference numeral 7 is a long bore formed in the frame 3.
Accordingly, if the main driving shaft 2 rotates, the cloth feed lever 1 moves to draw an elliptic locus vertically and transversely in FIG. 3. In other manner, the cloth feed lever 1 may move vertically and transversely through the intermediary of its projection fitted with a cam groove which is formed in the frame 3.
At an end of the cloth feed lever 1, a depending piece 8 is threadedly secured by screws 8' and 8" and a main feed rack 9 may be used to allow the same cloth feed as the conventional blind stitch sewing machine. According to the present invention, the cloth feed lever 1 is adapted to connect an auxiliary feed lever 10, on one end of which is mounted an auxiliary feed rack 11 in parallel relationship with the main feed rack 9. The auxiliary feed lever 10 is engaged to the cloth feed lever 1 at one end of a locking link 13 by means of a pin 14, and at the other end of the locking link is attached by a pin 12 to frame 3. The locking link 13 is connected to transmitting links 15 and 15' and the auxiliary feed rack 11 is secured by screws 16 and 17 to one end of the transmitting link 15'. Attached by the cloth feed lever 1 is a supporting lever 18 of the transmitting link 15'.
Secured to the depending piece 8 of the main feed rack 9 by means of screws 20 and 21 is a supporting plate 19 which prevents dropping of the auxiliary feed rack 11 and which is fitted to slide at the bottom of a fixed plate 22 of the auxiliary feed rack 11.
Accordingly, the auxiliary feed lever 10 is followed to the same locus as the elliptic locus of the cloth feed lever 1. Strokes S 1 and S 2 of the main feed rack 9 and auxiliary feed rack 11 are adapted to actuate at a rate corresponding to an engaging condition to the cloth feed lever 1 of the locking link 13.
In a preferred embodiment of the present invention, the feed speed of the auxiliary feed rack 11 can be adjusted in accordance with the thickness, material and stitching requirements of a cloth to be stitched. As shown in FIG. 5, a slide groove 23 formed in the locking link 13 loosely fits a rectangular slider therein and the pin 24" is inserted into a bore 24' of the slider and is secured to the cloth feed lever 1.
The locking link 13 is connected by the pin 12 to a mounting frame 26 of an operating lever 25 which is attached on the frame 3. Indicated by reference numeral 27 is a washer type spring to prevent the operating lever 25 from deplacing by vibration or the like.
Therefore, movement of the cloth feed lever 1 is transmitted to the locking link 13 through the intermediary of the slider 24 and if the operating lever 25 is removed against the spring 27 (see FIG. 8) the slider 24 slides in the slide groove 23 of the locking link 13 whereby the stroke of the transmitting link 15' can be adjusted by different point of contact between the locking link 13 and the cloth feed lever 1.
In operation, upon stitching if the stroke S 1 of the cloth feed lever and the stroke S 2 of the auxiliary feed lever are adjusted to the cloth to be stitched and the folded upper cloth and the lower cloth are respectively abutted to the auxiliary feed rack 11 and the main feed rack 9, the folded upper cloth is not allowed to be late to the rear of the cloth feed. Accordingly, because it is not necessary to pre-stitch to form gathers in the case of stitching the arc lower edge, the folded portion will be simply blind stitched.
In the device of the present invention, since the main feed rack 9 and the auxiliary feed rack 11 are juxtaposed in a direction perpendicular to the cloth feed direction and the auxiliary feed rack 11 is adapted to receive the movement transmitted from cloth feed lever 1 while the stroke S 2 of the auxiliary feed rack 11 being adjustable arbitrarily, the upper and lower cloth at their folded portions can be positively fed by the main feed rack 9 and the auxiliary feed rack 11, respectively. Accordingly, in the case of blind stitching the padding cloth on the surface cloth, the upper cloth does not have at the rear of the feed direction and does not cause a twisted seam.
As understood from the above description, in the device of the present invention, the stitching work is simplified as compared with the conventional device and work efficiency can be remarkably improved. Further since the movement of the auxiliary feed rack 11 is transmitted from the cloth feed lever 1 through the locking link 13 and the transmitting links 15 and 15' it is not necessary to provide a particular driving shaft for the auxiliary feed rack 11 in the sewing machine body. In this case, since the movement of the cloth feed lever 1 is divided to transmit to the main feed rack 9 and the auxiliary feed rack 11, accordingly, the feed device obtained according to the present invention is simple in its structure, rare in occurrence of obstacle and small in size.
In the other feature of the present invention, the stroke of the auxiliary feed rack 11 is free to change with the operating lever 25 and therefore the auxiliary feed stroke can be adjusted in accordance with the thickness or shape of the cloth to be stitched. As understood from this, the cloth feed device of the invention can completely prevent the lag of the upper cloth to the rear of the feed direction upon blind stitching the upper and lower cloth.
As many apparently widely different embodiments of the present invention may be made without departing from the spirit and scope thereof, it is to be understood, that the invention is not limited to the specific embodiments thereof except as defined in the appended claims.
|
A cloth feed device for blind stitch sewing machines comprises two cloth feed racks disposed in a direction perpendicular to a cloth feed direction and the two cloth feed racks are operatively connected to a main shaft of the sewing machine body, respectively, thereby obtaining individual and proper feed of each of the upper and lower cloth to be stitched.
| 3
|
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a National Stage of International Application No. PCT/KR2011/004717 filed Jun. 28, 2011, claiming priority based on Korean Patent Application No. 10-2010-0062374, filed Jun. 29, 2010, the contents of all of which are incorporated herein by reference in their entirety.
TECHNICAL FIELD
The following disclosure relates to a film for food packaging and a method for manufacturing the same, and more particularly, to a film for food packaging capable of having excellent adhesion with a metal deposition layer and thus retaining excellent moisture barrier property while having superior flexibility, transparency, and biodegradability, and a method for manufacturing the same.
BACKGROUND
Polyethylene, polypropylene, polyvinyl chloride, polystyrene, polyester, and the like from petroleum are used for general plastic shrinkable films. Since these shrinkable films are chemically and biologically stable, they need a significantly long time to decompose, which causes serious environmental problems.
Currently, commonly used biodegradable shrinkable films are mainly made of polylactic acid, but since they have low shrinkage ratios and have brittle characteristics due to a crystallization phenomenon in a film manufacturing procedure, the uses thereof are limited. In order to improve the crystallization phenomenon, biodegradable aliphatic polyester having a glass transition temperature of 0° C. or lower is blended in the film manufacture procedure. However, the usability thereof is deteriorated to lead an increase in film opacity, resulting in limited uses thereof, and thermal characteristics of the resin blended itself leads to reduced productivity and the shrinkage ratios of final products are difficult to control, resulting in limited uses thereof.
In addition, since the other processes are not carried out in the manufacturing procedure of the final film, aluminum deposited after an aluminum deposition process for being used in food packaging and the like may be delaminated or separated, resulting in limited uses.
SUMMARY
An embodiment of the present invention is directed to providing a film for food packaging, capable of having excellent moisture barrier property as well as excellent transparency, flexibility, and biodegradability.
Specifically, an embodiment of the present invention is directed to providing a film for food packaging having excellent moisture barrier property, by forming a metal deposition layer on one surface of a biodegradable flexible/shrinkable film containing lactic acid as a main component. Here, an embodiment of the present invention is directed to providing a film for food packaging, capable of having no occurrence of delamination of a metal deposition layer due to printing and lamination after forming the metal deposition layer.
Specifically, an embodiment of the present invention is directed to providing a film for food packaging, capable of having improved adhesion with a metal deposition layer, by a biodegradable film containing a lactic acid of 10˜99 wt % and an aliphatic or aliphatic-aromatic polyester resin of 1˜90 wt %, of which biodegradability is 95% or more, shrinkage ratios in the machine direction and the transverse direction at the time of shrinkage in a water bath at 90° C. for 10 seconds are 5˜60%, and tensile strength is 100˜600 Kg/cm 2 , and a polyurethane coating layer formed on one surface of the biodegradable film.
Specifically, the present invention relates to a film for food packaging capable of having excellent moisture barrier property and a method for manufacturing the same. The film for food packaging of the present invention includes: a biodegradable film containing 10˜99 wt % of lactic acid and 1˜90 wt % of aliphatic or aliphatic-aromatic polyester resin; a polyurethane coating layer formed by coating a polyurethane coating composition on one surface of the biodegradable film; and a metal deposition layer formed on the polyurethane coating layer.
The film for food packaging of the present invention is characterized by the polyurethane coating layer in order to enhance adhesive strength between the biodegradable film and the metal deposition layer. In particular, the polyurethane coating layer is formed through an in-line coating method in the stretching process of the biodegradable film, so that there can be provided a film for food packaging, capable of having excellent adhesion with the biodegradable film, excellent adhesion with the metal deposition layer in a subsequent process, and low moisture permeability, and being superior in overall physical properties.
Further, a method for manufacturing a shrinkable film having excellent moisture barrier property of the present invention, the method includes:
a) preparing an unstretched film by melting and extruding 10˜99 wt % of lactic acid and 1˜90 wt % of aliphatic or aliphatic-aromatic polyester resin;
b) coating a water-dispersed polyurethane coating composition on one surface of the unstretched film through an in-line coating process;
c) uniaxially stretching the unstretched film coated with the water-dispersed polyurethane coating composition in the transverse direction (TD);
d) heat-treating the uniaxially stretched film at 50˜100° C.; and
e) forming a metal deposition layer on a polyurethane coating layer of the uniaxially stretched film.
Hereinafter, the present invention will be described in more detail.
In the present invention, the biodegradable film is a uniaxially stretched film containing polylactic acid resin as a main component, and contains polylactic acid resin containing 10 wt % or more of lactic acid. More specifically, the biodegradable film contains 10˜99 wt % of lactic acid. If the content of lactic acid is below 10 wt %, crystallinity is low and thus heat resistance may be significantly deteriorated, and uniform shrinkage by increased shrinkage stress may not occur. The content of the lactic acid is preferably 70 wt % or more, and more preferably 90 wt % or more. In addition, an anti-oxidant agent, a heat stabilizer, a UV blocking agent, and the like may be added without affecting expression characteristics of the biodegradable film of the present invention.
In addition to the raw material resin, aliphatic or aliphatic-aromatic polyester resin having a glass transition temperature of −60˜60° C. may be blended for use together. As for the aliphatic polyester resin, at least one selected from the group consisting of phthalic acid dicarboxylic acid, diphenyl ether dicarboxylic acid, and the like, may be used at such a content that intrinsic biodegradability thereof is not affected. The biodegradable aliphatic/aromatic copolyester resin is prepared by polycondensation of aromatic dicarboxylic acid having a benzene ring, such as, dimethyl terephthalate or terephthalic acid, and aliphatic dicarboxylic acid, such as, succinic acid or adipic acid, as dicarboxylic acid components, and aliphatic (including cyclic aliphatic) glycol containing at least one selected from 1.4-buthandiol and ethylene glycol. Here, the mole ratio of aliphatic dicarboxylic acid and aromatic dicarboxylic acid is 60:40 to 50:50.
In the present invention, examples of the biodegradable aliphatic polyester resin may include polylactone, polybutylene succinate, and the like, but are not limited thereto.
The content of the aliphatic or aliphatic-aromatic polyester resin is preferably 1˜90 wt % based on the total weight of raw materials. If the content thereof is above wt %, kneadability with polylactic acid may be deteriorated and thus film formation is difficult, thermal characteristics may be deteriorated, and opacity of the final film may be increased. If the content thereof is below 1 wt %, it may be difficult to impart flexibility to a film. The content of the aliphatic or aliphatic-aromatic polyester resin is preferably 5˜80 wt % and more preferably 30˜60 wt % in view of transparency and flexibility of the film.
As the biodegradable film of the present invention, a biodegradable film having opacity of 30% or lower, biodegradability of 95% or higher, shrinkage ratios in the machine direction (MD) and the transverse direction (TD) at the time of shrinkage in a water bath at 90° C. for 10 seconds of 5˜60%, and tensile strength of 100˜600 Kg/cm 2 is preferably used.
If opacity thereof is above 30%, the film may not be used for a packaging purpose for showing the inside, and thus the use of the film is limited. In addition, as for the biodegradable film, the shrinkage ratios in the machine direction (MD) and the transverse direction (TD) at the time of shrinkage in a water bath at 90° C. for 10 seconds are preferably 5˜60%. If the shrinkage ratio is below 5%, shrinkage is too small and thus the film may not be applied to various types of containers, and problems on external appearance may occur even though the film shrinks. If the shrinkage ratio is above 60%, the shrinking rate is fast and thus problems on external appearance may occur. The tensile strength is preferably 100˜600 kg/cm 2 . If the tensile strength is below 100 Kg/cm 2 , wrinkles may be generated due to mechanical tension, resulting in defective printing, in the subsequent processes such as printing and laminating, or fracture may occur in the subsequent processes. If the tensile strength is above 600 Kg/cm 2 , the film may be brittle and thus may be easily fractured or broken due to external impact. The tensile strength is preferably 200 Kg/cm 2 ˜550 Kg/cm 2 , and more preferably 300 Kg/cm 2 ˜500 Kg/cm 2 .
Then, in the present invention, the polyurethane coating layer is configured to enhance adhesive strength between the biodegradable film and the metal deposition layer, and is preferably formed by coating a water-dispersed polyurethane coating composition through an in-line coating process. Here, the coating thickness, which is a dried coating thickness, is preferably 0.01˜0.1 μm since excellent adhesion is obtained without affecting physical properties such as moisture barrier property of the film. More specifically, the water-dispersed polyurethane coating composition contains 0.5˜1.0 wt % of polyurethane based binder resin, 0.01˜0.5 wt % of a silicon based wetting agent, and the remainder water.
In the present invention, the metal deposition layer made of such as aluminum layer or the like is formed on one surface of the film, more specifically, on the polyurethane coating layer, in order to more improve moisture barrier property of the final film. Sputtering or the like may be employed for a depositing method, and the deposition thickness of the metal deposition layer is preferably 200 Å or more, more preferably 200˜1000 Å, and most preferably, 500 Å-1000 Å. If the thickness of the metal deposition layer is below 200 Å, moisture barrier property required may not be satisfied, and thus the use of the film may be limited.
In the film for food packaging of the present invention, peeling strength of the metal deposition layer needs to be 100 g/cm or higher at room temperature and hydrothermal treatment (95° C., 30 min) after deposition of aluminum or the like. If the peeling strength is below 100 g/cm, the metal deposition layer may be delaminated during procedures of transfer, storage, and the like of products. The peeling strength is preferably 120 g/cm and more preferably 150 g/cm. In addition, the film having moisture permeability of 1×10 −2 ˜1×10 −4 (g/m 2 ×day) is suitably used as a film for food packaging.
Hereinafter, a method for manufacturing the film for food packaging of the present invention will be described in detail. The procedure of manufacturing a film for food packaging of the present invention may be divided into preparing an unstretched film by melting and extruding biodegradable resin; uniaxially stretching the unstretched film; performing heat-setting; performing cooling; and forming a metal deposition layer on the uniaxially stretched film.
More e specifically, the method for manufacturing a film for food packaging, the method including:
a) preparing an unstretched film by melting and extruding 10˜99 wt % of lactic acid and 1˜90 wt % of aliphatic or aliphatic-aromatic polyester resin;
b) coating a water-dispersed polyurethane coating composition on one surface of the unstretched film through an in-line coating process;
c) uniaxially stretching the unstretched film coated with the water-dispersed polyurethane coating composition in the transverse direction (TD);
d) heat-treating the uniaxially stretched film at 50˜100° C.; and
e) forming a metal deposition layer with a thickness of 200 Å-1000 Å on a polyurethane coating layer of the uniaxially stretched film.
Herein, in the melting and extruding of the step a), the raw material resin is melted, kneaded, and extruded by using an extruder at 180˜220° C., and then is rapidly cooled and solidified passing through cooling rollers, to thereby obtain an unstretched film. Here, the temperature of the cooling rollers is preferably 10˜60° C. If the temperature of the cooling rollers is below 10° C., the crystallizing rate may be too fast, resulting in increasing opacity, and the raw material resin may not adhere to the cooling rollers, resulting in surface defects due to non-uniform cooling. If the temperature of the cooling rollers is above 60° C., the raw material resin may adhere to the cooling rollers and thus manufacturing of the film is difficult. The temperature of the cooling rollers is preferably 20˜50° C. and more preferably 25˜40° C.
Next, the unstretched film is passed through rollers transferred in a machine direction (MD), subjected to an in-line coating (ILC) process, passed through a preheating section of 70˜90° C., stretched at a stretching ratio of 3˜6 times in a transverse direction (TD) at 60˜80° C., and then passed through a heat treatment section of 50˜100° C., to thereby manufacture a film. If the temperature for heat treatment is below 50° C., the shrinkage ratio may be excessively increased. If the temperature of heat treatment is above 100° C., the shrinkage ratio required may not be obtained, and thus the use of the film is limited.
In the uniaxial stretching of the unstretched film, the in-line coating (ILC) process employs a water-dispersed polyurethane coating composition, and the water-dispersed polyurethane coating composition contains a polyurethane resin solid content of 0.5 to 1.0 wt %, a silicon based wetting agent of 0.01˜0.5 wt %, and the remainder water.
DETAILED DESCRIPTION OF EMBODIMENTS
Hereinafter, the present invention will be in detail described by examples, but the present invention is not limited to the following examples.
Hereinafter, polylactic acid resin used in examples and comparative examples was 4032D purchased from NatureWorks LLC, having a melting point of 170° C., a glass transition temperature of 62° C., and a lactic acid content of 98.5%.
Example 1
A master batch was prepared by adding 60% of polylactic acid resin as raw material resin, polylactone (DAICELL Chemical Company, Celgreen), and silicon dioxide having an average particle size of 2.7 μm so as to be 450 ppm in a final film, followed by blending. The master batch was dried at 110° C. for 2 hours by using a hot air drier, melted and extruded at 200° C., and rapidly cooled and solidified passing through cooling rollers of 25° C., to thereby prepare an unstretched film.
A water-dispersed polyurethane coating composition was coated on one surface of the unstretched film through an in-line coating (ILC) process such that the dried coating thickness thereof was 0.04 μm. The water-dispersed polyurethane coating composition contained 0.8 wt % of solid of polyurethane resin (DKC, Superflex 210), 0.1 wt % of silicon based wetting agent (DowCorning, Q2˜5212), and the remainder water.
The unstretched film coated with the water-dispersed polyurethane coating composition was passed through a preheating section of 80° C. using rollers transferred in a machine direction (MD), stretched at a stretching ratio of 4.0 times in a transverse direction (TD) at 70° C., and then passed through a heat treatment section of 90° C., to thereby manufacture a film. Physical properties of the manufactured film were shown in Table 1.
An aluminum deposition layer with a thickness of 1000 Å was formed on one surface of the manufactured film by using a metal deposition system, to thereby manufacture a final film. Physical properties of the manufactured deposition film were shown in Table 1.
Example 2
A film was manufactured by the same method as Example 1, except that a master batch was prepared by using 45 wt % of polylactone, and physical properties of the film were shown in Table 1.
Example 3
A film was manufactured by the same method as Example 1, except that a master batch was prepared by using 30 wt % of polylactone, and physical properties of the film were shown in Table 1.
Example 4
A film was manufactured by the same method as Example 1, except that a master batch was prepared by using polybutylene succinate resin instead of polylactone, and physical properties of the film were shown in Table 1.
Example 5
A film was manufactured by the same method as Example 1, except that the thickness of the metal deposition layer was 200 Å, and physical properties of the film were shown in Table 1.
Comparative Example 1
A film was manufactured by the same method as Example 1, except that an in-line coating process is omitted and the temperature for a heat treatment section was 30° C., and physical properties of the film were shown in Table 1.
Comparative Example 2
A film was manufactured by the same method as Example 1, except that an in-line coating process is omitted and the temperature for a heat treatment section was 150° C., and physical properties of the film were shown in Table 1.
Characteristics of the films manufactured in Examples 1 to 5 and Comparative Examples 1 and 2 were evaluated.
1. Lactic Acid Content
Lactic acid content was measured using an automatic polarimeter (P-1020) at a wavelength of 589 nm of a sodium lamp and calculated by using software.
2. Tensile Strength
Tensile strength in a transverse direction of a film was measured by using a tensile test machine according to ASTM D 882.
3. Shrinkage Ratio
A film was cut into a rectangular size of 15 mm (MD)×400 mm (TD) in a machine direction (MD) and a transverse direction (TD). An unbroken line was drawn at 50 mm from both ends of the rectangular film in the TD along the MD, to thereby prepare a sample having an effective measurement length of 300 mm. The sample was completely immersed in warm water of 90° C.±0.5° C. under non-load while tweezers hold within 50 mm from one end of the sample without distinction of left and right, and in that state, the film was thermally shrunken for 10 seconds, and then left at room temperature for 1 minute. A reduced length of the measurement length of 300 mm in the TD, which was initially indicated by the unbroken line, was measured, to thereby obtain a thermal shrinkage ratio in the TD of the film according to Equation 1 below.
Thermal shrinkage ratio (%)=(300 mm−length after shrinkage)/300 mm×100 Equation 1
4. Opacity
Opacity was measured according to ASTM D-1003. Two edge sites, one center site, and seven random sites on a biodegradable flexible/shrinkage film were extracted, and then were cut into 5 cm×5 cm sizes. Opacity thereof (Haze, %) was measured by placing each in a film haze meter (NDH-5000). Five measurement values except for the maximum value and the minimum value were averaged, so that opacity (Haze, %) was calculated.
5. Biodegradability
The ratio of biodegradability value thereof measured according to KS M3100˜1(2003) based on that of a standard material was calculated by Equation 2 below.
Ratio of Biodegradability (%)=(biodegradability of sample/biodegradability of standard material)×100 Equation 2
6. Peeling Strength
50 wt % of thermosetting polyurethane based adhesive (Neoforce, KUB-338S) and 50 wt % of ethylacetate as a solvent were used with respect to an aluminum deposition layer of a deposition film, and 11 wt % of a polyurethane based curing agent (Neoforce, CL-100) was used with respect to 100 wt % of the adhesive. At the time of laminating, first laminating was performed by allowing 5 kg-rolls to reciprocate in the laminating section, and second laminating was performed on the first laminated sample by using a laminator with non-heat at speed level 3. This sample was hardened in a hot air oven of 60° C. for 15 hours under a pressure of 16 g/cm 2 . The thus laminated sample was cut at a width interval of 1 cm, and then peel strength (g/cm) between an aluminum deposition layer and a polyurethane coating layer was measured in a 180° peel manner by using a friction factor measuring instrument.
7. Moisture Permeability
Moisture Permeability was measured according to ASTM D-3985. The final deposition film was cut into A4-size, which was then placed in a moisture meter (Permatran-W, Model 3/61). Then, moisture permeability (g/m 2 ×day) was measured seven times at 38° C.±2° C. and 100 RH %, and five measurement values except for the maximum value and the minimum value were averaged, to thereby calculate moisture permeability (g/m 2 ×day).
TABLE 1
Uniaxially Stretched Film
Shrink-
Bio-
Deposition Film
Tensile
age
Opac-
degrad-
Peel
Moisture
Strength
ratio
ity
ability
Strength
Permeability
Kg/cm 2
%
%
%
g/cm
g/m 2 × day
Example
390
37
4.0
100
105
2.7 × 10 −3
1
Example
412
36
3.1
100
108
4.3 × 10 −3
2
Example
513
36
2.2
100
103
7.2 × 10 −3
3
Example
385
38
3.9
100
104
3.3 × 10 −3
4
Example
386
36
4.0
100
97
3.2 × 10 −1
5
Comparative
388
76
4.2
100
58
8.7 × 10 −2
Example
1
Comparative
393
7
4.1
100
61
5.7 × 10 −2
Example
2
It was confirmed from the results of Table 1 above that the biodegradable flexible/shrinkable film according to the present invention had excellent shrinkage, transparency, flexibility, deposition, and the like. Whereas, it can be seen that, in Comparative Example 1 out of the ranges of the present invention, the temperature for heat treatment of the biodegradable film was too low, resulting in lowering shrinkage ratio, and the polyurethane coating layer was not formed between the biodegradable film and the metal deposition layer, resulting in significantly decreasing peel strength of the metal deposition layer. In addition, it can be seen that, in Comparative Example 2, the temperature for the heat treatment section was too high, and thus the shrinkage ratio was too low.
The film for food packaging according to the present invention has excellent uniformity in shrinkage, transparency, flexibility, and deposition, and thus, can not be easily fractured by defects due to delamination of the deposition layer and external impact at the time of transfer/storage and can be used as various kinds of packaging materials in virtue of intrinsic flexibility thereof.
As set forth above, the film for food packaging according to the present invention has uniform shrinkage, transparency, flexibility, and deposition, and thus can not be easily broken by defects due to delamination of the deposition layer and external impact at the time of transfer/storage thereof, and can be used as various kinds of packaging materials due to intrinsic flexibility thereof.
|
Provided are a film for food packaging, capable of having excellent adhesion with a metal deposition layer and thus retaining moisture barrier property while having superior flexibility, transparency, and biodegradability, and a method for manufacturing the same.
| 8
|
BACKGROUND OF THE INVENTION
Advances in the fields of biotechnology and genetic engineering have resulted in the availability of sufficient quantities of biologically active macromolecules such as growth hormones and/or related compounds to make the administration of these agents on a commercial scale economically feasible. Administration of growth hormones and/or related compounds to animals has been reported to provide beneficial effects such as increasing weight gains, increasing milk production in lactating animals, increasing growth rate, increasing feed efficiency, increasing muscle size, decreasing body fat and improving the lean meat to fat ratio.
The above beneficial effects may be accomplished by daily injection or periodic injection of sustained release or prolonged release compositions. Pending Application for United States Letters Patent by S. Cady, R. Fishbein, U. Schroder, H. Erickson, and B. Probasco, Ser. No. 830,158, filed Mar. 20, 1986, and Application for United States Letters Patent of W. Steber, R. Fishbein and S. Cady, Ser. No. 895,608, filed Aug. 11, 1986 and now abandoned, described sustained release compositions utilizing water dispersible carbohydrate polymer-aqueous systems and solid fat and/or wax-oil systems respectively. Prolonged release nonaqueous compositions of polypeptides, preferably associated with metals or metal compounds, and which may additionally contain antihydration agents dispersed in biocompatible oils, are described in European Patent Application No. 85870135.2, published Apr. 4, 1986.
Multiple water-in oil-in water emulsions, represented as W/O/W emulsions, are described as suitable vehicles for the administration of chemotherapeutic agents by L. A. Elson, et al., in Rev. Europ. Etudes Clin. Et Biol., 1970, XV, 87-90 and by J. Benoy et al., in Proceedings of the British Pharmacological Society, Mar. 28 and 29, 1972, 135-136. The use of multiple W/O/W emulsions for oral administration of insulin has been reported by M. Schichiri et al., in Diabetes, Vol. 24, No. 11, 971-976 (1975), and Diabetologia, 10,317-321 (1974).
U.S. Pat. No. 4,083,798 describes pourable multiple W/O/W emulsion compositions which are stabilized by the presence of 1% to 4% on a weight basis of a water soluble protein and 1 to 4% on a weight basis of a gelling polysaccharide in the external aqueous phase. S. Matsumoto et al., Journal of Colloid and Interface Science, Vol. 77, No. 2, 555-563 (1980), describe the effects of osmotic pressure gradients on the water permeability of oil layers in W/O/W multiple emulsions; and A. Abd-Elbary, et al., Pharm. Ind., No. 9, 964-969 (1984) describe the efficacy of different emulsifying agents for preparing multiple emulsions.
It is an object of this invention to provide injectable sustained release compositions of a growth hormone and/or a related compound, wherein the internal aqueous phase contains the growth hormone and/or related compound emulsified in an oil phase which in turn is emulsified in an aqueous phase.
SUMMARY OF THE INVENTION
The present invention is directed to novel sustained release multiple water-in oil-in water (W 1 /O/W 2 ) emulsions comprising an internal aqueous phase (W 1 ) containing a growth hormone, growth factor, somatomedin, or biologically active fragment or derivative thereof: dispersed in a water immisciable liquid or oil phase (O); dispersed in an external aqueous phase (W 2 ). The invention is also directed to methods for elevating and maintaining elevated blood levels of a biologically active growth hormone, growth factor somatomedin, or a biologically active fragment or derivative thereof for the purpose of increasing weight gains, growth rate, milk production, or muscle size, improving feed efficiency, and/or decreasing body fat and improving lean meat to fat ratio in an animal.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The compositions of the invention comprise on a weight basis an internal aqueous phase (W 1 ) of about 55% to 99.7% water, 0.2% to 5% salts and/or buffers, 0.1% to 40% of growth hormone, growth factor, somatomedin or a biologically active fragment or derivatives thereof, 0% to 40% polyol, glycol or sugar, and 0% to 2% preservatives and/or stabilizers, dispersed in an oil phase (O) of about 65% to 98% pharmaceutically and pharmacologically acceptable oil or water immiscible liquid, 2% to 40% non-ionic surfactant(s), 0% to 15% thickening agent, gelling agent or a mixture thereof, dispersed in a second aqueous phase (W 2 ) of about 38% to 98% water, 0.2% to 5% salts and/or buffers, 2% to 20% non-ionic surfactant(s), 0% to 15% thickening agent, gelling agent, or a mixture thereof, 0% to 2% perservatives and/or stabilizer, 0% to 60% polyol, glycol or a sugar. Preferred compositions of the invention comprise a W 1 /O/W 2 emulsion on a weight ratio basis of from 1/1/1 to 1/3/8 of the various phases as described above.
Stabilizers, preservatives, surfactants, glycols, polyols, sugars, thickening agents, gelling agents, salts, buffers and mixtures thereof which are employed in the compositions of the invention normally comprise on a weight basis from 10% to 25% and preferably 14% to 25% of the total composition. These excipients provide maximum stability of the multiple emulsion, adjust the viscosity of the final composition and control the rate of release of the biologically active agent from the inner aqueous phase by providing the appropriate concentration gradient between the inner aqueous phase (W 1 ) and the outer aqueous phase (W 2 ).
Preferred salts and buffers employed in the aqueous phases of the invention are those which are normally used in the preparation of phosphate buffered saline (PBS), containing NaH 2 PO 4 .H 2 O (0.025 mol), Na 2 HPO 4 (0.025 mol), and NaCl (0.15 mol), adjusted to pH 7.1; carbonate buffered saline (CBS), containing Na 2 CO 3 (0.025 mol), HaHCO 3 (0.025 mol), and NaCl (0.15 mol), adjusted to pH 9.4; and saline.
Preferred stabilizers employed in the compositions of the invention include dehydroacetic acid and salts thereof, preferably the sodium salt; salicylanilide; sorbic acid, boric acid, benzoic acid and salts thereof; sodium nitrite and sodium nitrate.
Preferred non-ionic surfactants for use in the compositions of the invention include the sorbitan oleates and stearates, polyethoxylated sorbitan oleates, and block copolymers of ethylene oxide and propylene oxide; with total amounts of from 2% to 20% on a weight basis being distributed between the oil phase (O) and the outer aqueous phase being preferred.
A preferred embodiment of this invention is the incorporating of 1% to 10% of sorbitan monooleate, sorbitan trioleate, sorbitan sesquioleate, ethoxylated (5) soya sterol or sorbitan monostearate in the oil phase (O); in conjunction with the incorporation of 1.0% to 10% of polyoxyethylene (20) sorbitan monooleate or a block copolymer of ethylene oxide and propylene oxide in the outer aqueous phase (W 2 ).
Thickening agents, gelling agents and sugars useful in the compositions of the invention may be naturally occurring or synthetic in origin. Thickening agents, gelling agents, suspending agents, bulking substances, tonicity modifiers, or sugars with aluminum monostearate, aluminum distearate, aluminum tristearate, gelatin, polyvinyl pyrrolidone, sodium alginate, sodium carboxymethyl cellulose, methyl cellulose, polyethylene glycol, sorbitol, mannitol, glycerol, and lactose are preferred.
Pharmaceutically and pharmacologically acceptable water immiscible liquids suitable for use as the oil phase of the invention include oils, liquid fats, water immiscible alcohols and glycols or mixtures thereof.
Preferred water immisciable liquids for use as the oil phase (O) in the compositions of the invention include fatty acid glycerides and blends thereof which are liquid at ambient temperatures. Representative examples are synthetic oils, light mineral oils, heavy mineral oils, vegetable oils, such as olive, sesame seed, peanut, sunflower seed, soybean, cottonseed, corn, safflower, palm, rapeseed and coconut; animal oils such as fish oils, fish liver oils, sperm oils; or fractions derived therefrom; and mixtures thereof.
Biologically active agents suitable for administration in the compositions of the invention include growth hormones, somatomedins, growth factors, and other biological active fragments and derivatives thereof. Preferred agents include bovine, ovine, equine, porcine, avian, and human growth hormones. The term growth hormones encompasses those which are of natural, synthetic, recombinant or biosynthetic origin.
The invention is further illustrated by the following non-limiting examples.
EXAMPLE 1
Preparation of sustained release growth hormone multiple emulsions compositions
Procedures
A. Emulsification by Syringe Technique
Lyophilized recombinant bovine growth hormone is dissolved in the primary aqueous phase (W 1 ) and then taken up in a 10 mL all glass syringe. The oil phase is taken up into a second syringe. All air is expelled from both syringes and they are connected via a three way stopcock with Luer-Lok fittings (Pharmaseal K75). The two phases are mixed by passing them from one syringe to another for a specific number of exchanges. All of the sample (W 1 /O primary emulsion) is then pushed into one syringe and the secondary aqueous phase (W 2 ) taken up into the second syringe. Multiple emulsification (W 1 /O/W 2 ) is then accomplished by once again passing the contents of the syringe back and forth. Sufficient multiple emulsion is prepared to provide dosage for testing. The emulsions are remixed prior to each injection to insure that a homogeneous dispersion of the primary emulsion is being administered.
B. Emulsification by Homogenization
Lyophilized recombinant bovine growth hormone is dissolved in the primary aqueous phase (W 1 ) in a beaker and oil phases added to the beaker with continuous homogenization by a Tissumizer (Tekmar, model SDT-1810) at low speed (20-40 V). The W 1 /O primary emulsion formed is then added with homogenization to the beaker containing the external aqueous phase (W 2 ). The multiple emulsion formed is checked by brightfield light microscopy.
Utilizing the above procedures with the materials listed in Table I below yields the multiple (W 1 /O/W 2 ) emulsion growth hormone compositions listed in Table II below.
TABLE I______________________________________Abbreviation Material______________________________________K. Alg Potassium AlginateHVO Hydrogenated Vegetable OilLMO Light Mineral OilHMO Heavy Mineral OilCBS Carbonate Buffered SalineCB Carbonate BufferGel Gelatin Type A, 150 BloomCorn Corn OilCot Cotton Seed OilSes Sesame OilLect Lecithin UF--HAMS Aluminum MonostearateDextrin Carbohydrate (Nadex 772)BW BeeswaxSq SqualeneCO Castor Oil (Trylox-CO5, Emery)CMC Carboxymethyl cellulosePG Propylene GlycolSTO Sorbitan trioleateSMO Sorbitan monooleateSSO Sorbitan SesquioleateMMO Mannide monooleatePSMS Polyoxyethylene (20) sorbitan monostearatePSMO Polyoxyethylene (20) sorbitan monooleateSMS Sorbitan monosteatatePSML Polyoxyethylene (20) sorbitan monolauratePSE PoIyoxyethylene (2) stearyl etherPOE Polyoxyethylene (2) oleyl etherSLI Sodium lauriminodipropionateBCP.sub.1 Block copolymer of ethylene- oxide and propylene oxide Average molecular weight - 8,350BCP.sub.2 Block copolymer of ethylene- oxide and propylene oxide Average molecular weight - 5,000BCP.sub.3 Block copolymer of ethylene- oxide and propylene oxide Average molecular weight - 7,700BCP.sub.4 Block copolymer of ethylene- oxide and propylene oxide Average molecular weight - 10,800BCP.sub.5 Block copolymer of ethylene- oxide and propylene oxide Average molecular weight - 12,500Sorb Sorbitol aqueous solution USP (70% w/w)EPS Ethoxylated (5) Phytosterol______________________________________
TABLE II__________________________________________________________________________Multiple Emulsion Growth Hormone CompositionsCompo-Phase W.sub.1 containing growth hormone Phase O Phase W.sub.2 W.sub.1 /O/W.sub. 2sitionComponents (% w/w) Components (% w/w) Components (% ratio__________________________________________________________________________1 CBS(100) LMO(90),STO(10) CBS(93), Sorb(5),PSMO(2) 1/1/1.332 CBS(100) HMO(96),SMO(10),AMS(2),PSMO(2) CBS(93),PSMO(2),Sorb(5) 1/1/1.333 CBS(100) HMO(92.3),SMS(7.7) CBS(97),BCP.sub.1 (3) 1/1/1.334 CBS(100) HMO(89),EPS(11) CBS(97),BCP.sub.1 (3) 1/1/1.335 CBS(100) HMO(90),MMO(10) CBS(93),PSMO(2),Sorb(5) 1/1/26 CBS(100) HMO(82),Lect.(13),PSMO(5) CBS(91),SMO(2),PSMO(7) 1/1/27 CBS(100) LMO(88),AMS(1),MNO(10),PSMO(1) CBS(97.8),Gel(0.2),PSMO(2) 1/1/18 CBS(100) LMO(76),AMS(2),MMO(20),PSMO(2) CBS(97),BCP.sub.1 (3) 1/1/29 CBS(100) LMO(89),AMS(1),STO(10) CBS(93),Sorb(5),PSMO(2) 1/1/210 K.Alg(0.36),Sorb.(5),PSMO(2),CBS HVO(67),MMO(33), CBS(93),Sorb(5),PSMO(2) 1/1/111 Dextrin(3),CBS(90) HMO(87.2),SSO(10.5),PSMS(2.3) CBS(96),Gel(2),PSMO(2) 1/3/212 CBS(100) LMO(89),AMS(10),STO(1) CBS(96),Gel(2),PSMO(2) 1/3/813 CBS(100) LMO(89),AMS(1),STO(10) CBS(93),Sorb(5),PSMO(2) 1/1/1.3314 CBS(100) LMO(89),AMS(1),STO(10) CBS(93).Sorb(5),PSMO(2) 1/1/1.3315 CBS(73),Sorb(25),BCP.sub.1 (2) BCP.sub.2 (12.5),Sq(50),BW(37.5) CBS(18.75),Sorb(67.5), 1/1/2 PSMO(13.75)16 CBS(67),Sorb(33) Corn(83.4),CO(16.6) CBS(95.15),CMC(2),PSMO(1), 1/2/2 PSML(1),NaCl(0/85)17 CBS(67),Sorb(33) Cot(83.75),PSE(11.25),POE(5) CBS(83.3)CO(16.6) 1/2/218 CBS (100), Ses(95),SMO(5), CBS(90),BCP.sub.3 (5),BCP.sub.4 (5) 1.5/2.5__________________________________________________________________________
EXAMPLE 2
Effectiveness of injectable compositions of the invention
The efficacy of injectable compositions of this invention is demonstrated utilizing a hypophysectomized (hypox) rat assay. The hypophysectomized rat does not produce its own growth hormone and is sensitive to injected bovine growth hormone. The response measured is growth over a period of time such as ten days.
Each of the hypox albino rats (Taconic Farms, Sprague Dawley derived) is injected with a sufficient quantity of representative compositions prepared in Example 1 to provide a dose of 2400 micrograms of bovine growth hormone in 0.2 mL of W 1 /O/W 1 multiple emulsion.
Test Procedure
Prior to the test, the animlas are weighed and the animals to be used for the test are selected based on body weight. Only those animals whose body weights are one standard deviation from the mean body weight of the group are selected. The resulting group is then randomly divided into treatment groups consisting of eight rats/group by a computer generated randomization procedure. The test animals are then transferred to a clean cage and housed four rats/cage. On the initial day of the study the test animals are weighed and any animals with excessive weight gain or loss (±grams) are replaced. The animals are then assigned to test groups and treated.
At the end of the ten-day test period, total weight gain for each animal is recorded and the average weight gain per rat for each treatment determined. The results of these experiments, which are summarized in Table III below, demonstrate the effectiveness of injectable compositions of this invention.
TABLE III__________________________________________________________________________Efficacy of sustained release compositions of the invention forincreasing weight gains in hypox ratsAverage body weight (g)/animal Average weight gain (g)/animalCompo-Day Day Day Day Day Days Days Days Days Dayssition0 2 4 7 10 0-2 2-4 4-7 7-10 0-10__________________________________________________________________________1 90.3 93.4 98.9 103.4 105.6 3.1 5.4 4.6 2.1 15.22 90.0 94.4 98.1 100.3 102.6 4.4 3.8 2.1 2.4 12.73 84.8 89.5 92.0 92.5 93.0 4.8 2.5 0.5 0.5 6.34 86.4 89.6 93.4 97.4 95.5 3.3 3.8 4.0 -1.9 9.15 90.8 93.0 96.8 96.1 98.1 2.3 3.8 -0.6 2.0 7.56 86.0 94.1 95.4 95.4 97.4 6.1 1.3 0.0 2.0 9.47 93.8 104.7 105.5 108.3 110.0 10.8 0.8 2.8 1.7 16.18 86.9 91.7 91.7 93.1 95.1 4.9 0.0 1.4 2.0 7.39 89.3 92.1 94.8 99.6 102.6 2.9 2.6 4.9 3.0 13.410 92.9 95.9 99.3 100.1 101.6 3.0 3.4 0.9 1.5 9.811 94.3 103.1 102.3 100.8 100.4 8.9 -0.9 -1.5 -0.4 6.112 91.1 94.0 94.6 98.4 99.1 2.9 0.6 3.8 0.8 8.113 94.3 98.0 100.5 105.5 103.6 3.8 2.5 5.0 -1.9 9.414 94.6 97.3 103.8 106.4 104.8 2.6 6.5 2.6 -1.6 10.115 92.3 94.3 96.9 98.6 98.9 2.0 2.6 1.8 0.3 6.716.sup.190.9 91.0 92.7 96.4 94.9 0.1 1.7 3.7 -1.6 3.917.sup.189.3 89.6 92.4 92.5 92.0 0.4 2.8 0.1 -0.5 2.818 91.9 97.9 97.6 102.4 104.3 6.0 -0.3 4.8 1.9 12.4__________________________________________________________________________ .sup.1 Bovine growth hormone dose 1200 micrograms.
EXAMPLE 4
Effectiveness of compositions of the invention for increasing and maintaining increased levels of growth hormone in blood
Groups of three wether lambs weighing approximately 35 kg each are treated with the compositions described in Table IV below.
Prior to injecting the formulation, one pretreatment blood sample is obtained from each animal at 24 hours before treatment. These animals are acclimated to the facilities and fed daily at 8:00 a.m. Care is taken so as not to excite the sheep any more than necessary, as this may stimulate a natural release of growth hormone.
On the day of treatment, blood samples are taken just prior to injection. Each sheep then receives a single injection of the formulation. Blood samples are collected at 0, 2, 4, 6, 24, 48, 72, 96 hours and periodically thereafter.
The serum is separated from the clot by centrifugation and the serum frozen and delivered to the Analytical Laboratory for growth hormone by radioimmunoassay procedures.
The results of these experiments which are summarized in Table V below demonstrate the effectiveness of the compositions of the invention for increasing and maintaining increased blood levels of growth hormones. Comparable results are obtained with other compositions of the invention.
TABLE IV______________________________________ % w/w of % ofComposition Phase Total______________________________________A. W.sub.1 Phase Recombinant bovine growth hormone 12.5 3.75 CBS 87.5 26.3 O Phase LMO 89.0 27.1 AMS 1.0 0.03 STO 10.0 3.0 W.sub.2 Phase CBS 93.0 37.1 PSMO 2.0 0.8 Sorb(70%) 5.0 2.0B. W.sub.1 Phase Recombinant bovine growth hormone 7.3 2.8 Gel 13.3 5.1 Water 79.4 30.4 O Phase SES 91.9 24.9 CO 1.8 0.5 SSO 7.3 1.97 W.sub.2 Phase Gel 1.0 0.65 Water 79.0 26.9 BCP.sub.5 20.0 6.74C. W.sub.1 Phase Recombinant bovine growth hormone 13.25 2.65 CB 86.75 17.35 O Phase SES 95.0 28.5 SMO 5.0 1.5 W.sub.2 Phase BCP.sub.3 5.0 2.5 BCP.sub.4 5.0 2.5 Water 90.0 45.0______________________________________
TABLE V______________________________________Bovine growth hormone blood levels in sheep (ng/mL) Sheep #Time 1 2 3 Average______________________________________Composition A (2 mL)-24 hrs 7.1 8.0 6.6 ---23 hrs 5.1 4.0 4.8 4.6-22 hrs 5.4 4.5 3.8 4.60 hr 9.6 6.0 7.5 7.72 hrs 222.0 816.0 979.0 672.34 hrs 177.0 505.0 689.0 457.06 hrs 166.0 368.0 468.0 334.01 day 146.0 49.1 77.3 90.82 days 27.9 19.8 21.5 23.13 days 27.9 33.7 28.0 23.24 days 21.7 11.0 22.0 11.66 days 6.6 6.6 7.4 6.98 days 7.8 6.9 9.3 8.010 days 10.1 7.5 7.7 8.413 days 4.7 5.3 7.1 5.715 days 6.5 4.7 4.7 5.317 days 5.3 3.9 8.3 5.820 days 6.4 6.6 5.8 6.322 days 5.7 6.1 7.1 6.324 days 2.8 4.5 6.0 4.4Composition B (5 mL)-24 hrs 2.6 4.0 2.3 3.00 hr 1.5 4.0 2.9 2.81 hr 13.8 10.3 10.4 11.5 11.1 8.3 8.0 9.22 hrs 376.0 66.4 38.5 160.3 20.7 24.6 20.9 22.14 hrs 109.8 102.6 53.3 88.66 hrs 171.8 119.8 156.1 149.21 day 65.1 176.4 319.4 187.02 days 17.1 38.9 67.8 41.33 days 9.9 22.0 31.7 21.24 days 9.6 14.6 38.9 21.05 days 5.1 9.4 28.5 14.36 days 2.2 7.7 48.2 19.48 days 2.0 18.3 98.1 39.510 days 1.5 13.7 80.9 63.413 days 1.7 11.7 81.0 31.515 days 1.8 15.1 73.7 30.217 days 4.0 13.7 73.1 30.3Composition C (2.5 mL)-24 hrs 2.7 2.4 1.8 2.30 hr 2.9 1.8 2.2 2.31 hr 315.5 168.0 196.3 226.62 hrs 551.2 280.6 296.9 376.24 hrs 756.8 462.2 466.7 561.96 hrs 1007.1 593.1 624.6 741.61 day 70.4 91.5 142.5 101.52 days 29.0 36.0 41.1 35.43 days 21.3 23.8 26.2 23.84 days 15.3 11.4 18.5 15.15 days 19.2 8.3 14.3 13.96 days 22.0 5.4 11.9 13.18 days 21.7 8.5 8.7 12.910 days 21.6 12.3 7.2 13.713 days 16.3 19.9 4.1 13.415 days 17.0 19.2 3.1 13.117 days 14.5 17.5 2.2 11.420 days 16.0 14.4 2.3 10.9______________________________________
|
The invention relates to sustained release compositions of growth hormones and/or related compounds and multiple water-in oil-in-water emulsions. The invention also relates to methods for increasing and maintaining increased levels of growth hormones and/or related compounds in the blood of treated animals for extended periods of time, increasing weight gains in animals and increasing milk production of lactating animals by the administration of a composition of the invention.
| 8
|
REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from German Application No. 10 2005 037 086.1 filed Aug. 3, 2005, the disclosure of which is incorporated herein by reference together with each and every U.S. and foreign patent and patent application mentioned below.
BACKGROUND OF THE INVENTION
[0002] The invention relates to an apparatus for determining and/or monitoring a glue quantity or glue mass applied to a wrapping strip of the tobacco-processing industry, wherein an ultrasound measuring system is provided with at least two ultrasound generating sources for supplying the wrapping strip with ultrasound and with at least two ultrasound sensor receiving units for receiving the ultrasound signals penetrating the wrapping strip. Moreover, the invention relates to a machine of the tobacco-processing industry.
[0003] For connecting cigarette filters with tobacco rods, a sheet of tipping paper is normally provided, which encloses the filter on one side and connects one head end of the tobacco rod with the filter on the other side with the overlapping edge. The joining of the filter with the tobacco rod normally occurs through gluing.
[0004] European patent application EP-A-1 147 716 describes a device for applying glue to a wrapper material or a wrapping paper strip of a rod-shaped item of the tobacco-processing industry. In order to create a glue pattern with glue-free areas on a wrapping strip, the apparatus has means for interrupting the glue supply to the wrapping paper strip.
[0005] With high production speeds on a filter application machine, it can come about that the glue layer is applied too thin to the tipping paper web or holes or breaks form due to process-related malfunctions such as contamination in the gluing system, so that an insufficient connection is ensured between the filter and the tobacco rod.
[0006] EP-B-0 418 342 describes an apparatus for ascertaining sufficient moistness of a paper web, wherein the presence of glue on the paper web to be glued can be ascertained by means of a capacitive sensor.
SUMMARY OF THE INVENTION
[0007] Based on this state of the art, it is an object of the invention to provide another option for determining the glue quantity or mass as well as for monitoring the gluing on a wrapping strip of the tobacco-processing industry, in particular in the border area of the wrapping strip.
[0008] The above and other objects of the invention are accomplished by the invention wherein according to one exemplary embodiment there is an apparatus for determining and/or monitoring a glue quantity or glue mass applied to a wrapping strip of the tobacco-processing industry, the apparatus comprising: an ultrasound measuring system including: at least two ultrasound generating sources adapted to supply the wrapping strip with ultrasound; at least two ultrasound sensor receiving units adapted to receive the ultrasound signals penetrating the wrapping strip; and a separating wall arranged between at least two of the ultrasound generating sources and/or between at least two of the ultrasound sensor receiving units.
[0009] The invention is based on the idea that a deflection of the emitted beams or other artefacts on the ultrasound measuring system, in particular in the border area of the paper web to be checked or the wrapping strip to be checked, can be avoided in an ultrasound measuring system by attaching partition walls or separating walls between two ultrasound sources and/or two ultrasound receivers. With a fixed attachment or arrangement of an acoustic source on a receiver, signals from neighbouring ultrasound transmitters are suppressed or shielded by the separating walls and can be analyzed by a controller or an evaluation device, whereby a particularly reliable measurement of the glue quantity or a monitoring of the glue pattern also in the edge area of the wrapping strip is enabled overall. The ultrasound between an ultrasound transmitter and the corresponding ultrasound receiver is thereby channelled or aligned by the partition walls.
[0010] The measurement principle is based on the fact that a portion of the transmitted ultrasonic waves is absorbed by the glued paper web and the unabsorbed portion is available as a measurement signal on the receiving sensor so that the glue quantity of the applied glue is quasi continuously checked and monitored by means of ultrasound. A paper web conveyed and glued at a high transport speed can hereby be examined for gluing flaws. The measurement procedure is, in terms of the applied glue quantity, a direct measurement procedure and is independent of the composition, e.g. the amount of water in the glue. Moreover, vertical paper fluctuations hardly have an effect on the received ultrasonic measurement signals.
[0011] The ultrasound is created by at least two transmitter units, for example in the form of piezo elements, and is received by at least two receiver units, for example in the form of piezo-sensitive microphones. In order to continuously monitor the conveyed wrapping strip, the wrapping strip is supplied with ultrasound transversally to the transport direction, wherein the wrapping strip is conveyed between the transmitter unit and the sensor receiving unit. The ultrasound can thereby be arranged in a preferred alignment to the wrapping strip and can scan the wrapping strip. Ultrasound-transmitting piezo elements are arranged on the glued and non-glued side of the wrapping strip. The ultrasonic waves or signals are received by piezo-sensitive microphones or sensors on the respective other side.
[0012] The entire width of the wrapping strip is hereby monitored, whereby all widths of the wrapping strip can be measured unformatted with the same measuring system, consisting of a transmitter unit and a sensor receiving unit. The glue quantity of glue tracks of a glue pattern, preferably time-averaged, is measured using the received ultrasonic signals and/or defective areas in the glue pattern are detected.
[0013] Furthermore, it is advantageous if at least one ultrasound generating source and/or an ultrasound receiving unit is arranged between two separating walls.
[0014] The most reliable measurement results are then given if the separating walls are arranged at predetermined intervals, preferably regular, intervals from each other.
[0015] Moreover, it is advantageous if the height of the separating wall or the heights of the separating walls are greater than the heights of the ultrasound generating sources and/or the ultrasound receiving unit. The ultrasonic waves on the transmitter are hereby aligned exactly with the associated receiver so that the receiver does not receive any interfering ultrasonic signals from neighbouring transmitters. If the separating walls are arranged on the receiver, the measurement will be suppressed or largely prevented by the neighbouring transmitters.
[0016] The apparatus can be easily cleaned if at least one separating wall or several separating walls are arranged as removable units so that, for purposes of cleaning the ultrasound measuring system, the separating walls can be detached or removed and then repositioned again exactly.
[0017] Furthermore, it is advantageous if a cleaning device is provided for the ultrasound measuring system, whereby contamination or a change in the measurements by deposits is avoided.
[0018] For this, it is advantageous that the cleaning device is designed as an ultrasound transmitter and/or as a compressed-air device. The ultrasound measuring system or the individual components of the measuring system are hereby effectively cleaned in a simple manner, wherein the design effort can be minimized.
[0019] The wrapping strip is preferably guided between the ultrasound generating sources and the ultrasound-receiving units, which are spaced apart. For this, the ultrasound measuring system can be U-shaped or fork-shaped.
[0020] Furthermore, the apparatus is characterized in that piezo elements are provided as ultrasound generating sources and/or piezo-sensitive microphones are provided as an ultrasound sensor receiving unit. At least two ultrasound sources, in particular piezo elements, are arranged on one leg of the U shape, and at least two ultrasound sensor receiving units, in particular piezo-sensitive microphones, are arranged on the other leg of the U shape. A larger number of ultrasound-transmitting piezo elements, arranged in an array, is preferred in order to achieve a homogeneous sound field over the entire width of the wrapping strip. An array is also advantageous on the sensor receiving side so that better resolutions can be achieved.
[0021] In order to achieve a compensation of the paper thickness or the thickness of the wrapping strip, a second, preferably U-shaped, sensor device with an ultrasound generating source and an ultrasound-receiving unit is provided in front of a glue application unit for the wrapping strip, in terms of the transport direction of the wrapping strip, wherein the second transmitter or receiver unit preferably also has separating walls.
[0022] It is also advantageous if an evaluation device is provided for evaluating the received ultrasound signals.
[0023] The apparatus is furthermore characterized in that the entire width of the wrapping strip can be monitored by the ultrasound measuring system.
[0024] Moreover, the object of the invention is achieved through a machine of the tobacco-processing industry, which is equipped with an apparatus described above in accordance with the invention for determining and/or monitoring a glue quantity or glue mass applied to a wrapping strip of the tobacco-processing industry. In order to avoid repetitions, express reference is made to the above embodiments of the apparatus in accordance with the invention.
BRIEF DESCRIPTION OF THE INVENTION
[0025] The invention is described below, without restricting the general intent of the invention, based on exemplary embodiments in reference to the drawings, whereby reference is expressly made to the drawings with regard to the disclosure of all details according to the invention that are not explained in greater detail in the text. The enclosed schematic drawings illustrate the invention as follows:
[0026] FIG. 1 is a schematic perspective representation of a sensor in accordance with the invention; and
[0027] FIG. 2 is a cross-section through an ultrasound measuring system in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0028] In the following figures, the same or similar types of elements or corresponding parts are provided with the same reference numbers in order to prevent the item from needing to be reintroduced.
[0029] FIG. 1 shows a perspective view of an ultrasound measuring system 10 . The ultrasound measuring system 10 is shaped like a fork or a U. A tipping paper web 15 is passed through and transported between the two legs of the U shape. The tipping paper web 15 is provided with a glue pattern of applied glue, which has been applied to the tipping paper web 15 by a gluing unit that is not shown here. The glue pattern has several glue-free areas 17 , which are perforated after the cutting of the tipping paper web 15 into tipping patches and after the coiling of the cut tipping patched around filter plugs and tobacco rods with the help of processing units.
[0030] The peripheral zones are instrumental in the gluing of the tipping paper on the tobacco rod of the cigarette. A lack of glue on these areas leads to filters that are loose or that fall off; thus, the application of the glue is particularly important. For this reason, more glue is applied in places in the peripheral zone area than in the middle zones of the glue pattern.
[0031] Gluing mistakes in the middle zones can cause adhesive problems in the seam area of the filter, which can be indirectly detected by a downstream pneumatic detection system on an inspection drum, so that the cigarette provided with a defectively glued tipping paper can be ejected. The middle zones contain both continuous zones as well as glue-free zones 17 .
[0032] Depending on the type of glue as well as the shape of the glue application unit or other process parameters, superelevations and thus inhomogeneous distribution of the glue over the width of the tipping paper web 15 can result within the individual glue tracks of the glue pattern.
[0033] The glued tipping paper web 15 is guided without being touched through the U-shaped ultrasound measuring system 10 . A guiding device or guide not shown here is also provided in order to prevent the fluttering of the paper web or the tipping paper web 15 and to ensure a constant distance from the paper web 15 to the transmitters 131 and receivers 14 of the ultrasound measuring system 10 . A transmitting rail 13 with linearly arranged piezo elements for the creation of ultrasonic waves is located on the unglued side. A linear arrangement made up of sensors or piezo-sensitive microphones 14 is located on the opposite, glued side of the tipping paper web 15 .
[0034] The arrangement of microphones 14 is tuned to the ultrasonic frequency of the transmitting rail 13 . Frequencies of over 100 kHz, preferably over 400 kHz, are typically suitable for the identification of the glue quantity or the monitoring of the glue track or also the glue pattern on the tipping paper web 15 . The ultrasound created by the piezo elements of the transmitting rail 13 is directed transversally, preferably perpendicularly, to the transport direction. The created ultrasound is scanned through the tipping paper web 15 as well as the overlapping peripheral zones of the tipping paper web 15 .
[0035] The ultrasound measuring system 10 works in the pulse mode, i.e. the transmitting rail 13 sends a sound pulse so that the arrangement of the microphones 14 registers the intensity of the acoustic pressure received.
[0036] Depending on the thickness or mass per unit area of the applied glue on the tipping paper web 15 , there is a different quantity or mass profile as well as thickness profile over the width of the tipping paper strip 15 . Based on the amplitude changes in the receiving signal over the width of the tipping paper web 15 , which is captured by the microphones 14 , the amount or mass or the density of the glue will be measured over the width. The ultrasound measuring system 10 is connected to an evaluation device 20 for the evaluation of the received ultrasonic signals.
[0037] The transmitting rail 13 and the arrangement of the microphones 24 are designed such that they capture the glue pattern or the glue quantity over the entire width of the tipping paper web 15 . In particular, they are designed such that they are wider than the maximum format width of a wrapping strip 15 . Numerous widths of a tipping paper web 15 can thereby be captured format-free with the same measuring system 10 .
[0038] In order to eliminate the effects of the tipping paper web 15 on the measurements, a second ultrasound measuring system, which is also built in accordance with the ultrasound measuring system 10 shown in the drawing, is arranged in front of the glue application unit. This second ultrasound measuring system measures the fluctuations and effects of the thickness of a tipping paper web 15 that has not yet been glued. The second ultrasound measuring system is also connected to the evaluation device 20 so that a compensation of the paper thickness fluctuation occurs through a difference formation of the signals via the difference formation of the two measured ultrasound signals before and after the gluing of the tipping paper web 15 .
[0039] In order to be able to identify the amount or mass and the quality of the gluing or its temporal development or tendency over a longer period of time and thus to draw conclusions on the adhesive strength of the applied glue, the ultrasounds signals of the sensors are averaged. Glue mistakes or defective areas in the glue pattern are identified through the surpassing or shortfall of a set point for a specified glue quantity by means of an ultrasound system 10 in accordance with the invention.
[0040] FIG. 2 shows a cross-section through an ultrasound measuring system 10 in accordance with the invention. The tipping paper web 15 is hereby arranged perpendicular to the plane of projection between the linear arrangement of the microphones 14 and the linear arrangement of the transmitting rail 13 made up of the piezo elements 131 .
[0041] Each microphone 14 is surrounded by two separating walls 21 , whereby ultrasonic signals are suppressed, which are transmitted by the non-opposite-lying piezo element(s) 131 . The ultrasound measured at the microphones 14 thus always originates from the associated, opposite-lying piezo element 131 . The separating walls 21 are arranged with respective to each other, whereby a comb-shaped structure of the separating walls 21 is created.
[0042] FIG. 2 also shows separating walls 31 arranged at regular intervals on the transmitting rail opposite the microphones 14 , between each of which a piezo element 131 is arranged. In this arrangement of the separating walls 31 , it is also possible to channel or appropriately align the ultrasound transmitted by the piezo elements 131 so that the ultrasound is received on the opposite-lying side by the respective microphone 14 .
[0043] Moreover, a guide rod 32 is arranged above the piezo elements 131 for guiding and supporting the tipping paper web 15 , whereby a fluttering of the guided paper web 15 is avoided. The guide rod 32 is affixed to the transmitting rail via two lateral mounts 33 .
[0044] The arrangement of the separating walls 21 on the receiving side and/or the arrangement of the separating walls 31 on the transmitting side results in exact measurements of the density or an exact identification of the gluing pattern 19 on the tipping paper web 15 . The ultrasound is aligned perpendicular to the conveyed tipping paper web 15 and concentrated between a pair made up of a piezo element 131 and a microphone 14 by the separating walls 21 or 31 .
[0045] In particular, the measurements or the receipt of the ultrasonic signals are more exact due to the separating walls 21 and/or 31 , since deflections of the ultrasound on the outer edges of the tipping paper web 15 or other artefacts in the peripheral area of the tipping web are suppressed or eliminated.
[0046] The separating walls 21 or 31 are preferably designed as a compact unit, wherein the unit can be removed from the receiving rail or the transmitting rail for cleaning purposes. After removing the separating walls 21 or 31 , the microphones and the piezo elements are freely accessible for the removal of dust particles.
[0047] Moreover, it is possible to clean the ultrasound measuring system 10 mechanically, whereby a removal of the separating walls 21 or 31 arranged in a web-like or comb-like manner is not required. An ultrasound actor 22 is attached for cleaning in order to give a high-energy ultrasound pulse to the microphones 14 and the separating walls 21 arranged between them.
[0048] As an alternative or in addition to the ultrasound actor 22 , the cleaning device can be designed using an air nozzle 23 , which is supplied with compressed air from a compressed-air source 24 . The dust particles in the ultrasound measuring system or on the separating walls 21 are hereby blown away.
[0049] The invention has been described in detail with respect to referred embodiments, and it will now be apparent from the foregoing to those skilled in the art, that changes and modifications may be made without departing from the invention in its broader aspects, and the invention, therefore, as defined in the appended claims, is intended to cover all such changes and modifications that fall within the true spirit of the invention.
|
An apparatus for determining and/or monitoring a glue quantity or glue mass applied to a wrapping strip of the tobacco-processing industry includes an ultrasound measuring system. The ultrasound measuring system comprises at least two ultrasound generating sources adapted to supply the wrapping strip with ultrasound, at least two ultrasound sensor receiving units adapted to receive the ultrasound signals penetrating the wrapping strip, and a separating wall arranged between at least two of the ultrasound generating sources and/or between at least two of the ultrasound sensor receiving units.
| 6
|
RELATED APPLICATIONS
[0001] This application claims priority to the following U.S. Patent Application 61/050,207, entitled “Sample collection devices with sample processing and data storage capability,” filed on May 3, 2008; 61/052,215, entitled “Processing Non-liquid Samples on a Droplet Actuator,” filed on May 11, 2008; 61/052,224, entitled “Reagent Storage for Field-based Detection,” filed on May 11, 2008; 61/075,616, entitled “Rapid Detection of Methicillin Resistant Staphylococcus aureus (MRSA) Using Digital Microfluidics,” filed on Jun. 25, 2008; 61/085,032, entitled “Rapid Pathogen Detection on a Droplet Actuator,” filed on Jul. 31, 2008; 61/088,555, entitled “Fluidic Systems for and Methods of Loading a Droplet actuator,” filed on Aug. 13, 2008; 61/093,462, entitled Nucleic Acid Sample Preparation and Analysis on a Droplet Actuator,” filed on Sep. 2, 2008; and 61/157,302, entitled “Droplet Actuator Techniques Using Non-liquid Fluids,” filed on Mar. 4, 2009.
GOVERNMENT SUPPORT
[0002] This invention was made with government support under grant number AI066590-02 awarded by the National Institutes of Health. The United States Government has certain rights in the invention.
[0003] The foregoing statement applies only to those aspects of the invention described and claimed in this application arising out of U.S. Patent Application No. 61/075,616, entitled “Rapid Detection of Methicillin Resistant Staphylococcus aureus (MRSA) Using Digital Microfluidics,” filed on Jun. 25, 2008; and 61/085,032, entitled “Rapid Pathogen Detection on a Droplet Actuator,” filed on Jul. 31, 2008.
BACKGROUND
[0004] Droplet actuators are used to conduct a wide variety of droplet operations. A droplet actuator typically includes two substrates separated to form a droplet operations gap. The substrates include electrodes for conducting droplet operations. The gap between the substrates is typically filled with a filler fluid that is immiscible with the liquid that is to be subjected to droplet operations. Droplet operations are controlled by electrodes associated with one or both of the substrates. There is a need for droplet actuator devices, techniques and systems for making and using droplet actuators. There is a need for devices, techniques and systems for preparing samples and/or reagents for loading onto a droplet actuator; for loading samples and/or reagents onto a droplet actuator; for storing samples and/or reagents on a droplet actuator and/or for use on a droplet actuator; and/or for conducting droplet operations using samples and/or reagents on a droplet actuator. There is a need for devices, techniques and systems for conducting flow through bead handling and washing. For example, there is a need for techniques for splitting droplets in a flow-through system, compartmentalizing beads in droplets in a flow-through system, and washing droplets in a flow-through system. There is a need for droplet actuator devices, techniques and systems for making and using droplet actuators to process viscous, solid or semi-solid samples. For example, there is a need for a techniques for processing process viscous, semisolid, and/or solid samples. There is a need for droplet actuator devices including a gel for use in gel electrophoresis, along with techniques and systems for conducting gel electrophoresis on a droplet actuator. There is a need for a fluidics system and technique for using the system for loading liquids onto a droplet actuator. There is a need for droplet actuators loaded using the fluidics system and method of the invention and methods of using such droplet actuators to conduct droplet operations. There is a need for droplet actuator devices, techniques and systems for processing samples for use on a droplet actuator device. There is a need for droplet actuator devices, techniques and systems for capturing, concentrating and/or eluting nucleic acids; and sensitively isolating nucleic acids using one or more droplet operations to perform separation protocols. There is a need for kits including droplet actuators of the invention along with various other components suitable for executing the techniques of the invention, such as reagents, sample collection devices, and/or instructions.
SUMMARY OF THE INVENTION
[0005] The invention provides a droplet actuator, and methods of making and using the droplet actuator. The droplet actuator may include two substrates separated to provide a droplet operations gap. One or more electrodes may be associated with one or both substrates and arranged for conducting one or more droplet operations in the droplet operations gap. The droplet actuator may include a reagent storage cassette with one or more reservoirs including one or more liquids. One or more fluid paths may be provided from the one or more reservoirs into the droplet operations gap. The fluid paths may be blocked by a film or other breakable, removable or puncturable material. A plunger may be associated with the reservoir and arranged to force liquid from the reservoir into the fluid path when depressed into the reservoir. A series of the reservoirs and a series of the plungers may be included. Each of the reservoirs may be associated with a corresponding plunger arranged to force liquid from the reservoir into the fluid path. The plungers may be coupled to a common plunger depressor. The film may be selected with physical and/or chemical characteristics which permit it to break upon application of pressure to liquid in the reservoir or reservoirs when the plunger or plungers are depressed. For example, film may be scored or include a thin or weakened region that breaks upon application of pressure to liquid in the reservoir or reservoirs by depressing the plunger or plungers. The reagent storage cassette may include an awl, scribe or other puncturing device arranged to puncture the film and thereby permit liquid to flow through the fluid path. The device may include an awl, point, scribe or other puncturing device slideably inserted within a slot in the plunger and arranged to puncture the film and thereby permit liquid to flow through the fluid path. The droplet actuator may include a series of reservoirs, wherein each reservoir in the series of the reservoirs may be associated with a connecting fluid path extending from the reservoir and into a channel of the fluid path, such that upon depression of the plungers, a series of droplets may be forced through the connecting fluid path and into the channel. The channel may include a liquid filler fluid which may be immiscible with the series of droplets. The channel may be coupled to a pressure or vacuum source for flowing droplets through the channel and into the droplet operations gap. The channel may be associated with one or more electrodes configured for transporting droplets through the channel and into the droplet operations gap. The droplet actuator may include a series of reservoirs, wherein each reservoir in the series of reservoirs is associated with a fluid path from the reservoir into the droplet operations gap. Liquid forced through the fluid path into the droplet operations gap may be subject to one or more droplet operations in the droplet operations gap. In some embodiments, the fluid path from the reservoir into the droplet operations gap passes through an opening in an electrode. The electrode may, for example, be a droplet operations electrode, such as a reservoir electrode. In some embodiments, the fluid path may be fluidly coupled with one or more filler fluid channels arranged for flowing filler fluid around droplets in the fluid path.
[0006] The invention provides a method of conducting a droplet operation including providing a channel; flowing an immiscible liquid including a droplet through the channel and into proximity with a set of one or more electrodes; using the set of one or more electrodes with the droplet to conduct a droplet operation; and continuing to flow the droplet or one or more daughter droplets formed during the droplet operation through the channel. The droplet operation may be effected without stopping flow of the immiscible liquid through the channel. The droplet operation may include splitting the droplet into two or more daughter droplets. The droplet operation may include interrupting the flow of the droplet through the channel. In some embodiments, the channel splits into first and second branches, and the droplet operation may include splitting the droplet into two or more droplets, one or more droplets flowing into a first of the two or more branches and a second of the two or more droplets flowing into a second of the two or more branches. In some embodiments, the channel splits into first and second branches, and the droplet operation causes the droplet to flow down one or the other of the first and second branches.
[0007] The invention also provides a method of manipulating a droplet, the method comprising providing a channel; flowing a liquid filler fluid including a magnetically-responsive, bead-containing droplet through the channel and into proximity with a magnetic field to substantially immobilize the magnetically responsive bead and thereby capture the bead-containing droplet; releasing the magnetically responsive bead from the magnetic field, thereby permitting it to continue to flow through the channel. In some cases, substantially all of the liquid volume of the bead-containing droplet remains with the magnetically responsive bead when it may be substantially immobilized by the magnetic field. In other cases, at least a portion of the liquid volume of the bead-containing droplet breaks away from the magnetically responsive bead when it may be substantially immobilized by the magnetic field and continues to flow with the liquid filler fluid through the channel. The method may also include flowing a second droplet in the flowing filler fluid into contact with the captured bead-containing droplet, wherein the second droplet merges with the bead-containing droplet. In some embodiments the flowing filler fluid causes a bead-free droplet to break away from the bead-containing droplet and continue to flow with the liquid filler fluid through the channel. The second droplet may, for example, include a wash buffer. The method may also include repeating the flowing of a second droplet in the flowing filler fluid into contact with the captured bead-containing droplet using a series of two or more of such second droplets to reduce the concentration and/or quantity of a substance present in the liquid volume of the bead-containing droplet. The method may also include repeating the flowing of a second droplet in the flowing filler fluid into contact with the captured bead-containing droplet until the liquid volume of the bead-containing droplet may be substantially replaced. The second droplet may include a sample droplet having a target for which the bead may have affinity. The method may also include repeating the flowing of a second droplet in the flowing filler fluid into contact with the captured bead-containing droplet using a series of two or more of such second droplets to concentrate a target substance on the bead of the bead-containing droplet. The target substance may, for example, include organic molecules, inorganic molecules, peptides, proteins, macromolecules, subcellular components of a biological cell, cells, group of cells, single celled organisms, multicellular organisms. The method may also include flowing a third droplet in the flowing filler fluid into contact with the captured bead-containing droplet, wherein the third droplet merges with the bead-containing droplet; the flowing filler fluid causes a bead-free droplet to break away from the bead-containing droplet and continue to flow with the liquid filler fluid through the channel. The third droplet may, for example, include a wash buffer. The method may also include repeating the flowing of a third droplet in the flowing filler fluid into contact with the captured bead-containing droplet using a series of two or more of such third droplets sufficient to reduce the concentration and/or quantity of a substance present in the liquid volume of the bead-containing droplet. The method may also include repeating the flowing of a third droplet in the flowing filler fluid into contact with the captured bead-containing droplet until the liquid volume of the bead-containing droplet may be substantially replaced. The method may also include releasing the magnetically responsive bead from the magnetic field, e.g., to permit a reconstituted magnetically responsive bead containing droplet to flow in the filler fluid through the channel. In some embodiments the magnetic field may be in proximity with a set of one or more electrodes and the method may include using the set of one or more electrodes with the bead-containing droplet to conduct a droplet operation. The method may include continuing to flow the droplet or one or more daughter droplets formed during the droplet operation through the channel. The method may include flowing the reconstituted magnetically responsive bead containing droplet into a droplet actuator reservoir and/or into a droplet operations gap of a droplet actuator, where the magnetically responsive bead containing droplet may be subjected to one or more droplet operations. The one or more droplet operations may include steps in an assay protocol to analyze a target substance on the magnetically responsive bead. The droplet operation may be effected without stopping flow of the immiscible liquid through the channel. The droplet operation may include splitting the droplet into two or more daughter droplets: one or more of such daughter droplets including the magnetically responsive bead; and one or more of such daughter droplets substantially lacking in magnetically responsive beads. The droplet operation may include interrupting the flow of the droplet through the channel. In some cases, the channel splits into first and second branches; and the droplet operation includes splitting the droplet into two or more droplets, including one or more daughter droplets flowing into a first of the two or more branches and including the magnetically responsive bead; and one or more daughter droplets flowing into a second of the two or more branches and substantially lacking in magnetically responsive beads.
[0008] The invention also provides a method of encapsulating a magnetically responsive bead in a droplet, the method may include providing a channel; flowing an immiscible liquid including a magnetically responsive bead through the channel and into proximity with a magnetic field; capturing the magnetically responsive bead in the magnetic field; flowing an immiscible liquid including a droplet into contact with the magnetically responsive bead to encapsulate the magnetically responsive bead in the droplet, thereby yielding a bead-containing droplet. The magnetically responsive bead may have affinity for an aqueous medium, the droplet may include an aqueous medium, and the filler fluid may include a non-aqueous liquid. The method may also include releasing the magnetically responsive bead from the magnetic field, thereby permitting the bead-containing droplet to continue to flow with the filler fluid through the channel.
[0009] The invention provides a method of sampling a non-liquid sample on a droplet actuator, the method may include providing a droplet actuator including a droplet operations and electrodes configured to conduct one or more droplet operations on the droplet operations surface; supplying a non-liquid sample in proximity to or in contact with the droplet operations surface; effecting one or more droplet operations to contact a droplet on the droplet operations surface into contact with the non-liquid sample to dissolve into the droplet one or more components of the non-liquid sample; effecting one or more droplet operations to conduct the droplet away from the non-liquid sample. The non-liquid sample may include a solid sample, a semi-solid sample and/or a viscous sample. The droplet may include one or more beads having affinity for one or more of the components of the non-liquid sample. The droplet may include an enzyme having affinity for a component of the non-liquid sample. The droplet may have pH selected to dissolve the non-liquid sample. The sample may include cells and the droplet may include a lysis buffer solution selected to lyse the cells. The one or more droplet operations may include an electrode-mediated droplet operation. The one or more droplet operations may include an electrowetting-mediated droplet operation. The one or more droplet operations may include a dielectrophoresis-mediated droplet operation. The non-liquid sample sufficiently viscous, semi-solid or solid to permit a droplet to contact the sample and be transported away from the sample without being substantially combined with the sample. The non-liquid sample may be selected from the group consisting of sputum, coagulated blood, animal tissue samples, plant tissue samples, soil samples, and rock samples. The non-liquid sample may include a matrix used to collect the sample. The droplet may include an aqueous droplet. The droplet may include a non-aqueous droplet. The method may include using the droplet to conduct an assay analyzing a component of the sample. In some cases, the assay analyzes a protein or peptide present in the sample. In some cases, the assay may include amplifying a nucleic acid present in the sample. The method may include removing the droplet from the droplet actuator.
[0010] The invention provides a method of providing a polymerized material on a droplet operations surface. The method may include providing a droplet actuator including a substrate including electrodes arranged for conducting droplet operations on a droplet operations surface of the substrate. The method may include providing on the droplet operations substrate a polymerizable droplet on the droplet operations substrate and a catalyst droplet including a catalyst selected to accelerate polymerization of the polymerizable droplet. The method may also include conducting droplet operations mediated by the electrodes to combine the polymerizable droplet with the catalyst droplet to yield a polymerizing droplet. Further, the method may include permitting the polymerizing droplet to polymerize, thereby yielding a polymerized material on the droplet operations surface. The droplet actuator may include a second substrate separated from the droplet operations surface to provide a droplet operations gap in which the droplet operations may be conducted. In some embodiments the droplet operations may be conducted in a liquid filler fluid which may be immiscible with the polymerizable droplet and the catalyst droplet. In some embodiments the polymerized material may include a gel selected for conducting gel electrophoresis. The polymerized material may, for example, be a polyacrylamide gel or an agarose gel. The method may include activating a series of two or more electrodes underlying the polymerizable droplet to elongate the droplet prior to combining the polymerizable droplet with the catalyst droplet. The method may include activating a series of two or more electrodes underlying the polymerizing droplet to elongate the droplet prior to permitting the polymerizing droplet to polymerize.
[0011] The invention also provides a method of causing separation of one or more substances. The method may include providing a sample droplet including substances for separation on the droplet operations surface or in a reservoir associated with a fluid path arranged to flow liquid from the reservoir into contact with the polymerized material. The method may include contacting the sample droplet with the polymerized material. The method may include applying current to the polymerized material to cause separation of one or more of the substances provided in the sample droplet. In some cases, the droplet actuator may include a second substrate separated from the droplet operations surface to provide a droplet operations gap, the second substrate including an opening providing a fluid path from an exterior locus into the droplet operations gap; and providing a sample droplet may include supplying a sample droplet through the opening in the second substrate into contact with the polymerized material. The method may include marking one or more target substances for detection. For example, in some cases, the one or more substances for separation may include one or more nucleic acids, and the marking may include staining the one or more nucleic acids. In some embodiments the marking may include providing a marker droplet on the droplet operations surface, and using one or more droplet operations to transport the marker droplet into contact with the polymerized material.
[0012] The invention also provides a droplet actuator including a substrate including electrodes arranged for conducting droplet operations on a droplet operations surface of the substrate; a polymerized material for conducting gel electrophoresis; negative and positive electrodes in contact with the polymerized material. The droplet actuator may include a second substrate separated from the droplet operations surface to provide a droplet operations gap in which the droplet operations may be conducted. The droplet actuator may include a liquid filler fluid in contact with the droplet operations surface. The polymerized material may, for example, include a gel selected from the group consisting of polyacrylamide gels and agarose gels. The droplet actuator may include a sample droplet including substances for separation on the droplet operations surface or in a reservoir associated with a fluid path arranged to flow liquid from the reservoir into contact with the polymerized material. The substances for separation may, for example, include proteins, peptides and/or nucleic acids. The droplet actuator may include a second substrate separated from the droplet operations surface to provide a droplet operations gap. In some cases, the second substrate including an opening providing a fluid path from an exterior locus into the droplet operations gap. The droplet actuator may include including a marker droplet including reagents for marking one or more target substances in the polymerized material for detection.
[0013] The invention provides a droplet actuator loading circuit including a primary fluid circuit arranged to flow fluid through a fluid path including a droplet operations gap of a droplet actuator and a an external fluid circuit. The droplet actuator loading circuit may include a reagent fluid path branching from the primary fluid circuit and fluidly connecting the primary fluid path to one or more reservoirs including reagents and/or filler fluid. The droplet actuator loading circuit may include a mechanism for switching the reagent fluid path from one reservoir to another reservoir. The mechanism for switching the reagent fluid path between reagent reservoirs may include a robotic device for moving a terminus of the reagent fluid path from one reservoir to another reservoir. The droplet actuator loading circuit may include one or more valves configured in the primary fluid circuit and/or the reagent fluid path to permit switching between circulating liquid in the primary fluid circuit, and flowing liquid from the one or more reservoirs including reagents and/or filler fluid into the primary fluid circuit. The droplet actuator loading circuit may include a reagent fluid path branching from the primary fluid circuit and fluidly connecting the primary fluid path to one or more reservoirs including reagents, and a filler fluid path branching from the primary fluid circuit and fluidly connecting the primary fluid path to one or more reservoirs including a liquid filler fluid. The droplet actuator loading circuit may include one or more valves configured in the primary fluid circuit and/or the reagent fluid path to permit switching between circulating liquid in the primary fluid circuit, and flowing liquid reagent from the one or more reservoirs including reagents into the primary fluid circuit, flowing filler fluid from the one or more reservoirs including liquid filler fluid into the primary fluid circuit. The droplet actuator loading circuit, wherein the reagent fluid path and/or the filler fluid path branches from the primary fluid circuit at a locus which may be in the external fluid circuit. The droplet actuator loading circuit including a pump disposed to pump liquid through the primary fluid circuit. The pump may, for example, include a reversible pump. The pump may include a peristaltic pump. The pump may be disposed to pump liquid through the primary fluid circuit, wherein the pump may be disposed in the primary fluid circuit at a locus which lies between a locus in the primary fluid circuit at which the reagent fluid path branches from the primary fluid circuit, and a locus in the primary fluid circuit at which the filler fluid path branches from the primary fluid circuit. The droplet actuator loading circuit may also include an overflow fluid path fluidly coupled into the droplet operations gap. The droplet actuator loading circuit may also include a reservoir and a pump disposed to pump liquid from the droplet operations gap through the overflow fluid path and into a reservoir. The reservoir and pump together may comprise a syringe pump.
[0014] The invention provides a method of loading a droplet actuator. The method may include providing a droplet actuator loading circuit including a primary fluid circuit arranged to flow fluid through a fluid path including a droplet operations gap of a droplet actuator and a an external fluid circuit. The method may include filling the loading circuit, including the droplet operations gap, with a liquid filler fluid and thereby purging the loading circuit of air. The method may include flowing reagent liquid into the external fluid circuit to form droplets in the liquid filler fluid contained therein. The method may include flowing contents of the external fluid circuit into the droplet operations gap of the droplet actuator. Filling the loading circuit, including the droplet operations gap, with a liquid filler fluid may include flowing filler fluid into the primary fluid circuit via a filler fluid branch in the primary fluid circuit. The filler fluid branch in the primary fluid circuit may be situated in the external fluid circuit. Flowing reagent liquid into the external fluid circuit may include flowing reagent into the primary fluid circuit via a reagent branch in the primary fluid circuit. The reagent branch in the primary fluid circuit may be situated in the external fluid circuit. Different kinds of reagent droplets may be loaded into the external fluid circuit. Reagent types may be selected by switching the reagent branch from one reservoir to another reservoir. The switching may be effected by a robotic device configured to move a terminus of the reagent fluid path from one reservoir to another reservoir. Valves configured in the primary fluid circuit and/or the reagent fluid path to switch between circulating liquid in the primary fluid circuit, and flowing liquid from the one or more reservoirs including reagents and/or filler fluid into the primary fluid circuit. The method further may include flowing liquid from the droplet operations gap through an overflow fluid path fluidly coupled into the droplet operations gap. Flowing liquid from the droplet operations gap through an overflow fluid path may include pumping the liquid through the overflow path into a reservoir. The reservoir and pump together may include a syringe pump.
[0015] The invention provides a method of preparing a sample droplet. The method may include providing a droplet actuator substrate including a droplet operations surface and electrodes configured to conduct droplet operations on the droplet operations surface. The method may include providing a sample droplet including cells including a target substance on the droplet operations surface. The method may include providing a lysis droplet including a lysis buffer on the droplet operations surface. The method may include using one or more droplet operations mediated by the electrodes to combine the lysis droplet with the sample droplet to yield a lysed droplet including lysed cells. The method may include providing in the lysed droplet beads having affinity for the target substance. The sample droplet may include beads. Beads may be added to the sample droplet buffer prior to providing the sample droplet on the droplet operations surface. The sample droplet may be merged with a bead droplet including the beads on the droplet operations surface. The lysis droplet may be provided with the beads. Beads may be added to the lysis buffer prior to providing the lysis droplet on the droplet operations surface. The lysis droplet may be merged with a bead droplet including the beads on the droplet operations surface. The method may include washing the beads to yield a washed bead droplet substantially lacking in unbound material from the sample. The method may include providing an elution droplet on the droplet operations surface, and using one or more droplet operations to combine the elution droplet with the washed bead droplet to yield an eluted droplet in which the target substance may be eluted from the beads. The method may include heating the combined elution droplet and washed bead droplet to accelerate elution of target substance from the beads. The method may include trapping the beads and using one or more droplet operations to transport away from the beads a substantially bead-free droplet on the droplet operations surface. The target substance may include a target protein or target peptide. The target substance may include a target nucleic acid. The method may include supplying the substantially bead-free droplet or the washed bead droplet with reagents for conducting nucleic acid amplification to yield an amplification-ready droplet. One or more droplet operations may be used to combine the substantially bead-free droplet or the washed bead droplet with an amplification reagent droplet including reagents for conducting nucleic acid amplification. The method may include thermal cycling the amplification-ready droplet to amplify the target nucleic acid. The cells may include eukaryotic cells or prokaryotic cells. The cells may include bacterial cells. In some embodiments, the bacterial cells may include cells from Staphylococcus species, Streptococcus species, Enterococcus species, Pseudomonas species, Clostridium species, and/or Acinetobacter species. In some embodiments, the bacterial cells may include cells from Staphylococcus aureus, Pseudomonas aeruginosa, Clostridium difficile, Acinetobacter baumannii, Bacillus anthracis, Franciscella tularensis, Mycoplasma pneumoniae , and Eschericia coli.
[0016] The invention provides a droplet actuator device including a droplet actuator including a electronic storage and/or transmission element. The electronic storage and/or transmission element may be affixed to or incorporated in a droplet actuator. The electronic storage and/or transmission element may be affixed to or incorporated in a droplet actuator cartridge including a droplet actuator. The electronic storage and/or transmission element may include a computer readable data storage element. The computer readable data storage element may include semiconductor memory, magnetic storage, optical storage, volatile memory, non-volatile memory, a radio-frequency identification tag, read-only memory, random access memory, electrically erasable programmable read-only memory, flash memory, and/or a magnetic stripe. The magnetic stripe may be provided on a magnetic stripe card, and the droplet actuator may be mounted on the magnetic stripe card. The droplet actuator mounted on the magnetic stripe card may include electrical contacts arranged to couple with electrical contacts on a droplet actuator instrument when the magnetic stripe card may be inserted in a magnetic card slot of a magnetic card reading instrument. The droplet actuator may be electrically connected to wires on the card. The wires on the card may terminate in contacts arranged to be electrically coupled to electrical contacts on an instrument so that the droplet actuator may be controlled by the instrument. The card may have a shape and size of a standard credit card. The electronic storage and/or transmission element may include a unique identifier for the droplet actuator. The droplet actuator device may be configured with a connect device for connecting the droplet actuator device to a computer as a peripheral device. The connect device may, for example, include a universal serial bus connector. The droplet actuator device may also include a positioning device, such as a global positioning device.
[0017] The invention also includes a networked system including the droplet actuator device distributed in a target geographical region with communications capabilities for transmitting data to one or more data aggregation centers. The droplet actuators may be installed on fixed bases. The fixed bases may be selected from the group consisting of: buildings, farms, water supply sources, buoys, and weather balloons. The droplet actuators may be installed on fixed bases. The mobile bases may be selected from the group consisting of: mobile robotic devices, airplanes, unmanned drones, vehicles in vehicle fleets. The mobile bases may be selected from the group consisting of: police cars, school buses, ambulances, military vehicles, oceangoing vessels, postal vehicles, and vehicles in commercial vehicle fleets.
[0018] The invention provides a system including the droplet actuator device and a global position sensor. The invention provides a system including one or more kiosks including a dispenser for dispensing a droplet actuator device. The invention provides a system including one or more kiosks including a receptacle for receiving a droplet actuator device. The kiosk may also include an input device for inputting information associated with a droplet actuator device.
DEFINITIONS
[0019] As used herein, the following terms have the meanings indicated.
[0020] “Activate” with reference to one or more electrodes means effecting a change in the electrical state of the one or more electrodes which, in the presence of a droplet, results in a droplet operation.
[0021] “Bead,” with respect to beads on a droplet actuator, means any bead or particle capable of interacting with a droplet on or in proximity with a droplet actuator. Beads may be any of a wide variety of shapes, such as spherical, generally spherical, egg shaped, disc shaped, cubical and other three dimensional shapes. The bead may, for example, be capable of being transported in a droplet on a droplet actuator or otherwise configured with respect to a droplet actuator in a manner which permits a droplet on the droplet actuator to be brought into contact with the bead, on the droplet actuator and/or off the droplet actuator. Beads may be manufactured using a wide variety of materials, including for example, resins, and polymers. The beads may be any suitable size, including for example, microbeads, microparticles, nanobeads and nanoparticles. In some cases, beads are magnetically responsive; in other cases beads are not significantly magnetically responsive. For magnetically responsive beads, the magnetically responsive material may constitute substantially all of a bead or one component only of a bead. The remainder of the bead may include, among other things, polymeric material, coatings, and moieties which permit attachment of an assay reagent. Examples of suitable magnetically responsive beads are described in U.S. Patent Publication No. 2005-0260686, entitled, “Multiplex flow assays preferably with magnetic particles as solid phase,” published on Nov. 24, 2005, the entire disclosure of which is incorporated herein by reference for its teaching concerning magnetically responsive materials and beads. The fluids may include one or more magnetically responsive and/or non-magnetically responsive beads. Examples of droplet actuator techniques for immobilizing magnetically responsive beads and/or non-magnetically responsive beads and/or conducting droplet operations protocols using beads are described in U.S. patent application Ser. No. 11/639,566, entitled “Droplet-Based Particle Sorting,” filed on Dec. 15, 2006; U.S. Patent Application No. 61/039,183, entitled “Multiplexing Bead Detection in a Single Droplet,” filed on Mar. 25, 2008; U.S. Patent Application No. 61/047,789, entitled “Droplet Actuator Devices and Droplet Operations Using Beads,” filed on Apr. 25, 2008; U.S. Patent Application No. 61/086,183, entitled “Droplet Actuator Devices and Methods for Manipulating Beads,” filed on Aug. 5, 2008; International Patent Application No. PCT/US2008/053545, entitled “Droplet Actuator Devices and Methods Employing Magnetic Beads,” filed on Feb. 11, 2008; International Patent Application No. PCT/US2008/058018, entitled “Bead-based Multiplexed Analytical Methods and Instrumentation,” filed on Mar. 24, 2008; International Patent Application No. PCT/US2008/058047, “Bead Sorting on a Droplet Actuator,” filed on Mar. 23, 2008; and International Patent Application No. PCT/US2006/047486, entitled “Droplet-based Biochemistry,” filed on Dec. 11, 2006; the entire disclosures of which are incorporated herein by reference.
[0022] “Droplet” means a volume of liquid on a droplet actuator that is at least partially bounded by filler fluid. For example, a droplet may be completely surrounded by filler fluid or may be bounded by filler fluid and one or more surfaces of the droplet actuator. Droplets may, for example, be aqueous or non-aqueous or may be mixtures or emulsions including aqueous and non-aqueous components. Droplets may take a wide variety of shapes; nonlimiting examples include generally disc shaped, slug shaped, truncated sphere, ellipsoid, spherical, partially compressed sphere, hemispherical, ovoid, cylindrical, and various shapes formed during droplet operations, such as merging or splitting or formed as a result of contact of such shapes with one or more surfaces of a droplet actuator. For examples of droplet fluids that may be subjected to droplet operations using the approach of the invention, see International Patent Application No. PCT/US 06/47486, entitled, “Droplet-Based Biochemistry,” filed on Dec. 11, 2006. In various embodiments, a droplet may include a biological sample, such as whole blood, lymphatic liquid, serum, plasma, sweat, tear, saliva, sputum, cerebrospinal liquid, amniotic liquid, seminal liquid, vaginal excretion, serous liquid, synovial liquid, pericardial liquid, peritoneal liquid, pleural liquid, transudates, exudates, cystic liquid, bile, urine, gastric liquid, intestinal liquid, fecal samples, liquids containing single or multiple cells, liquids containing organelles, fluidized tissues, fluidized organisms, liquids containing multi-celled organisms, biological swabs and biological washes. Moreover, a droplet may include a reagent, such as water, deionized water, saline solutions, acidic solutions, basic solutions, detergent solutions and/or buffers. Other examples of droplet contents include reagents, such as a reagent for a biochemical protocol, such as a nucleic acid amplification protocol, an affinity-based assay protocol, an enzymatic assay protocol, a sequencing protocol, and/or a protocol for analyses of biological fluids.
[0023] “Droplet Actuator” means a device for manipulating droplets. For examples of droplet actuators, see U.S. Pat. No. 6,911,132, entitled “Apparatus for Manipulating Droplets by Electrowetting-Based Techniques,” issued on Jun. 28, 2005 to Pamula et al.; U.S. patent application Ser. No. 11/343,284, entitled “Apparatuses and Methods for Manipulating Droplets on a Printed Circuit Board,” filed on filed on Jan. 30, 2006; U.S. Pat. No. 6,773,566, entitled “Electrostatic Actuators for Microfluidics and Methods for Using Same,” issued on Aug. 10, 2004 and U.S. Pat. No. 6,565,727, entitled “Actuators for Microfluidics Without Moving Parts,” issued on Jan. 24, 2000, both to Shenderov et al.; Pollack et al., International Patent Application No. PCT/US2006/047486, entitled “Droplet-Based Biochemistry,” filed on Dec. 11, 2006; and Roux et al., U.S. Patent Pub. No. 20050179746, entitled “Device for Controlling the Displacement of a Drop Between two or Several Solid Substrates,” published on Aug. 18, 2005; the disclosures of which are incorporated herein by reference. Certain droplet actuators will include a substrate, droplet operations electrodes associated with the substrate, one or more dielectric and/or hydrophobic layers atop the substrate and/or electrodes forming a droplet operations surface, and optionally, a top substrate separated from the droplet operations surface by a gap. One or more reference electrodes may be provided on the top and/or bottom substrates and/or in the gap. In various embodiments, the manipulation of droplets by a droplet actuator may be electrode mediated, e.g., electrowetting mediated or dielectrophoresis mediated or Coulombic force mediated. Examples of other methods of controlling liquid flow that may be used in the droplet actuators of the invention include devices that induce hydrodynamic fluidic pressure, such as those that operate on the basis of mechanical principles (e.g. external syringe pumps, pneumatic membrane pumps, vibrating membrane pumps, vacuum devices, centrifugal forces, piezoelectric/ultrasonic pumps and acoustic forces); electrical or magnetic principles (e.g. electroosmotic flow, electrokinetic pumps, ferrofluidic plugs, electrohydrodynamic pumps, attraction or repulsion using magnetic forces and magnetohydrodynamic pumps); thermodynamic principles (e.g. gas bubble generation/phase-change-induced volume expansion); other kinds of surface-wetting principles (e.g. electrowetting, and optoelectrowetting, as well as chemically, thermally, structurally and radioactively induced surface-tension gradients); gravity; surface tension (e.g., capillary action); electrostatic forces (e.g., electroosmotic flow); centrifugal flow (substrate disposed on a compact disc and rotated); magnetic forces (e.g., oscillating ions causes flow); magnetohydrodynamic forces; and vacuum or pressure differential. In certain embodiments, combinations of two or more of the foregoing techniques may be employed in droplet actuators of the invention.
[0024] “Droplet operation” means any manipulation of a droplet on a droplet actuator. A droplet operation may, for example, include: loading a droplet into the droplet actuator; dispensing one or more droplets from a source droplet; splitting, separating or dividing a droplet into two or more droplets; transporting a droplet from one location to another in any direction; merging or combining two or more droplets into a single droplet; diluting a droplet; mixing a droplet; agitating a droplet; deforming a droplet; retaining a droplet in position; incubating a droplet; heating a droplet; vaporizing a droplet; cooling a droplet; disposing of a droplet; transporting a droplet out of a droplet actuator; other droplet operations described herein; and/or any combination of the foregoing. The terms “merge,” “merging,” “combine,” “combining” and the like are used to describe the creation of one droplet from two or more droplets. It should be understood that when such a term is used in reference to two or more droplets, any combination of droplet operations that are sufficient to result in the combination of the two or more droplets into one droplet may be used. For example, “merging droplet A with droplet B,” can be achieved by transporting droplet A into contact with a stationary droplet B, transporting droplet B into contact with a stationary droplet A, or transporting droplets A and B into contact with each other. The terms “splitting,” “separating” and “dividing” are not intended to imply any particular outcome with respect to volume of the resulting droplets (i.e., the volume of the resulting droplets can be the same or different) or number of resulting droplets (the number of resulting droplets may be 2, 3, 4, 5 or more). The term “mixing” refers to droplet operations which result in more homogenous distribution of one or more components within a droplet. Examples of “loading” droplet operations include microdialysis loading, pressure assisted loading, robotic loading, passive loading, and pipette loading. Droplet operations may be electrode-mediated. In some cases, droplet operations are further facilitated by the use of hydrophilic and/or hydrophobic regions on surfaces and/or by physical obstacles.
[0025] “Filler fluid” means a liquid associated with a droplet operations substrate of a droplet actuator, which liquid is sufficiently immiscible with a droplet phase to render the droplet phase subject to electrode-mediated droplet operations. The filler fluid may, for example, be a low-viscosity oil, such as silicone oil. Other examples of filler fluids are provided in International Patent Application No. PCT/US2006/047486, entitled, “Droplet-Based Biochemistry,” filed on Dec. 11, 2006; International Patent Application No. PCT/US2008/072604, entitled “Use of additives for enhancing droplet actuation,” filed on Aug. 8, 2008; and U.S. Patent Publication No. 20080283414, entitled “Electrowetting Devices,” filed on May 17, 2007; the entire disclosures of which are incorporated herein by reference. The filler fluid may fill the entire gap of the droplet actuator or may coat one or more surfaces of the droplet actuator. Filler fluid may be conductive or non-conductive.
[0026] “Immobilize” with respect to magnetically responsive beads, means that the beads are substantially restrained in position in a droplet or in filler fluid on a droplet actuator. For example, in one embodiment, immobilized beads are sufficiently restrained in position to permit execution of a splitting operation on a droplet, yielding one droplet with substantially all of the beads and one droplet substantially lacking in the beads.
[0027] “Magnetically responsive” means responsive to a magnetic field. “Magnetically responsive beads” include or are composed of magnetically responsive materials. Examples of magnetically responsive materials include paramagnetic materials, ferromagnetic materials, ferrimagnetic materials, and metamagnetic materials. Examples of suitable paramagnetic materials include iron, nickel, and cobalt, as well as metal oxides, such as Fe3O4, BaFe12O19, CoO, NiO, Mn2O3, Cr2O3, and CoMnP.
[0028] “Washing” with respect to washing a magnetically responsive bead means reducing the amount and/or concentration of one or more substances in contact with the magnetically responsive bead or exposed to the magnetically responsive bead from a droplet in contact with the magnetically responsive bead. The reduction in the amount and/or concentration of the substance may be partial, substantially complete, or even complete. The substance may be any of a wide variety of substances; examples include target substances for further analysis, and unwanted substances, such as components of a sample, contaminants, and/or excess reagent. In some embodiments, a washing operation begins with a starting droplet in contact with a magnetically responsive bead, where the droplet includes an initial amount and initial concentration of a substance. The washing operation may proceed using a variety of droplet operations. The washing operation may yield a droplet including the magnetically responsive bead, where the droplet has a total amount and/or concentration of the substance which is less than the initial amount and/or concentration of the substance. Examples of suitable washing techniques are described in Pamula et al., U.S. Pat. No. 7,439,014, entitled “Droplet-Based Surface Modification and Washing,” granted on Oct. 21, 2008, the entire disclosure of which is incorporated herein by reference.
[0029] The terms “top,” “bottom,” “over,” “under,” and “on” are used throughout the description with reference to the relative positions of components of the droplet actuator, such as relative positions of top and bottom substrates of the droplet actuator. It will be appreciated that the droplet actuator is functional regardless of its orientation in space.
[0030] When a liquid in any form (e.g., a droplet or a continuous body, whether moving or stationary) is described as being “on”, “at”, or “over” an electrode, array, matrix or surface, such liquid could be either in direct contact with the electrode/array/matrix/surface, or could be in contact with one or more layers or films that are interposed between the liquid and the electrode/array/matrix/surface.
[0031] When a droplet is described as being “on” or “loaded on” a droplet actuator, it should be understood that the droplet is arranged on the droplet actuator in a manner which facilitates using the droplet actuator to conduct one or more droplet operations on the droplet, the droplet is arranged on the droplet actuator in a manner which facilitates sensing of a property of or a signal from the droplet, and/or the droplet has been subjected to a droplet operation on the droplet actuator.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] FIGS. 1A and 1B illustrate a reagent storage cassette of the invention. FIG. 1A shows the reagent storage cassette and an open position. FIG. 1B shows the reagent storage cassette in a closed position.
[0033] FIGS. 2A and 2B illustrate a reagent storage cassette of the invention including a protective film configured to protect reagents from contamination and/or prevent leaking of reagents. FIG. 2A shows the reagent storage cassette and an open position. FIG. 2B shows an alternative embodiment of the reagent storage cassette in a closed position where the film includes a pull tab.
[0034] FIGS. 3A , 3 B, 3 C, 3 D, and 3 E show cross-sectional views of segments of top and bottom members of a reagent storage cassette of the invention that makes use of plungers to force droplets from storage reservoirs. FIG. 3A illustrates a segment of the bottom member with the protective film in place. FIG. 3B illustrates the segment of the bottom member with plungers fully inserted to force droplets from storage reservoirs. FIGS. 3C and 3D illustrate a corresponding segment of a top member of a reagent storage cassette juxtaposed with the cross sectional view of a segment of the bottom member of the reagent storage cassette. In FIG. 3C , the droplets are present in the reservoirs. In FIG. 3D , plungers are fully inserted to force droplets from storage reservoirs. FIG. 3E illustrates an end-wise cross-sectional view of the reagent storage cassette showing a section of the top member juxtaposed with a corresponding section of the bottom member.
[0035] FIG. 4 illustrates another embodiment of the invention in which a droplet actuator cartridge is provided with a droplet actuator portion an integral reagent cassette portion.
[0036] FIGS. 5A and 5B illustrate a side cross-sectional view and a top view, respectively, of a droplet actuator configured to supply droplets into reservoirs in a droplet operations gap.
[0037] FIGS. 6A , 6 B, 6 C, 6 D, 6 E, and 6 F illustrate another aspect of the invention in which a plunger is used to force liquid into the droplet operations gap of a droplet actuator. FIG. 6A shows liquid in a reservoir outside the droplet operations gap, prior to being forced into the droplet operations gap. FIG. 6B shows a top view of a reservoir electrode through which liquid is supplied into the droplet operations gap of the droplet actuator. FIG. 6C illustrates puncturing the dielectric layer so that liquid may flow into the droplet operations gap. FIG. 6D illustrates the plunger fully inserted and liquid having been forced into the droplet operations gap. FIG. 6E shows an alternative embodiment in which a single electrode is provided on a top substrate of the droplet actuator. FIG. 6F illustrates an alternative embodiment in which a reservoir electrode and droplet operations electrodes are provide on the top substrate and a ground or reference electrode is provided on the bottom substrate.
[0038] FIG. 7 illustrates an alternative embodiment of the reagent cassette of the invention including a first channel into which droplets are loaded, and a second channel for flowing liquid filler fluid around the droplets in the first channel.
[0039] FIG. 8 illustrates a flow-through system that makes use of droplet operations for splitting droplets.
[0040] FIG. 9 illustrates a flow-through system configured for adding beads to droplets.
[0041] FIG. 10 illustrates a flow-through system that makes use of droplet operations to wash beads in droplets.
[0042] FIGS. 11A , 11 B, and 11 C illustrate a section of a droplet actuator and a method of processing a viscous, solid or semi-solid sample on a droplet actuator.
[0043] FIGS. 12A , 12 B, and 12 C illustrate a section of a droplet actuator and a process of separating and analyzing a sample using gel electrophoresis.
[0044] FIGS. 13A , 13 B, 13 C, 13 D, 13 E, 13 F, 13 G, 13 H, and 13 I are schematic diagrams of fluidics system for loading liquid receptacle, such as a channel or droplet operations gap of a droplet actuator, with liquid. FIG. 13A illustrates the system generally, while FIGS. 13B-13I each illustrate a specific step in a loading process.
[0045] FIGS. 14A , 14 B, 14 C, 14 D, 14 E, and 14 F are schematic diagrams of another fluidics system for loading liquid receptacle, such as a channel or droplet operations gap of a droplet actuator, with liquid. FIG. 14A illustrates the system generally, while FIGS. 14B-14F each illustrate a specific step in a loading process.
[0046] FIG. 15A shows a plot of real-time PCR data for detection of MRSA using digital microfluidics. FIG. 15B shows a plot of real-time PCR data for detection of Bacillus anthracis using digital microfluidics.
[0047] FIG. 16 shows a plot resulting from amplification of MRSA genomic DNA captured, concentrated and eluted on a droplet actuator.
[0048] FIG. 17 illustrates a droplet actuator device of the invention, including a droplet actuator with an electronic storage and/or transmission element.
[0049] FIG. 18 illustrates another droplet actuator device of the invention, including a droplet actuator with an electronic storage and/or transmission element, where the electronic storage and/or transmission element includes a magnetic stripe card.
[0050] FIG. 19 is a functional diagram of a sample collection and analysis system of the invention.
[0051] FIG. 20 is a functional diagram of another sample collection and analysis system of the invention.
DESCRIPTION
[0052] The invention provides droplet actuator devices, techniques and systems for making and using droplet actuators. The invention provides devices, techniques and systems for preparing samples and/or reagents for loading onto a droplet actuator; for loading samples and/or reagents onto a droplet actuator; for storing samples and/or reagents on a droplet actuator and/or for use on a droplet actuator; and/or for conducting droplet operations using samples and/or reagents on a droplet actuator. The invention also provides devices, techniques and systems for conducting flow through bead handling and washing. For example, the invention provides techniques for splitting droplets in a flow-through system, compartmentalizing beads in droplets in a flow-through system, and washing droplets in a flow-through system. The invention provides droplet actuator devices, techniques and systems for making and using droplet actuators to process viscous, solid or semi-solid samples. For example, the invention provides techniques for processing viscous, semisolid, and/or solid samples. The invention provides droplet actuator devices including a gel for use in gel electrophoresis, along with techniques and systems for conducting gel electrophoresis on a droplet actuator. The invention provides a fluidics system and technique for using the system for loading liquids onto a droplet actuator. The invention also provides droplet actuators loaded using the fluidics system and method of the invention and methods of using such droplet actuators to conduct droplet operations. The invention provides droplet actuator devices, techniques and systems for processing samples for use on a droplet actuator device. In some cases, the processing includes pre-processing steps conducted prior to introduction of the samples onto a droplet actuator. The invention provides droplet actuator devices, techniques and systems for capturing, concentrating and/or eluting nucleic acids; and sensitively isolating nucleic acids using one or more droplet operations to perform separation protocols. The invention also provides kits including droplet actuators of the invention along with various other components suitable for executing the techniques of the invention, such as reagents, sample collection devices, and/or instructions.
Liquid Storage and Loading
[0053] The invention provides devices, techniques and systems for preparing samples and/or reagents for loading onto a droplet actuator; for loading samples and/or reagents onto a droplet actuator; for storing samples and/or reagents on a droplet actuator and/or for use on a droplet actuator; and/or for conducting droplet operations using samples and/or reagents on a droplet actuator. The reagents may be stored on the droplet actuator itself, and/or in reagent storage containers that are provided with a droplet actuator cartridge. In some cases, the droplet actuator cartridge may be provided in a kit along with reagents stored and storage containers.
[0054] Reagents selected for storage in accordance with the invention may be reagents which are useful in conducting an assay. For example, the reagents may be useful in an assay for assessing the presence or absence of, and/or quantify the amount of, a chemical or a biochemical substance. Examples of suitable assay types include immunoassays, nucleic acid amplification assays, nucleic acid sequencing assays, enzymatic assays, and other forms of assays. Assays may be conducted with various purposes; examples include medical diagnostics, veterinary diagnostics, weapons or explosives detection, chemical weapons detection, biological weapons detection, environmental testing, water testing, air testing, soil testing, food quality testing, forensics, species identification etc.
[0055] Samples may be collected and tested at a point of sample collection. For example, the point of sample collection may be in a medical care facility, at a subject's bedside, in a laboratory, or in the field. A sample may be collected, loaded onto the droplet actuator cartridge; the cartridge may be inserted into an instrument, an assay may be run, and results may be provided, all at the point of sample collection. In other embodiments, one or more of these steps may be accomplished remotely from the point of sample collection, e.g., in a central laboratory. A sample may be collected in the field, and transported to a laboratory, where it is loaded into a cartridge which is mounted on an instrument; the assay may be run, and results provided. A sample may be collected in the field and loaded into a cartridge in the field, e.g., loaded into a sample reservoir in a droplet actuator cartridge; the cartridge may be returned to a laboratory, where it is mounted on an instrument, an assay is run, and results are provided. Various other combinations are also possible within the scope the invention. The instrument may include electronic and detection components, as well as a means for mounting the cartridge on the instrument, or otherwise coupling the cartridge to the instrument, in a manner in which aligns electronic and detection components with corresponding components or regions of the droplet actuator. The cartridge may include a droplet actuator, electrical components which correspond to the electrical components of the instrument, and one or more detection regions, which are aligned with detection components on the instrument. In various embodiments, the reagent storage and loading techniques described in this specification may also be used for loading sample, e.g., sample may be collected and loaded into a reservoir, where it is stored. Sample may be loaded from the reservoir into the droplet operations gap of the droplet actuator cartridge in preparation for conducting an assay using the droplet actuator cartridge.
[0056] The reagent storage and reconstitution techniques of the invention may be useful in a variety of fluidics devices, such as droplet actuator devices. In some cases, the devices of the invention are packaged with or include reagents. The reagents may be provided in a format that is suitable for use in the field. In certain embodiments, the devices are suitable for use without requiring refrigeration and/or specialized dispensing equipment. Reagents may be rapidly reconstituted and used in express testing. Assay results, currently available by in-laboratory testing, may be made available substantially in ‘real-time.’ Decisions made using assay results can be made more quickly.
[0057] FIG. 1 illustrates a reagent storage cassette 100 of the invention. Cassette 100 includes a bottom member 105 and a top member 110 . Bottom member 105 and a top member 110 may be coupled by a flexible hinge portion or member 115 . FIG. 1A shows bottom member 105 and a top member 110 in an open position. FIG. 1B shows bottom member 105 and a top member 110 in a closed position. In one embodiment, the storage cassette is provided with bottom member 105 and a top member 110 in an open position, and the cassette is manipulated by a user into the closed position shown in FIG. 1B . The flexible member 115 may have different electrical and physical properties in the regions overlying bottom member 105 , overlying top member 110 , and at the hinge and thus can comprise of multiple materials or a same material with different properties or a same material with substantially similar properties. The flexible member 115 may be an insulating material that serves dual purpose of insulating the electrodes on substrate 105 that are used for effecting droplet operations and also serve as a tether to the top plate. The flexible member 115 may have different properties in the portions overlying members 105 and 110 so that it is insulating on bottom member 105 but substantially conductive on top member 110 or vice versa. In other embodiments, the flexible member 115 may be rigid over members 105 and 110 but flexible only at the hinge connecting both the members. In another embodiment, the flexible member may also comprise a gasket or standoff material that forms a gap between the members 105 and 110 so that droplets can reside between members 105 and 110 . The flexible member may also be hydrophobized so that it is ready for droplet operations.
[0058] FIG. 2 illustrates a reagent storage cassette 100 of the invention with protective film 205 . Protective film 205 may be included to provide a seal, enclosing reagent components to protect them from the environment and/or separating reagent components from one another. One embodiment, shown in FIG. 2A illustrates a protective film 205 covering facing surfaces of the bottom member 105 and a top member 110 of cassette 100 . In operation, protective film 205 is removed to expose reagent components, and then bottom member 105 and a top member 110 of cassette 100 are sealed together. FIG. 2B illustrates a protective film inserted between facing surfaces of the bottom member 105 and a top member 110 of cassette 100 . In operation, protective film 205 is removed to expose reagent components in bottom member 105 to reagent components in top member 110 of cassette 100 . The protective film can also serve as a removable insulating or hydrophobic material. After droplet operations are performed, the members 110 and 105 may be separated and a new film 205 may be attached so that the surfaces of the droplet actuator are clean and can be reused without any concern for cross contamination.
[0059] FIG. 3 illustrates cross-sectional views 300 of a segment of bottom member 105 . Bottom member 105 includes reservoir 305 formed therein, which serve as reservoirs for droplets 315 of liquid reagents or samples. Openings 310 provide a liquid path for forcing droplets 315 onto a surface of bottom member 105 . During storage, protective film 205 , illustrated in FIG. 3A , may be maintained in place to seal droplets 315 in reservoirs 310 . Droplets 315 may be pre-metered; however, in some cases, exact premetering is not required, since the droplets will be subject to dispensing operations on the droplet actuator in which dispensed subdroplets will have precise volumes suitable for conducting assays.
[0060] Reservoir 305 is associated with plungers 325 and plunger depressor 330 . Plunger depressor 330 is configured to force plungers 325 into openings 310 , thereby forcing droplets 315 out of openings 310 . Plunger depressor 330 may be manually operated, such that an operator may, by applying pressure to plunger depressor 330 , force plungers 325 into openings 310 , thereby forcing droplets 315 out of openings 310 . Plunger depressor 330 may be automatically operated, for example, so that when an operator inserts the droplet actuator cartridge into an instrument, the active insertion also forces plunger depressor 330 to move plungers through 25 into openings 310 . While reservoir/plunger assemblies are illustrated in FIGS. 3 A/ 3 B, it will be appreciated that in some cases only a single such reservoir/plunger assembly is required. In other cases, more than two reservoir/plunger assemblies may be provided.
[0061] Prior to forcing plungers 325 into openings 310 , protective film 205 may be removed. Alternatively, protective film 205 may be scored or otherwise weakened in regions atop openings 310 so that by applying pressure to plunger depressor 330 , droplets 315 may be forced out of openings 310 and through protective film 205 . In yet another embodiment, an awl, scribe, needle, or other puncturing component may be used to puncture or weaken protective film 205 . For example, top member 110 may be equipped with an awl, scribe or other component configured to puncture or weaken protective film 205 when bottom member 105 and top member 110 are fitted together.
[0062] One or more of droplets 315 may be a fully constituted reagent. One or more of droplets 315 may, when forced out of opening 310 , contact and combine with one or more reagents on surface of bottom member 105 and/or top member 110 of cassette 100 to yield a fully constituted reagent. In another embodiment, droplet 315 constitutes a sample. For example, a sample may be loaded in reservoir 305 at a point of sample collection, and may later be loaded in accordance with the reagent loading techniques described herein. In another embodiment, droplet 315 constitutes a standard solution with known amount of material that can either be used as a calibrant or can be diluted using droplet operations to setup a standard curve using multiple concentrations derived from performing dilutions.
[0063] In some embodiments, protective film 205 also serves as an adhesive and/or dielectric layer. For example, a droplet actuator substrate 105 may include electrodes (not shown) associated with substrate 105 . Protective film 205 may be a dielectric layer atop the electrodes, arranged such that the electrodes may be used to conduct droplet operations atop protective film 205 . Protective film 205 may or may not be bound to substrate 105 using an adhesive layer. A hydrophilic coating (not shown) may, in some cases, be provided atop protective film 205 .
[0064] Substrate 105 may be any rigid substrate, such as a silicon, PCB, plastic, or other polymeric substrate. Electrodes may be any material which is suitably conductive to permit electrodes to mediate droplet operations atop protective film 205 . Examples include copper, chrome, aluminum, gold, silver, indium tin oxide, and other conductive materials. The adhesive layer, when present, may be any adhesive which is suitable for binding protective film 205 to the underlying layers of substrate 105 . In alternative embodiments, the adhesive layer may be absent. Protective film 205 may be any dielectric material, and hydrophobic coating may be any hydrophobic coating that binds to the underlying layers in a manner which is sufficient to permit one or more droplet operations to be conducted atop droplet actuator substrate 105 . The protective film 205 may be coated with a hydrophobic layer. Examples of suitable hydrophobic coatings include fluoropolymers and perfluoroploymers, such as polytetrafluoroethylenes; perfluoroalkoxy polymer resins; fluorinated ethylene-propylenes; polyethylenetetrafluoroethylenes; polyvinylfluorides; polyethylenechlorotrifluoroethylenes; polyvinylidene fluorides; polychlorotrifluoroethylenes; and perfluoropolyethers. In one embodiment, the hydrophobic coating includes an amorphous Teflon fluoropolymer or a TEFLON® fluoropolymer. In another embodiment, the hydrophobic coating includes a CYTOP™ perfluoropolymer.
[0065] In one embodiment, an adhesive layer binds protective film 205 to electrodes and substrate 105 . In one example, protective film 205 is a polyimide film. In yet another example, the adhesive layer includes an acrylic adhesive. In still another example, an adhesive-backed polyimide film provides adhesive layer and protective film 205 . For example, adhesive-backed polyimide film may be a PYRALUX® LF flexible composite (DuPont). PYRALUX® LF7013, for example is an approximately 13 μM viscous, solid or semi-solid DuPont KAPTON® polyimide film and 25 μM viscous, solid or semi-solid acrylic adhesive. Other examples of suitable adhesive-backed films include PYRALUX® LF LF0110, LF0120, LF0130, LF0150, LF0210, LF0220, LF0230, LF0250, LF0310, LF7001, LF7082, LF1510, and LF7034.
[0066] In some embodiments, the adhesive is selected to be releasable, so that the adhesive-backed film may be removed following use and replaced with a fresh adhesive-backed film. In some embodiments, the adhesive may serve as the protective film and the backing may serve as a hydrophobic coating. In other embodiments, the dielectric may be formed as a permanent part of the substrate, and a protective film having a hydrophilic backing may be applied to the permanent dielectric. In yet another embodiment, multiple films may be used and replaced together or separately. For example, a hydrophobic film may be used atop a protective film, and both films may be applied atop a droplet actuator substrate including electrodes. Each of the hydrophobic film and protective film may be replaced together or separately, as needed.
[0067] In one embodiment, the protective film includes a dielectric film, and the droplet actuator substrate includes the substrate, electrodes and a dielectric atop the substrate. The protective film is placed atop the dielectric, and an adhesive may optionally be included between the dielectric and the protective film.
[0068] In another embodiment, the protective film includes a dielectric film, and the droplet actuator substrate includes the substrate, electrodes and a dielectric atop the substrate. The protective film may be placed atop the dielectric, and an adhesive may optionally be included between the dielectric and the protective film. Alternatively, the droplet actuator substrate may include the substrate and electrodes with no dielectric atop the substrate. The protective film may be placed atop the substrate and electrodes, and an adhesive may optionally be included between the substrate and electrodes and the film.
[0069] Top member 110 may be equipped with an awl, scribe or other component configured to puncture or weaken protective film 205 when bottom member 105 and top member 110 are fitted together. Plungers 325 may be equipped with an awl, scribe or other component configured to puncture or weaken protective film 205 when plungers 325 are inserted in reservoirs 305 . Once liquid 315 is forced atop substrate 105 , electrodes associated with top member 110 and/or bottom member 105 may be used to effect droplet operations using droplets 315 . In certain embodiments, the awl, scribe or other component configured to puncture or weaken protective film has a hydrophobic surface.
[0070] In yet another embodiment, the protective film may double as a hydrophobic layer. For example, the wells may be located in the top substrate and separated from the gap by the protective film, doubling as a hydrophobic layer. The protective film may be punctured during loading of droplets into the gap, e.g., by an awl, scribe or other component configured to puncture or weaken protective film, permitting droplets to flow through the punctured region and into the gap where they are subject to droplet operations. In certain embodiments, the awl, scribe or other component configured to puncture or weaken protective film has a hydrophobic surface.
[0071] In an alternative embodiment, the top substrate and bottom substrate are provided bound together, and separated to provide a droplet operations gap. In this embodiment, the droplets 315 would be forced by the plungers 325 into the gap, where they would be subject to droplet operations using electrodes associated with the top member 110 and/or the bottom member 105 .
[0072] FIGS. 3C and 3D illustrates a length-wise cross sectional view 301 of a segment of top member 110 juxtaposed with a cross sectional view 300 of a segment of bottom member 105 described with reference to FIG. 3B . As shown in FIG. 3C , top member 110 includes dried reagent 375 affixed thereto. When droplet 315 is forced out of its opening and into contact with dried reagent 375 , droplet 315 combines with dried reagent 375 to yield a fully constituted reagent, as illustrated in FIG. 3D .
[0073] FIG. 3E illustrates an end-wise cross-sectional view of reagent storage cassette 302 showing top member 110 juxtaposed with bottom member 105 . Top member 110 includes channel 306 , which may be any type of liquid path. Bottom member 105 includes reservoirs 305 formed therein. Film 205 seals channel 306 and reservoir 305 . Reservoir 305 includes a liquid, such as a sample or a reagent or a calibrant. Cassette 302 may include multiple reservoirs. Channel 306 may include one or more dried, concentrated or viscous, solid or semi-solidened reagents 375 . Each dried, concentrated or viscous, solid or semi-solidened reagent 375 may be aligned with a corresponding reservoir 305 , such that when liquid 315 is caused to flow into channel 306 , each dried reagent 375 is combined with a droplet of liquid 315 to yield a constituted reagent. Reservoir 305 is associated with plungers 325 and plunger depressor 330 . Plunger depressor 330 is configured to permit a user to force plungers 325 into reservoir 305 , thereby forcing droplets 315 out of openings 310 and into channel 306 . Reservoir 305 is thus bounded and substantially sealed by substrate 105 along opening 310 , film 205 and plunger 325 . In some embodiments, compressible material 380 may be provided between plunger compressor 330 and bottom member 105 to retain plunger 325 in place during storage and shipment.
[0074] In operation, film 205 may be removed. Plunger 325 may be forced into reservoir 305 , thereby forcing liquid 315 into channel 306 . A series of such liquids 315 may be forced into channel 306 , thereby forming a series of droplets separated by a filler fluid. In cases where the reagent storage cassette is provided as an integral part of a droplet actuator cartridge, droplets 315 may be transported and from the reagent storage cassette into another region of the cartridge. For example, reagent droplets 315 may be transported from the reagent storage cassette into a droplet operations gap of a droplet actuator. Similarly, droplets 315 may be transported from the reagent storage cassette into a reservoir of a droplet actuator, from where they may be transported through a liquid path into a droplet operations gap of a droplet actuator. In the droplet operations gap, droplets 315 and/or sub-droplets dispensed therefrom may be subjected to droplet operations. For example, the droplet operations may be part of a droplet operations protocol which is designed to use droplets 315 to perform an assay.
[0075] In some embodiments, a pressure source may provide pressure for forcing droplets from the reagent storage cassette into a droplet actuator, or into another region of a droplet actuator cassette. As illustrated in FIG. 3D , a pressure source may forced droplets 315 through channel 306 and into the droplet actuator. Channel 306 may be in any configuration, for example, it may be linear or curvilinear. Channel 306 may be provided generally in a common plane with a droplet operations gap, such that droplets 315 may flow along a common plane through channel 306 and into the droplet operations gap. Alternatively, channel 306 may be provided in a different plane than the plane of the droplet operations gap. For example, channel 306 may be located in a plane which is separate, but parallel to the playing of the droplet operations gap. A liquid passage may connect channel 306 to the droplet operations gap, such that the pressure source may cause the droplets 315 to flow through channel 306 , through the connecting liquid passage, and into the droplet operations gap. In yet another embodiment, the channel 306 need not be parallel to the droplet operations gap, e.g., the channel may be in a position relative to the droplet operations gap which establishes an angle which is between 0 and 180°.
[0076] In one embodiment, pressure may be applied to the contents of channel 306 , thereby forcing droplets and filler fluid into a droplet operations gap of the droplet actuator. Alternatively, a vacuum source may be used to pull the contents of channel 306 into a droplet operations gap of a droplet actuator. Further, channel 306 may itself be associated with electrodes capable of effecting forces suitable for causing the transport of droplets 315 along the path of channel 306 . Such electrodes may, for example, form a path having one or more electrode members which are adjacent to electrode members in a droplet operations gap of a droplet actuator. In this manner, the electrodes may be used to transport one or more droplets through channel 306 , and from channel 306 into a droplet operations gap of a droplet actuator.
[0077] FIG. 4 illustrates another embodiment of the invention in which a droplet actuator cartridge 400 is provided with a droplet actuator portion 401 and an integral reagent cassette portion 402 . In the embodiment illustrated, droplet actuator portion 401 includes top substrate 410 separated from bottom substrate 415 by droplet operations gap 420 . Bottom substrate 415 includes electrodes 418 arranged for conducting one of more droplet operations in droplet operations gap 420 . It will also be appreciated that one or more droplet operations and/or reference electrodes may be associated with top substrate 410 and/or bottom substrate 415 . Reagent cassette portion 402 includes bottom substrate 410 , which is the same as top substrate 410 of droplet actuator portion 401 . Reagent cassette portion 402 also includes top substrate 405 , which includes reservoirs 435 formed therein. As illustrated, plungers 325 are inserted into reservoirs 435 . Channel 306 is formed in top substrate 405 and/or bottom substrate 410 . Channel 306 is connected to droplet actuator gap 420 by liquid path 440 . Channel 306 may also be coupled to a pressure source 445 configured for providing pressure into channel 306 . Pressure source 445 may be coupled to channel 306 by a liquid path 448 established, for example, by capillary tube 450 and associated fitting 455 . Similarly, an output flow path 460 may be coupled to droplet operations gap 420 ; the coupling may, for example, be established by a capillary tube 465 and associated fitting 470 . In this manner, a liquid path is established from pressure source 445 through liquid path 448 , through channel 306 , through connecting liquid path 440 , through droplet operations gap 420 , and through exit liquid path 460 . In some cases, rather than a pressure source 445 , a vacuum source 480 may be coupled via liquid path 460 to droplet operations gap 420 . In operation, droplets 315 may be stored in reservoirs 435 . A film (not shown) may be provided over openings to reservoirs 435 to retain droplets 315 therein. As noted above, the film may be scored in order to facilitate breaking of the film upon application of pressure thereto by insertion of plungers 325 . Alternatively, a puncturing device may be employed, e.g., as illustrated below with respect to FIG. 6 . In any case, plungers 325 may be forced into reservoirs 435 , thereby forcing droplets 315 into channel 306 . Pressure from pressure source 445 and/or vacuum from vacuum source 480 may be used to cause droplets 315 to flow through channel 306 , through liquid path 440 , and into droplet operations gap 420 where such droplets may be subject to droplet operations mediated by electrodes 418 . In an alternative embodiment, droplet operations and/or reference electrodes may be associated with surfaces adjacent to channel 306 and/or connecting liquid path 440 , and droplets 315 may be transported into droplet operations gap using one or more droplet operations facilitated by such electrodes. The figure is illustrative, and many other embodiments are possible. For example, FIG. 4 can be considered as a top view (top plate not shown and 410 serves as only a gasket with no electrodes) where the plungers are inserted within the gap of the droplet actuator and electrodes 418 move to underneath the channel 420 while 415 serves as a gasket.
[0078] FIGS. 5A and 5B illustrate a side cross-sectional view and a top view, respectively, of a droplet actuator 500 according to the invention. Droplet actuator 500 is like droplet actuator 400 , except that rather than forcing droplets into a channel, which is used to supply droplets into a droplet operations gap, droplet actuator 500 supplies droplets directly into reservoirs in a droplet operations gap. One or more sub-droplets may be dispensed from the reservoirs. Droplet actuator 500 includes top substrate 505 and bottom substrate 510 , separated by gasket 515 to form gap 520 . Top substrate 505 includes droplet operations electrodes 523 , though it will be appreciated that as described elsewhere herein, in an alternative embodiment, droplet operations electrodes 523 may be supplied on bottom substrate 510 rather than top substrate 505 . Bottom substrate 510 also includes reservoirs 525 into which plungers 530 are inserted. Gasket 515 also forms reservoirs 535 in droplet operations gap 520 . Each reservoir 535 includes an electrode 523 associated with top substrate 505 and aligned with reservoir 535 . Adjacent to each electrode 523 is a path of droplet operations electrodes 524 . The paths of droplet operations electrodes 524 are arranged in a network of paths. It will be appreciated that the network of paths illustrated in FIG. 5B is illustrative only, and that a wide variety of similar such networks is possible within the scope of the invention. FIG. 5A shows droplets 536 , including one droplet in each reservoir 535 . As illustrated, the droplets have been forced in the place using plungers 530 , i.e., by forcing plungers 530 into reservoirs 525 . In operation, droplet actuator 500 may include a protective film as described herein, which may be removed and/or punctured prior to forcing droplets 536 into place within reservoirs 535 . Ideally, the top surface of each plunger is hydrophobic or is coated with a hydrophobic material in order to facilitate droplet operations conducted using electrodes 523 and 524 . Further, the surface of reservoir 525 and/or reservoir 535 may also be hydrophobic or coated with a hydrophobic material.
[0079] FIGS. 6A , 6 B, 6 C, 6 D, 6 E, and 6 F illustrate another aspect of the invention in which a plunger is used to force liquid into the droplet operations gap of a droplet actuator. As illustrated in FIG. 6A , droplet actuator 600 includes a top substrate 605 and a bottom substrate 610 separated by gasket 615 the form drop operations gap 620 . Reservoir 625 is formed on bottom substrate 610 . As illustrated, reservoir 625 includes a liquid 630 , which may, for example, include reagent and/or sample. Bottom substrate 610 further includes electrodes 635 arranged for conducting droplet operations in the droplet operations gap. Bottom substrate 610 further includes an electrode 636 , which includes an opening 637 therein. FIG. 6A shows liquid 630 in reservoir 625 outside the droplet operations gap 620 , prior to being forced by plunger 650 into the droplet operations gap 620 .
[0080] FIG. 6B shows a top view of electrode 636 . Opening 637 is shown as being centrally located, but it will be appreciated that the opening may be provided in any region of electrode 636 . Further, in an alternative embodiment, no opening is provided in electrode 636 , and instead, an opening providing a liquid path into the droplet operations gap is provided adjacent to electrode 636 . It will also be appreciated that while the opening is shown as being generally circular, any shape is suitable. Moreover, while a single opening is shown, multiple openings may be provided. Opening 637 provides a liquid path 645 from reservoir 625 into droplet operations gap 620 .
[0081] Bottom substrate 610 further includes a dielectric layer 640 atop electrodes 635 and 636 . Dielectric layer 640 blocks the liquid path. Various examples of a dielectric layer are as described above with respect to aspects in which protective film 205 is a dielectric layer. A hydrophobic layer may also be provided atop dielectric layer 640 . Droplet actuator 600 also includes a plunger 650 , which extends into reservoir 625 , and seals liquid 630 therein. Plunger 650 includes an awl 655 arranged for puncturing dielectric layer 640 to open liquid path 645 , thereby permitting liquid 630 to flow through liquid path 645 and into droplet operations gap 620 . As illustrated, awl 655 is inserted through an opening in plunger 650 and aligned to puncture dielectric layer 640 through opening 637 .
[0082] Puncturing of dielectric layer 640 is illustrated in FIG. 6C . On puncturing dielectric layer 640 , plunger 650 may be forced into reservoir 625 , thereby forcing liquid 630 through liquid path 645 into droplet operations gap 620 .
[0083] FIG. 6D illustrates plunger 650 in a fully inserted position, and shows liquid 630 situated in droplet operations gap 620 atop electrode 636 . From this position, droplets may be dispensed from liquid 630 using electrodes 635 and 636 . Awl 655 is shown in a retracted position in which the tip of awl 655 is removed from the punctured region of dielectric 640 in order to permit liquid to flow with reduced obstruction through liquid path 645 .
[0084] FIG. 6E shows droplet actuator 601 , which is like droplet actuator 600 , except that in droplet actuator 601 , a single electrode 660 is provided on top substrate 605 . Electrode 660 may serve as a reference electrode. In one embodiment, top substrate 605 is made from a transparent material, such as glass or plastic, while electrode 660 is also made from a transparent electrode material, such as indium tin oxide.
[0085] FIG. 6F shows droplet actuator 602 , which is like droplet actuator 601 in FIG. 6E , except that in droplet actuator 602 , a reservoir electrode 636 and droplet operations electrodes 635 are provided on top substrate 605 , while ground or reference electrode 660 is provided on bottom substrate 610 . Fluid 630 flows into droplet operations gap 620 through liquid path 645 , which includes an opening 637 in ground electrode 660 .
[0086] In other embodiments, the plunger 650 is not required and only the awl/needle 655 is utilized. As shown in FIG. 6D , plunger 650 serves as a fixed element and an integral part of bottom substrate 610 and in some cases they both may be the same element. The needle 655 in this case may be actuated during the action of loading the cartridge. The needle puncturing the dielectric 640 and part of the electrode 636 may be hydrophilic so that upon puncturing the liquid automatically is drawn onto electrode 636 . In another embodiment, the needle and the reservoir arrangement could be on the top plate 605 .
[0087] FIG. 7 illustrates an alternative embodiment of the reagent cassette of the invention. In addition to the components already described, this embodiment includes a channel 705 for flowing an immiscible liquid filler fluid around droplets 315 and/or droplets 605 . Further, top member includes a top plunger member 710 , which may be used to agitate droplet 315 in the presence of dried reagent 481 to promote mixing. Top plunger member 710 may be associated with a sonicator arranged to vibrate top plunger member 710 and thereby promote mixing of dried reagent 481 in droplet 315 .
[0088] Steps A-F illustrate the following: Step A shows top member 305 and bottom member 405 with protective film 205 in place, protecting droplets 315 and dried reagent 481 . Step B shows top member 305 and bottom member 405 with protective film 205 removed, and top member 305 and bottom member 405 fitted together. Step C shows plunger 325 compressed to force droplet 315 into channel 505 . Step D shows droplet 315 mixed with dried reagent 418 . Step E shows filler fluid flowed through channels 705 into space in channel 505 surrounding droplets 315 . Step F shows compression of plunger member 710 to compress droplet 315 , e.g., to cause mixing of droplet 315 .
[0089] Various embodiments may include a filler fluid reservoir in association with channel 705 and/or channel 505 for flowing oil into channel 505 . In other embodiments, droplets 315 may include beads and/or dried reagents may include beads which dissolve into droplets 315 . Beads may, for example, have affinity for target analytes or compounds that interfere with assay chemistry. Some embodiments may include vents from channel 705 and/or channel 505 for venting bubbles prior to loading droplets onto a droplet actuator or other microfluidic device. Protective films may be made from any material which is suitably non-reactive with reagents contacting the films. Examples include aluminum and various polymeric films. Dried reagents for use in the cassette may be prepared using methods known to one of skill in the art, such as commercial off-the-shelf (COTS) equipment and well-established procedures.
Flow Through Bead Handling and Washing Techniques
[0090] The invention also provides devices, techniques and systems for conducting flow through bead handling and washing. For example, the invention provides techniques for splitting droplets in a flow-through system, compartmentalizing beads in droplets in a flow-through system, and washing droplets in a flow-through system.
[0091] FIG. 8 illustrates a flow-through system 800 that makes use of droplet operations for splitting droplets. Flow-through system 800 includes channel 805 which intersects with channel 810 . A set of electrodes 812 are associated with channel 810 at a position which is approximately opposite to an entry point of channel 805 into channel 810 . The internal walls of channels 805 and 810 are hydrophobic. Channels 805 and 810 are filled with a liquid filler fluid which is substantially immiscible with parent droplets 815 . Parent droplets 815 flow through channel 805 in the direction of arrow A. When electrodes 812 are activated, the internal wall of channel 810 in the region of electrodes 812 behaves in hydrophilic manner. When a parent droplet 815 impacts the electrode-associated region, the droplet spreads to conform to the shape of the activated electrodes. When an intermediate electrode is deactivated, the droplet splits into two sub-droplets 816 . In the embodiment illustrated, the two sub-droplets 816 flow into channel 810 in opposite directions, as illustrated by arrows B and C. In operation, by controlling the flow of filler fluid through channels 805 and 810 , droplets 815 may be sequentially contacted with electrodes 812 , electrode 812 may be used to split each droplet into two sub-droplets 816 , and sub-droplets 816 may be flowed into channel 810 , as indicated. In an alternative embodiment, it will be appreciated that a flow may be established in channel 810 which causes sub-droplets 816 to flow in the same direction, i.e., arrows B and C may indicate a flow in a common direction, rather than opposite directions.
[0092] FIG. 9 illustrates a flow-through system 900 configured for adding beads to droplets. System 900 includes channel 905 which intersects with channel 910 . A liquid filler fluid in channel 905 flows in the direction of arrow A. A liquid filler fluid in channel 910 flows in the direction of arrow B. Droplets 915 are provided in channel 905 . The liquid filler fluid in channel 905 is substantially immiscible with droplets 915 . Droplets 915 flow through channel 905 into channel 910 at a velocity sufficient to cause them to impact a region on the wall of channel 910 . The various dimensions of channel 905 , channel 910 as it enters the intersection between the two channels, and channel 910 as it exits the intersection between the two channels, as well as the angle of intersection and the velocity of filler fluid flow through the respective channels may be adjusted as needed to achieve the pre-selected droplet impact on the wall of channel 910 . A magnet 920 is associated with channel 910 at a position which is approximately the point of impact of droplets 915 on the wall of channel 910 . The magnet may be adjustable in order to align it with the appropriate location at which droplets 915 impact the wall of channel 910 . The magnet may be an electromagnet, which may be switched on and off. The magnet may be a permanent magnet, which is movable, e.g., generally in the direction of the axis indicated by arrow A. Beads 916 are provided in the filler fluid which flows through channel 910 . Beads 916 may be hydrophilic and may be provided in a hydrophobic filler fluid. As each bead comes into proximity with magnet 920 , the bead is substantially immobilized on magnet 920 . When a droplet 915 impacts a bead 916 immobilized on magnet 920 , bead 916 is engulfed by the droplet, yielding bead containing droplet 917 . The bead-containing droplet 917 may continue to flow through channel 910 in the direction of arrow C. Various techniques may be used to separate bead containing droplet 917 from the magnet 920 to permit bead containing droplet 917 to continue to flow-through channel 910 . For example, the surface tension of droplet 915 may be selected to overcome the attractive force of magnet 920 on the bead, as the bead containing droplet 917 is forced through channel 910 by the flowing filler fluid. In this embodiment, it is not necessary to remove or deactivate magnet 920 . In another embodiment, magnet 920 is an electromagnet, and the electromagnet is switched off to release the bead-containing droplet 917 . In yet another embodiment, magnet 920 is removable, and magnet 920 is physically moved away from channel 910 in order to permit the release of bead containing droplet. The spacing of droplets 915 and beads 916 may be adjusted in order to achieve a pre-selected number of beads and each droplet. For example, several beads may be permitted to collect at magnet 920 between each droplet 915 in order to provide droplets with multiple beads. Droplets potentially containing beads may be tested downstream, and sorted to exclude any droplets which lack beads or which lack the pre-selected number of beads. Sorting may, for example, be based on optical properties and/or electrical properties of the bead-containing droplets.
[0093] FIG. 10 illustrates a flow-through system 1000 which makes use of droplet operations to wash beads in droplets. Flow-through system 1000 includes channel 1005 , which intersects with channel 1010 . A liquid filler fluid in channel 1005 flows in the direction of arrow A. A liquid filler fluid in channel 1010 flows in the direction of arrow B. Bead-containing droplets 1015 are provided in channel 1005 . Wash droplets 1016 are provided in channel 1010 . Wash droplets 1016 may include a wash buffer. It will also be appreciated that in an alternative embodiment, rather than washing the beads, the method is used to concentrate one or more substances onto the beads. In such other embodiment, wash droplets 1016 may be replaced with sample droplets or other droplets including droplets including one or more target substances for which the beads have affinity. In yet another embodiment, rather than a single magnet 1020 attracting bead-containing droplet 1015 to the wall of channel 1010 , one or more magnets may be provided around channel 1010 and arranged to substantially immobilized the bead within the channel, but away from the wall of the channel. The size of channel 1010 at magnet 1020 may be selected to ensure that wash droplets 1016 impact immobilized bead containing droplet 1015 as they flow past magnet 1020 or other magnet arrangement. The velocity of impact is selected to cause droplets 1016 to impact droplet 1015 , merge with droplet 1015 , followed by a breaking off of a new droplet 1017 moving in the direction of arrow C. In this manner, by sequentially merging the bead containing droplet with a wash droplet in and breaking off a separate droplet, the liquid surrounding the bead-containing droplet maybe be depleted of unwanted substances. Upon completion of the wash cycle, when the depletion of unwanted substances is calculated to have been achieved based on the number of wash droplets passed across the bead, the bead containing droplet may be released to continue to flow-through channel 1010 . Downstream, the bead containing droplets may be separated from the used wash droplets 1017 . Thus, the invention provides a technique for washing beads in a flow-through operation, wherein a bead containing droplet is immobilized using a magnet, and one of more wash droplets are caused to impact and merge with the bead-containing droplet, and wherein the filler fluid flowing through the channel is at a velocity sufficient to cause one or more droplets to break off of the combined droplet, thereby leaving a bead containing droplet with a reduced amount of one or more substances relative to the starting bead-containing droplet. Similarly, the invention provides a technique for concentrating a substance on beads in a flow-through operation, wherein a bead containing droplet is immobilized using a magnet in a channel, and one of more droplets including a target substance are caused to impact and merge with the immobilized bead-containing droplet, thereby causing a bead in the bead-containing droplet having affinity for the target substance to concentrate target substance thereon. As with the washing operation, the filler fluid flowing through the channel may cause one or more droplets to break off of the combined droplet, thereby leaving a bead containing droplet with an increased amount of one or more substances concentrated on the bead relative to the starting bead-containing droplet. The various sizes of channels 1005 and 1010 , as well as the angle of intersection between the two channels, may be adjusted in order to improve efficiency of the washing operation. Multiple beads may also be present in droplets 1015 . The ratio of spacing and velocity of bead containing droplets 1015 flowing through channel 1005 relative to the spacing and velocity of wash droplets or sample droplets flowing through channel 1010 may be adjusted to achieve the pre-selected effect. In yet another embodiment, channel 1010 may include a series of sample droplets for concentrating sample onto the immobilized bead, followed by a series of wash droplets for washing the immobilized bead. In an alternative embodiment, the splitting off of wash droplets following merging of the wash droplets with the immobilized beat-containing droplet may be facilitated by droplet operations mediated by electrodes, e.g. as described above with reference to FIG. 8 .
[0094] In the various flow-through embodiments described herein, it is possible for droplets to be sorted to select out a pre-selected subset of droplets from the overall droplet population. For example, droplets may be sorted as described in Link et al., US Patent Publication No. 20080014518, entitled “Microfluidic Devices and Methods of Use Thereof,” published on Jan. 17, 2008, the entire disclosure of which is incorporated herein by reference for its teaching concerning sorting of droplets in microfluidic devices. Further, once droplets of interest are isolated, the droplets may be flowed onto a droplet actuator of the invention for further analysis. For example, a subset of droplets of interest from a flow-through droplet sorting operation may be flowed into a droplet operations gap of a droplet actuator where they are subject to droplet operations mediated by electrodes. Similarly, a subset of droplets of interest from a flow-through droplet sorting operation may be flowed into a reservoir of the droplet actuator, which reservoir is coupled by a liquid path to a droplet operations gap of a droplet actuator, such that the droplets of interest may be transported from the reservoir into the droplet operations gap where they may be subject to droplet operations mediated by electrodes. In one embodiment, multiple droplets of interest are pooled together in a reservoir of a droplet actuator prior to being subjected to droplet operations in a droplet operations gap of the droplet actuator.
Techniques Using Viscous, Solid, or Semi-Solid Samples
[0095] The invention provides droplet actuator devices, techniques and systems for making and using droplet actuators to process viscous, solid or semi-solid samples. For example, the invention provides a technique for processing viscous, semisolid, and/or solid samples. Target substances of interest are extracted from the viscous, solid or semi-solid sample, and then processed using standard droplet operations.
[0096] FIGS. 11A , 11 B, and 11 C illustrate a section of a droplet actuator 1100 and a method of processing a viscous, solid or semi-solid sample on a droplet actuator. Droplet actuator 1100 includes a top substrate 1105 and a bottom substrate 1110 separated by droplet operations gap 1112 . In certain embodiments, top substrate 1105 may be omitted. Droplet operations electrodes 1115 (e.g., electrowetting electrodes) and reference electrodes (not shown) are associated with top substrate 1105 and/or bottom substrate 1110 . Droplet operations electrodes 1115 are configured for conducting one or more droplet operations in droplet operations gap 1112 . Top substrate 1105 includes an opening 1120 therein for loading sample 1125 into droplet operations gap 1112 . Sample 1125 includes one or more target substances 1130 . As illustrated in FIG. 11A , droplet 1135 is positioned in droplet operations gap 1112 atop one or more droplet operations electrodes 1115 . FIG. 11B shows droplet 1135 being transported into contact with sample 1125 , such that one or more target substances 1130 is dissolved into droplet 1135 . Transport of droplet 1135 may be effected using one or more droplet operations. For example, in one embodiment, transport is effected by sequentially activating/deactivating electrodes 1115 . Droplet 1135 may be transported away from sample 1125 via droplet operations as shown in 11 C. Droplet 1135 that potentially included one or more target substances may be used as input for conducting one or more assays to identify and/or quantify one or more target substances 1130 . In one embodiment, sample 1125 is sufficiently viscous, semi-solid, or solid in order to permit droplet 1135 to contact sample 1125 and be transported away from sample 1125 without being substantially mixed with sample 1125 .
[0097] FIGS. 11A , 11 B, and 11 C illustrate a general principle in which a micro or nano liquid is transported into contact with a viscous or solid sample for collection of a target substance and then transported away. As illustrated, using one or more droplet operations, droplet 1135 contacts sample 1125 , which brings droplet 1135 into lateral contact with sample 1125 . However, it will be appreciated that sample 1125 may be positioned at any angle relative to droplet 1135 , e.g., above or below droplet 1135 . For example, sample 1125 may project only slightly into droplet operations gap 1112 , in which case, droplet 1135 may be transported along a path of electrodes underneath sample 1125 . In this example, contact is between the top of droplet 1135 and the bottom of sample 1125 . Alternatively, sample 1125 may be exposed to droplet operations gap 1112 and droplet 1135 via an opening (not shown) in bottom substrate 1110 .
[0098] The methods of the invention are particularly suitable for tests involving viscous, solid or semi-solid samples. Samples may, for example, be environmental samples, process samples, or biological samples. Examples of suitable samples include sputum, coagulated blood, animal tissue samples, plant tissue samples, soil samples, rock samples, and the like. In some cases, samples are sufficiently viscous, semi-solid or solid to permit a droplet to contact the sample and be transported away from the sample without being substantially mixed with the sample. Further, the sample may include foreign matter, such as a matrix (e.g., a swab) used to collect the sample. For example, when a droplet of sputum is loaded, it may not be readily transportable using droplet operations then a droplet that lyses sputum can be brought in contact with sputum. After incubation and preferably some agitation of the lysis droplet, the sputum will be liquefied rendering it to be transportable using droplet operations.
[0099] Droplet 1135 may be aqueous or non-aqueous. In one embodiment, droplet 1135 is an aqueous buffer established at a pH which is suitable for dissolving sample 1125 . Droplet 1135 may also include one or more reagents. The chemical characteristics of droplet 1135 may be adjusted to render droplet 1135 suitable for acquiring one or more target substances 1130 . In one example, droplet 1135 includes a lysis buffer solution. A lysis buffer solution is used to lyse cells for use in assays involving target substances, which are sub-components of the cells. In some embodiments, droplet 1135 includes one or more beads, e.g., magnetically responsive or non-magnetically responsive beads. Examples of suitable magnetically responsive beads are described in U.S. Pat. No. 7,205,160, entitled, “Multiplex flow assays preferably with magnetic particles as solid phase,” granted on Apr. 17, 2007. The beads may have an affinity for one or more target substances or contaminants. For example, the beads may have affinity for target cells, protein, DNA, and/or antigens. In one example, the beads may have an affinity for one or more target substances 1130 from the sample 1125 of interest.
[0100] Examples of droplet actuator techniques for immobilizing magnetic beads and/or non-magnetic beads are described in the foregoing international patent applications and in Sista, et al., U.S. Patent Application Nos. 60/900,653, entitled “Immobilization of Magnetically-responsive Beads During Droplet Operations,” filed on Feb. 9, 2007; Sista et al., U.S. Patent Application No. 60/969,736, entitled “Droplet Actuator Assay Improvements,” filed on Sep. 4, 2007; and Allen et al., U.S. Patent Application No. 60/957,717, entitled “Bead Washing Using Physical Barriers,” filed on Aug. 24, 2007; the entire disclosures of which are incorporated herein by reference.
Gel Electrophoresis Techniques
[0101] The invention provides droplet actuator devices including a gel for use in gel electrophoresis, along with techniques and systems for conducting gel electrophoresis on a droplet actuator. The gel electrophoresis techniques of the invention are useful for separating substances present in a droplet on a droplet actuator. For example, the invention is useful for separating complex biomolecules (e.g., proteins and/or nucleic acids) using an electric current applied to a gel matrix on a droplet actuator. The gel matrix may, for example, be a cross-linked polymer whose composition and porosity are selected based on the specific weight (e.g., molecular weight) and composition of the substances being analyzed. In one embodiment, the gel may be composed of different concentrations of acrylamide and a cross-linker to produce different-sized mesh networks of polyacrylamide. Polyacrylamide may be used to separate and analyze proteins or small nucleic acids (e.g., DNA, RNA, or oligonucleotides). In another embodiment, the gel may be composed of a purified agarose matrix. Agarose gels may be used to separate larger nucleic acids and/or complex biomolecules.
[0102] The methods of the invention make use of gel electrophoresis on a droplet actuator for analytical purposes (e.g., separation and quantitation of a specific target(s)). In another embodiment, gel electrophoresis may be used as a preparative technique (e.g., for isolation of a specific target(s)) prior to use of other assay techniques for further characterization of a substance. Other assay techniques may, for example, include PCR, cloning, nucleic acid sequencing, immunoassays, enzymatic assays, exposure to sensors, etc. In another embodiment, a “capture” droplet may be used to capture a target droplet as it elutes off the gel slug as a fraction collector, e.g. using the techniques described with reference to FIG. 11 .
[0103] FIGS. 12A , 12 B, and 12 C illustrate a section of droplet actuator 1200 and a process of separating and analyzing a sample using gel electrophoresis. Droplet actuator 1200 may include bottom substrate 1210 separated from top substrate 1214 by droplet operations gap 1213 . Path 1216 of droplet operations electrodes 1217 is arranged on bottom substrate 1210 ; however, it will be appreciated that droplet operations electrodes and/or ground electrodes may be associated with top substrate 1214 and/or bottom substrate 1210 . Droplet operations electrodes 1217 may, for example, be electrowetting electrodes. Electrophoresis electrodes 1218 a and 1218 b , are arranged on top substrate 1214 , but may be on either or both substrates. One of electrodes 1218 a and 1218 b may be a negative electrode, while the other may be a positive electrode.
[0104] Droplet operations gap 1213 may be provided with one or more gel droplets 1226 and one or more catalyst droplets 1230 , although in some cases neither a catalyst nor a catalyst droplet are required. In some cases, the catalyst may just be photoinitiation. Gel droplets 1226 may typically be from about 1× to about 5× or larger droplets. A 3× droplet, for example, has a footprint that is approximately 3 times the area of one droplet operations electrode 1217 . Gel droplet 1226 may, for example, include reagents suitable for forming a polyacrylamide gel, such as acrylamide, bis-acrylamide, and buffer. Gel droplet 1226 remains in a liquid form until polymerization of the acrylamide is initiated by the addition of a catalyst. Catalyst droplet 1230 contains the chemical reagents required to accelerate polymerization of gel droplet 1226 . For example, catalyst droplet 1230 may include N,N,N,N-Tetramethyl-Ethylenediamine (TEMED) and ammonium persulfate to accelerate polymerization of the acrylamide in gel droplet 1226 .
[0105] Droplet operations gap 1213 may be provided with one or more sample droplets, e.g., sample droplet 1234 . Sample droplet 1234 includes one or more target substances 1242 to be evaluated. Target substances 1242 may, for example, be fluorescently labeled proteins or nucleic acids. To evaluate target substances 1242 , an imaging device 1240 is associated with droplet actuator 1200 . Imaging device 1240 may be used to capture digital images of substances separated in gel droplet 1226 , such as labeled proteins or nucleic acids. In some cases, imaging device 1240 may capture images through top substrate 1214 , which may be, for example, a glass or a plastic plate that is substantially transparent.
[0106] FIG. 12A shows a first step in which droplet operations may be executed in order to form a gel for conducting gel electrophoresis on droplet actuator 1200 . Activated electrodes are shown in black. Using one or more droplet operations, gel droplet 1226 may be elongated along several droplet operations electrodes in contact with electrophoresis electrodes 1218 a and 1218 b . Catalyst droplet 1230 may be transported using one or more droplet operations into contact with gel droplet 1226 . Catalyst droplet 1230 and gel droplet 1226 merge, initiating polymerization in gel droplet 1226 to form the gel matrix for electrophoresis. FIG. 12B shows a second step in which sample droplet 1234 is transported into contact with the polymerized gel droplet 1226 . FIG. 12C shows a third step in which an electrical potential (e.g., about 40 to about 100 volts) may be applied to gel droplet 1226 via electrophoresis electrodes 1218 a and 1218 b . In some cases, electrode 1218 a might directly contact droplet 1234 . The electrical current causes target substances 1242 in sample droplet 1234 to electrophorese into and through gel droplet 1226 . Separation of target substances 1242 in gel droplet 1226 is typically determined by charge such that different molecules will move at different rates. As an example, target substances 1242 may be negatively charged (e.g., nucleic acids) and migrate from electrophoresis electrode 1218 a (i.e., negative electrode) toward electrophoresis electrode 1218 b (i.e., positive electrode). Imaging device 1240 may be used to capture an image of separated target substances 1242 in gel droplet 1226 and/or as they elute off the end of gel droplet 1226 . The captured image may be used to identify and/or quantitate different target substances 1242 in sample 1234 .
[0107] It will be appreciated that the method of the invention also provides a generic method of forming a polymerized structure in a droplet operations gap of a droplet actuator. The method may include using one or more droplet operations to form a first droplet into a pre-selected shape, and to contact the first droplet with a second droplet to cause polymerization of the combined droplets. One of the first droplet and/or second droplet may be a polymer droplet, while the other of the first droplet and/or second droplet may be a catalyst droplet. In addition to use for forming gels for electrophoresis, the method may be used to provide a physical obstacle on a droplet actuator. The physical obstacle may, for example, be useful for sealing off a region of the droplet actuator. In one embodiment a droplet actuator is provided that includes a barrier in the droplet operations gap establishing two regions on the droplet actuator. An opening is provided in the barrier, and electrodes are arranged for transporting droplets through the opening. When it is desirable to close the opening, a polymer droplet is polymerized in the opening. For example, a polymer droplet may be transported into the opening. A catalyst droplet may be combined with the polymer droplet in the opening. Upon polymerization, the opening may be substantially closed.
Fluidics System for Loading Droplet Actuator
[0108] The invention provides a fluidics system and technique for using the system for loading liquids onto a droplet actuator. The invention also provides droplet actuators loaded using the fluidics system and method of the invention and methods of using such droplet actuators to conduct droplet operations. In some embodiments, the loading provides a droplet actuator in which the droplet operations gap or a reagent storage channel is fully filled with filler fluid and reagents that is substantially lacking in air bubbles.
[0109] FIG. 13A-13I are schematic diagrams of fluidics system 1300 for loading liquid receptacle, such as a channel or droplet operations gap of a droplet actuator, with liquid. Fluidics system 1300 may include an arrangement of one or more valves, one or more pumps, one or more capillaries, and one or more liquid supply vessels; all fluidly connected. Additionally, a droplet actuator may be fluidly connected to fluidics system 1300 , such that liquid may be flowed from fluidics system 1300 into a liquid receptacle of droplet actuator 1320 .
[0110] Fluidics system 1300 includes a plurality of valves, illustrated here as pinch valves (PV): PV1, PV2, PV3, PV4, and PV5. A pinch valve is a valve in which a flexible tube is pinched between one or two moving external elements in order to stop the flow through the tube.
[0111] Fluidics system 1300 includes one or more pumps, illustrated here as peristaltic pump P1. In a peristaltic pump, liquid is contained within a flexible tube fitted inside a circular pump casing. A rotor with one or more of rollers, shoes, or wipers that are attached to the external circumference compresses the flexible tube. As the rotor turns, the part of tube under compression closes, which forces the liquid to be pumped to move through the tube. Referring to FIG. 13A , peristaltic pump P1 may controlled to operate in a clockwise (CW) and counter clockwise (CCW) direction. The peristaltic pump may be replaced with any suitable pump type, such as gear pumps, progressing cavity pumps, roots-type pumps, reciprocating-type pumps, double-diaphragm pumps, peristaltic pumps, kinetic pumps, centrifugal pumps, eductor-jet pumps, etc.
[0112] Fluidics system 1300 also includes a pump, such as syringe pump P2. Syringe pump includes a cylinder that holds a quantity of liquid, such as filler fluid (e.g., silicone oil), which is expelled by a piston. The piston may be advanced or retracted by a motor (not shown) connected thereto, in order to provide smooth pulseless flow.
[0113] Fluidics system 1300 includes a liquid supply vessel V1, which is, for example, any vessel for holding a quantity of liquid, such as filler fluid (e.g., silicone oil).
[0114] Fluidics system 1300 includes another liquid supply, illustrated here as a multi-well plate (MWP1). MWP1 contains, for example, multiple reservoirs including reagents 1310 (and/or sample) under a layer of filler fluid 1314 (e.g., silicone oil). A mechanically or robotically controlled supply line 1318 may be manipulated in the X, Y, and Z directions in order to access a certain one of the multiple fluids that are contained in MWP1. In an alternative embodiment, multiple supply lines may be provided extending into the MWP1 reservoirs from the top, or through an opening in the reservoirs, such as opening in the bottom of the reservoirs.
[0115] Fluidics system 1300 includes a capillary CP1, which is a small diameter tube of any pre-selected length, depending on the pre-selected quantity of liquid to be contained therein. Various liquid lines L fluidly connect the parts of the invention.
[0116] Fluidics system 1300 may include droplet actuator 1320 , which is the droplet actuator to be loaded by fluidics system 1300 . Droplet actuator 1320 is fluidly connected to fluidics system 1300 via one or more liquid input/output ports. The ports provide a fluid path from an exterior of the droplet actuator into a droplet operations gap of the droplet actuator or into another reservoir in the droplet actuator, such as a channel reservoir. In one example, the droplet operations gap of droplet actuator 1320 is fluidly connected to fluidics system 1300 via ports C1, C2, and C3. In some cases, the ports may provide access to one or more channels within droplet actuator 1320 , and the one or more channels are used to supply filler fluids and/or reagents into a droplet operations gap of droplet actuator 1320 .
[0117] Referring again to FIG. 13A , the elements of fluidics system 1300 are fluidly connected as follows. A liquid line L fluidly connects vessel V1 to one opening of valve PV1. A liquid line L fluidly connects to the opposite opening of valve PV1 to an opening of T-connection T1. A liquid line L fluidly connects a first branch of T1 to an opening of valve PV2. A liquid line L fluidly connects the opposite opening of valve PV2 to port C1 of droplet actuator 1320 . A liquid line L fluidly connects a second branch of T1 to one opening of peristaltic pump P1. A liquid line L fluidly connects to the opposite opening of peristaltic pump P1 to one opening of capillary CP1. A liquid line L fluidly connects the opposite opening of capillary CP1 to a T-connection, T2. A liquid line L fluidly connects a first branch of T2 to one opening of valve PV4. A liquid line L fluidly connects the opposite opening of valve PV4 to port C2 of droplet actuator 1320 . A liquid line L fluidly connects a second branch of T2 to one opening of valve PV5. A liquid line L fluidly connects the opposite opening of valve PV5 to supply line 1318 that fluidly connects to MWP1. An input/output port of syringe pump P2 fluidly connects to port C3 of droplet actuator 1320 through valve PV3. Note that all liquid lines of fluidics system 1300 may be capillaries and that capillary CP1 may be formed of an extended length of capillary that couples peristaltic pump P1 and junction T2.
[0118] Fluidics system 1300 of FIG. 13A is exemplary only, other system variations are possible. For example, syringe pump P2 may be replaced with other types of pumps. Alternatively, fluidics system 1300 may include a single pump only. An exemplary method of purging air from fluidics system 1300 and droplet actuator 1320 and filling fluidics system 1300 and droplet actuator 1320 with substantially bubble-free liquid is described with reference to FIGS. 13B-13I .
Purging Fluidics System—Step 1
[0119] FIG. 13B , with reference to Table 1 below, illustrates a purging step in which valves PV1 and PV5 are open, valves PV2, PV3, and PV4 are closed, peristaltic pump P1 is activated in the CW direction, and syringe pump P2 is stopped. This arrangement establishes a flow of liquid from vessel V1, through valve PV1, through peristaltic pump P1, and into capillary CP1. Liquid displaces air in the path from vessel V1 to capillary CP1. Air is vented through valve PV5 to supply line 1318 . Upon completion of this step, a quantity of liquid from vessel V1 that is sufficient to fill the liquid line between T1 and port C1 of droplet actuator 1320 is contained in capillary CP1.
[0000]
TABLE 1
PV1
PV2
PV3
PV4
PV5
P1
P2
OPEN
CLOSED
CLOSED
CLOSED
OPEN
CW
STOP
Purging Fluidics System—Step 2
[0120] FIG. 13C , with reference to Table 2 below, illustrates a second purging step in which valves PV2 and PV4 are open, valves PV1, PV3, and PV5 are closed, peristaltic pump P1 is activated in the CCW direction, and syringe pump P2 is stopped. This arrangement establishes a flow of liquid from capillary CP1, through peristaltic pump P1, through valve PV2, and into port C1 of droplet actuator 1320 . Liquid displaces air in the path from T1 to port C1 of droplet actuator 1320 . Air is vented through port C2 of droplet actuator 1320 and through valve PV4.
[0000]
TABLE 2
PV1
PV2
PV3
PV4
PV5
P1
P2
CLOSED
OPEN
CLOSED
OPEN
CLOSED
CCW
STOP
Purging Fluidics System—Step 3
[0121] FIG. 13D , with reference to Table 3 below, illustrates a third purging step in which valves PV1 and PV5 are open, valves PV2, PV3, and PV4 are closed, peristaltic pump P1 is activated in the CW direction, and syringe pump P2 is stopped. This arrangement establishes a flow of liquid from vessel V1, through valve PV1, through peristaltic pump P1, through capillary CP1, through one branch of T2, through valve PV5, and through supply line 1318 to MWP1. Liquid displaces air in the path from vessel V1 to MWP1. Air is vented through supply line 1318 to MWP1.
[0000]
TABLE 3
PV1
PV2
PV3
PV4
PV5
P1
P2
OPEN
CLOSED
CLOSED
CLOSED
OPEN
CW
STOP
Purging Fluidics System—Step 4
[0122] FIG. 13E , with reference to Table 4 below, illustrates a fourth purging step in which valves PV1, PV2, and PV3 are open, valves PV4 and PV5 are closed, peristaltic pump P1 is stopped (i.e., pump P1 acts as a closed valve), and syringe pump P2 is activated in a direction selected to pull liquid from fluidics system 1300 . This arrangement establishes a flow of liquid from vessel V1, through valve PV1, through T1, through valve PV2, through droplet actuator 1320 from port C1 to port C3, through valve PV3, and into the cylinder of syringe pump P2. Liquid displaces air in the path from vessel V1 to syringe pump P2. Droplet actuator 1320 is purged of air. Air is drawn into syringe pump P2.
[0000]
TABLE 4
PV1
PV2
PV3
PV4
PV5
P1
P2
OPEN
OPEN
OPEN
CLOSED
CLOSED
STOP
PULL
Purging Fluidics System—Step 5
[0123] FIG. 13F , with reference to Table 5 below, illustrates a fifth purging step in which valves PV3, PV4, and PV5 are open, valves PV1 and PV2 are closed, peristaltic pump P1 is stopped (i.e., pump P1 acts as a closed valve), and syringe pump P2 is activated in a direction to push liquid into fluidics system 1300 . This arrangement establishes a flow of liquid from syringe pump P2, through valve PV3, through droplet actuator 1320 from port C3 to port C2, through valve PV4, through T2, through valve PV5, and through supply line 1318 to MWP1. Liquid displaces air in the path from syringe pump P2 to MWP1. Air is vented through supply line 1318 to MWP1.
[0000]
TABLE 5
PV1
PV2
PV3
PV4
PV5
P1
P2
CLOSED
CLOSED
OPEN
OPEN
OPEN
STOP
PUSH
[0124] At the completion of this step, all air has been purged from fluidics system 1300 , and droplet actuator 1320 . All liquid lines and elements of fluidics system 1300 and all channels of droplet actuator 1320 are filled with liquid and substantially free of air bubbles.
Loading Droplet Actuator—Step 1
[0125] FIG. 13G , with reference to Table 6 below, illustrates an exemplary first step in a method of loading a droplet actuator. Fluidics system 1300 has two pumps, peristaltic pump P1 and syringe pump P2, that are available for loading reagents into droplet actuator 1320 . Peristaltic pump P1 of fluidics system 1300 is used for loading reagents into droplet actuator 1320 . Valves PV1 and PV5 are open, valves PV2, PV3, and PV4 are closed, peristaltic pump P1 is activated in the CCW direction, and syringe pump P2 is stopped. Additionally, using the xyz-motion, supply line 1318 is inserted into a well of MWP1 that contains the pre-selected reagent 1310 . A certain amount of reagent 1310 is drawn from MWP1 in a flow loop through peristaltic pump P1 and toward vessel V1, as indicated in FIG. 13G . Subsequently, supply line 1318 is lifted out of reagent 1310 and into filler fluid 1314 and a certain amount of filler fluid 1314 is drawn from MWP1. In some embodiments, supply line 1318 may oscillate up and down in the well to create multiple slugs. A train of reagent slugs that are separated by filler fluid flows toward capillary CP1. When the entire train of reagent slugs is present within CP1, peristaltic pump P1 is stopped.
[0000]
TABLE 6
PV1
PV2
PV3
PV4
PV5
P1
P2
OPEN
CLOSED
CLOSED
CLOSED
OPEN
CCW
STOP
Loading Droplet Actuator—Step 2
[0126] FIG. 13H , with reference to Table 7 below, illustrates an exemplary next step in a method of loading a droplet actuator. Fluidics system 1300 has two pumps, peristaltic pump P1 and syringe pump P2, that are available for loading reagents into droplet actuator 1320 . Peristaltic pump P1 of fluidics system 1300 is used for loading reagents into droplet actuator 1320 . Valves PV2 and PV4 are open, valves PV1, PV3, and PV5 are closed, peristaltic pump P1 is activated in the CW direction, and syringe pump P2 is stopped. This arrangement establishes a flow loop through droplet actuator 1320 that includes peristaltic pump P1 and capillary CP1, as indicated in FIG. 13H . The train of reagent slugs within capillary CP1 flows into droplet actuator 1320 , from port C2 toward port C1, and droplet actuator 1320 is, thus, loaded with the pre-selected reagent and ready for operation.
[0000]
TABLE 7
PV1
PV2
PV3
PV4
PV5
P1
P2
CLOSED
OPEN
CLOSED
OPEN
CLOSED
CW
STOP
Direct Dispensing Method of Loading a Droplet Actuator
[0127] FIG. 13I , with reference to Table 8 below illustrates another step in a method of loading a droplet actuator. Fluidics system 1300 has two pumps, peristaltic pump P1 and syringe pump P2, that are available for loading reagents into droplet actuator 1320 . Syringe pump P2 of fluidics system 100 is used for loading reagents into droplet actuator 1320 . Valves PV3, PV4, and PV5 are open, valve PV1 is closed, PV2 is optionally closed, peristaltic pump P1 is stopped (i.e., pump P1 acts as a closed valve), and syringe pump P2 is activated in a direction to pull liquid from fluidics system 1300 . Additionally, using the xyz motion, supply line 1318 is inserted into a pre-selected well of MWP1 that contains the pre-selected reagent 1310 . A certain amount of reagent 1310 is drawn from MWP1 in a flow loop through droplet actuator 1320 from port C2 to port C3 and toward syringe pump P2, as indicated in FIG. 13I . In one example, syringe pump P2 is used for loading a large volume reagent slug from MWP1 into droplet actuator 1320 .
[0000]
TABLE 8
PV1
PV2
PV3
PV4
PV5
P1
P2
CLOSED
CLOSED
OPEN
OPEN
OPEN
STOP
PULL
[0128] FIGS. 14A-14F are schematic diagrams of an example of another fluidics system 1400 for loading a droplet actuator with liquid. With reference to FIG. 14A , fluidics system 1400 may include any arrangement of one or more valves, one or more pumps, one or more capillaries, and one or more liquid supply vessels; all fluidly connected. A droplet actuator to be loaded is fluidly connected to fluidics system 1400 . In one example, fluidics system 1400 is substantially the same as fluidics system 1300 , except that a vent path that includes a pinch valve PV6 is provided between peristaltic pump P1 and capillary CP1, and MWP1 is replaced with a capillary CP2, which is preloaded with a certain train of reagent slugs. Note that, like fluidics system 1300 , all liquid lines L of fluidics system 1400 may be capillaries or other tubes and that capillary CP1 may be an extended length of capillary that couples peristaltic pump P1 and junction T2. Similarly, capillary CP2 may be formed of an extended length of capillary coupled to pinch valve P5.
[0129] Fluidics system 1400 is exemplary only, other system variations are possible within the scope of the invention. For example, syringe pump P2 may be replaced with other types of pumps. Alternatively, fluidics system 1400 may include a single pump only.
[0000] Purging Air from Fluidics System—Step 1
[0130] FIG. 14B , with reference to Table 9 below, illustrates a first purging step, in which valve PV1 is optionally open, valves PV3 and PV4 are open, valves PV2, PV5, and PV6 are closed, peristaltic pump P1 is activated in the CW direction, and syringe pump P2 is activated in a direction to pull liquid from fluidics system 1400 . By using peristaltic pump P1 and syringe pump P2 simultaneously, liquid is drawn from vessel V1, through valve PV1, through peristaltic pump P1, through capillary CP1, through valve PV4, through droplet actuator 1420 , through valve PV3, and into syringe pump P2. Liquid displaces air in the path from vessel V1 to syringe pump P2. Air is drawn into syringe pump P2.
[0000] TABLE 9 PV1 PV2 PV3 PV4 PV5 PV6 P1 P2 OPEN CLOSED OPEN OPEN CLOSED CLOSED CW PULL
Purging air from Fluidics System—Step 2
[0131] FIG. 14C , with reference to Table 10 below, illustrates a second purging step, in which valves PV1, PV2, PV3, PV5, and PV6 are open, valve PV4 is closed, peristaltic pump P1 is stopped (i.e., pump P1 acts as a closed valve), and syringe pump P2 is activated in a direction to push liquid into fluidics system 1400 . This arrangement establishes a flow of liquid from syringe pump P2, through droplet actuator 1420 from port C3 to port C1, through valve PV2, through T1, through valve PV1, and into vessel V1, as indicated in FIG. 14C . Liquid displaces air in the path from syringe pump P2 to vessel V1. Air is vented at vessel V1.
[0000] TABLE 10 PV1 PV2 PV3 PV4 PV5 PV6 P1 P2 OPEN OPEN OPEN CLOSED OPEN OPEN STOP PUSH
Purging Air from Fluidics System—Step 3
[0132] FIG. 14D , with reference to Table 11 below, illustrates a third purging step, in which valves PV1 and PV5 are open, valves PV2, PV3, PV4, and PV6 are closed, peristaltic pump P1 is activated in the CCW direction, and syringe pump P2 is stopped. Peristaltic pump P1 pumps liquid from capillary CP2, through valve PV5, and through T2. Peristaltic pump P1 is operated until such time that any air that precedes the train of reagent slugs from preloaded capillary CP2 is trapped between peristaltic pump P1 and T3.
[0000] TABLE 11 PV1 PV2 PV3 PV4 PV5 PV6 P1 P2 OPEN CLOSED CLOSED CLOSED OPEN CLOSED CCW STOP
Purging Air from Fluidics System—Step 4
[0133] FIG. 14E , with reference to Table 12 below, illustrates a fourth purging step, in which valves PV1 and PV6 are open, valves PV2, PV3, PV4, and PV5 are closed, peristaltic pump P1 is activated in the CW direction, and syringe pump P2 is stopped. This arrangement establishes a flow of liquid between vessel V1 and valve PV6, which is the vent path. Pump P1 pushes air trapped between peristaltic pump P1 and T3 through PV6, through which air is vented from fluidics system 1400 .
[0000]
TABLE 12
PV1
PV2
PV3
PV4
PV5
PV6
P1
P2
OPEN
CLOSED
CLOSED
CLOSED
CLOSED
OPEN
CW
STOP
[0134] At the completion of this step, all air has been purged from fluidics system 1400 and droplet actuator 1420 , as all liquid lines and elements of fluidics system 1400 and all channels of droplet actuator 1420 are filled with liquid and substantially free of air bubbles.
Loading a Droplet Actuator
[0135] FIG. 14F , with reference to Table 13 below illustrates a step in a method of loading a droplet actuator. Valves PV2 and PV4 are open, and valves PV1, PV3, PV5, and PV6 are closed, peristaltic pump P1 is activated in the CW direction, and syringe pump P2 is stopped. Because fluidics system 1400 contains all filler fluid and reagent slugs necessary for the operation of droplet actuator 1420 , the pumping action of peristaltic pump P1 moves the train of reagent slugs into droplet actuator 1420 , from port C2 to port C1, as indicated in FIG. 14F .
[0000]
TABLE 13
PV1
PV2
PV3
PV4
PV5
PV6
P1
P2
CLOSED
OPEN
CLOSED
OPEN
CLOSED
CLOSED
CW
STOP
Sample Processing
[0136] The invention provides a droplet actuator device and methods for processing samples for use on a droplet actuator device. For example, the invention provides methods of processing samples for conducting genetic analysis of microbiological organisms in a biological sample. The device and methods of the invention may be used to detect and identify microorganisms such as bacteria, viruses, and/or fungi in a biological sample. Examples of biological samples include, blood, plasma, serum, isolated microorganisms, nucleic acid spiked into an assay buffer, other samples described herein, and other known sample types. In various embodiments, the invention provides for droplet actuator-based sample preparation and nucleic acid analysis. The device and methods of the invention may, in one embodiment, be used for rapid and accurate identification of atypical bacteria that have specific treatment implications, such as selection of effective antibiotics and length of therapy. For example, in the immunosuppressed population the ability to distinguish between bacteria, viruses, and fungi both rapidly and accurately will be life-saving.
Sample Preprocessing
[0137] The invention provides a droplet actuator device and methods for pre-processing samples prior to introduction of the samples onto a droplet actuator. Prior to transfer of sample to the droplet actuator, the sample may be combined with magnetic beads having affinity for analytes (e.g., DNA and/or RNA) of interest. The analytes of interest may be bound to the magnetically responsive capture beads. The magnetically responsive beads may be concentrated in a small part of the processed sample volume. The reduced sample volume that contains the magnetically responsive beads may be loaded onto the droplet actuator. For example, volume reduction may be from about ≧1 milliliter (mL) to about ≦10 microliters (μL).
[0138] The droplet actuator may be provided as part of a system which is programmed to execute analysis protocols using electrical fields to perform droplet operations. For example, in a real-time PCR assay, thermocycling is accomplished by transporting reaction droplets through isothermal temperature zones within the droplet actuator rather than by cycling the heaters (“flow-through” PCR). This and other PCR approaches are described in Pollack et al., International Patent Application No. PCT/US 06/47486, entitled “Droplet-Based Biochemistry,” filed on Dec. 11, 2006, the entire disclosure of which is incorporated herein by reference.
[0139] The droplet actuator may be electrically coupled with the system using mating alignment features to ensure proper positioning. The mating alignment features align the droplet actuator with various functional elements, such as heaters, magnets, and detection elements, that are aligned with specific regions of droplet actuator. A sample is loaded into the sample well. The sample well may be sealed before the analysis protocol can be started. Once the analysis protocol is started, it proceeds to completion without requiring operator intervention. Using one or more droplet operations, the sample is combined in the cassette with appropriate reagents, such as lysis buffer, capture buffer, and capture beads, as required by the analysis protocol. Meanwhile the droplet actuator is primed for performing the final assay (e.g., real-time PCR).
[0140] The low thermal mass of the droplets combined with the speed and agility with which they can be positioned using one or more droplet operations enables extremely rapid and precise thermal profiles to be achieved. The inventors have successfully implemented real-time PCR in microfluidic format, which includes tests for bacterial and fungal pathogens ( Bacillus anthracis, Franciscella tularensis, Candida albicans, Mycoplasma pneumoniae, Eschericia coli , Methicillin-resistant Staphylococcus aureus (MRSA)), human gene targets (RPL4, CFTR, PCNA) and RNA.
[0141] FIG. 15A shows a plot of real-time PCR data for detection of MRSA using digital microfluidics. FIG. 15B shows a plot of real-time PCR data for detection of Bacillus anthracis using digital microfluidics.
[0142] Referring to FIG. 15A , for detection of MRSA by real-time PCR, a forward primer mecii574 (5′-GTC AAA AAT CAT GAA CCT CAT TAC TTA TG-3′) and reverse primer Xsau325 (5′-GGA TCA AAC GGC CTG CAC A-3′) were used to amplify a 176 bp fragment of Staphylococcus aureus genomic DNA (ATCC #700699D-5). The 50 μl PCR mix was comprised of 20 mM Tris HCl (pH 8.4), 50 mM KCl, 200 μM dNTPs, 1 μM of each primer, 2× Evagreen (Biotium), 6.125U of KAPA2G Fast DNA polymerase (Kapa Biosystems). This mix was adjusted to 50 μl with H20 and approximately 1-2 μL of this mixture was loaded in one of the droplet actuator reservoirs.
[0143] The protocol performed on the droplet actuator was to dispense two (450 nL) droplets from the reservoir and combine them to form a single (900 nL) reaction droplet. When sample and reagent are provided separately one droplet would be for the sample and the other droplet would be for the 2× reaction mixture. The droplets are then transported to the 95° C. zone and, following an initial activation step, the droplets are cycled between the 60° C. and 95° C. zones 40 times. A fluorescence reading was taken at the end of each extension cycle within the 60° C. zone. The two positions were spanned by 16 electrodes and the droplets were typically transferred at a rate of 20 electrodes per second, thus the time to transfer the droplet between the two thermal zones was approximately 750 milliseconds (ms). Real-time PCR curves obtained for 10-fold dilutions of MRSA genomic DNA concentration exhibited roughly the expected 3.3 cycle separation. The results were confirmed by gel analysis of the amplified product collected from the droplet actuator (not shown). In all cases the amplified product was of the expected length and no by-products were observed.
[0144] Referring to FIG. 15B , an experiment was also conducted to evaluate detection of Bacillus anthracis (anthrax) using digital microfluidic PCR. These experiments were performed using an early version of a droplet actuator and instrument and were not optimized for speed. Genomic DNA (chromosomal & plasmids) and primers targeted against B. anthracis protective antigen were provided from a commercially available kit (Idaho Technology, Salt Lake City, Utah) and combined with a similar reaction mixture to that described above for detection of MRSA. These experiments were performed with varying amounts of the DNA (i.e., 1 ng, 100 pg, 10 pg, 1 pg genomic DNA) added into the reactions which were amplified on the droplet actuator. Cycling conditions were 10 sec at 95° C. and 60 sec at 60° C. times 40 cycles. The data demonstrate the expected quantitation with detection down to 1 pg of genomic DNA.
Capture, Concentration and Elution of Nucleic Acids
[0145] The invention provides droplet actuator devices, techniques and systems for capturing, concentrating and/or eluting nucleic acids.
[0146] FIG. 16 shows a plot resulting from amplification of MRSA genomic DNA captured, concentrated and eluted on a droplet actuator. In operation, a droplet actuator is electrically coupled to the instrument (not shown). A suspension of magnetically responsive beads that contain captured DNA in a lysis solution was loaded into a sample reservoir of the droplet actuator. In an alternative embodiment, the lysis solution that contains MRSA genomic DNA may be provided as a droplet on a droplet actuator and combined with the bead-containing droplet on the droplet actuator. A permanent magnet located in close proximity to the droplet actuator is used to collect the magnetically responsive beads at the bottom of the well. A single droplet is dispensed from the sample reservoir. The single droplet contains substantially all of the magnetically responsive beads from the original sample, effectively concentrating the beads by a factor of about 50 or more. The droplet is then transported to a wash station where the magnetically responsive beads are magnetically immobilized and repeatedly washed. For about the last several washes, the wash fluid is switched to an elution buffer. The droplets that contain eluted DNA are accumulated within another reservoir. The purified DNA droplet is subsequently dispensed from the reservoir and mixed with multiple sets of PCR reagent droplets. The droplets are transported to the heater zone of the deck and flow-through real-time PCR is performed.
[0147] As a proof of concept, genomic MRSA DNA was added to several mL of cell lysis solution that contained DNA-capture magnetically responsive beads. The beads were then concentrated off-actuator and transferred in 15 μL of solution to the sample well of the droplet actuator. The beads were further concentrated into a single (˜300 nL) DNA capture droplet. The DNA capture droplet was washed using a merge-and-split protocol with 8 droplets of TE buffer (pH 7.0) and then eluted with 12 droplets of TE buffer (pH 8.5) into a reservoir. Droplets of purified DNA were then dispensed and mixed in a 1:1 ratio with a real-time PCR mix.
[0148] Data indicate that sample concentration, elution, and detection were successfully performed on a droplet actuator.
Sample Preparation on a Droplet Actuator
[0149] On-actuator preparation of biological samples provides a method for sensitive isolation of nucleic acids using one or more droplet operations to perform separation protocols. Droplet actuator-based sample preparation includes lysis (when necessary) of a sample, capture of nucleic acids (e.g., on magnetically responsive beads), pre-concentration of nucleic acids, a washing of captured nucleic acids to remove unbound material prior to analysis. The flexibility and programmability of the droplet actuator provides for variation in the order in which sample and reagents may be combined during sample preparation.
[0150] In one embodiment, a sample droplet may be combined using one or more droplet operations with a lysis buffer droplet in order to yield a lysed sample droplet in which nucleic acid has been released. A droplet that includes magnetically responsive capture beads may be combined with the lysed sample droplet in order to bind nucleic acid, yielding a nucleic acid capture droplet in which nucleic acid is bound to the magnetically responsive beads. The nucleic acid capture droplet may be transported using one or more droplet operations into the presence of a magnet and washed using a merge-and-split wash protocol to remove unbound material, yielding a washed bead-containing droplet substantially lacking in unbound material. In some applications, the washed bead-containing droplet may be merged with an elution buffer droplet to elute the nucleic acid, yielding a bead-containing elution droplet. The bead-containing elution droplet may be transported using one or more droplet operations into a thermal zone in order to promote release of the nucleic acid. In other applications, the washed bead-containing droplet may be transported using one or more droplet operations into a thermal zone to promote release of the nucleic acid. The eluted nucleic acid contained in the droplet surrounding the magnetically responsive beads may then be transported away from the magnetically responsive beads for further processing, e.g., PCR analysis.
[0151] In an alternative embodiment, a lysis buffer droplet that includes magnetically responsive beads may be combined using one or more droplet operations with a sample droplet to yield a nucleic acid capture droplet in which nucleic acid is bound to the magnetically responsive beads.
[0152] In yet another embodiment, a sample droplet that includes magnetically responsive beads may be combined using one or more droplet operations with a lysis buffer droplet to yield a nucleic acid capture droplet in which nucleic acid is bound to the magnetically responsive beads.
[0153] In yet another embodiment, a sample droplet may be combined using one or more droplet operations with a lysis buffer droplet in order to yield a lysed sample droplet. A wash buffer droplet that includes magnetically responsive beads may be combined with the lysed sample droplet in order to yield a nucleic acid capture droplet in which nucleic acid is bound to the magnetically responsive beads.
[0154] In yet another embodiment, magnetically responsive beads may be pre-concentrated prior to being loaded on the droplet actuator. For example, as the result of off-actuator processing, analytes in (e.g., nucleic acid) may be captured on magnetically responsive beads. The magnetically responsive beads may, for example, be provided in the sample, a lysis solution, or a wash solution. This approach permits the beads to be assembled into a volume which is a small part of the total sample volume. This small volume of beads may then be loaded onto the droplet actuator, e.g., into a reservoir for on-actuator dispensing. Dispensing may result in the production of a number of unit-sized, bead-containing droplets. The magnetic capture beads may be further consolidated, as needed, on the droplet actuator for conducting a droplet-based assay protocol.
Preparation of Viral RNA
[0155] Viral RNA may be prepared using, for example, Dynabeads SILANE viral NA from Dynal. A droplet including Proteinase K and a viral sample may be combined using one or more droplet operations with a lysis buffer droplet to yield a lysed sample droplet in which RNA has been released. A droplet including magnetically responsive Dynabeads may be combined with the lysed sample droplet to bind RNA, yielding an RNA capture droplet in which RNA is bound to the Dynabeads. The RNA capture droplet may be transported using one or more droplet operations into the presence of a magnet and washed using a merge-and-split wash protocol to remove unbound material, yielding a washed bead-containing droplet substantially lacking in unbound material. A droplet including elution buffer may be merged with the washed bead-containing droplet to elute RNA, yielding a bead-containing elution droplet. The bead-containing elution droplet may be transported using one or more droplet operations into a thermal zone to promote release of RNA from the Dynabeads, e.g., by heating to approximately 70° C. The eluted RNA contained in the droplet surrounding the Dynabeads may then be transported away from the Dynabeads for further processing, e.g., for execution of a droplet based RT-PCR protocol. Viral DNA may be prepared using, for example, Dynabeads SILANE viral NA from Dynal.
Preparation of Bacterial Genomic DNA
[0156] Bacterial genomic DNA, such as genomic DNA from Bacillus anthracis , may be prepared using beads having an affinity for DNA. For example, Dynabeads DNA DIRECT from Dynal may be used. A droplet including lysis buffer and magnetically responsive Dynabeads may be combined using one or more droplet operations with a bacterial sample to yield a lysed sample droplet in which released DNA is bound to the Dynabeads. The DNA capture droplet may be transported using one or more droplet operations into the presence of a magnet and washed using a merge-and-split wash protocol to remove unbound material, yielding a washed bead-containing droplet substantially lacking in unbound material. A droplet including resuspension buffer may be merged with the washed bead-containing droplet, yielding a DNA/bead-containing droplet. The DNA/bead-containing droplet is ready for further processing, e.g., for execution of a droplet based PCR protocol. Alternatively, the DNA/bead-containing droplet may be transported using one or more droplet operations into a thermal zone to promote release of DNA from the Dynabeads, e.g., by heating to approximately 65° C. The eluted DNA contained in the droplet surrounding the Dynabeads may then be transported away from the Dynabeads for further processing, e.g., for execution of a droplet based PCR protocol.
Droplet Actuator Systems
[0157] The invention provides droplet actuators with storage and/or transmission devices useful for controlling and/or monitoring distribution and/or use of droplet actuators. The invention also provides networked systems and methods of using such networked systems for controlling and/or monitoring distribution and/or use of droplet actuators.
[0158] FIG. 17 illustrates a droplet actuator device 1700 of the invention. Droplet actuator device 1700 includes droplet actuator 1724 . Droplet actuator 1724 includes an electronic storage and/or transmission element 1714 . Electronic storage and/or transmission element 1714 may be affixed to and/or incorporated in droplet actuator 1724 or affixed to and/or incorporated in a cartridge incorporating droplet actuator 1724 . Storage and/or transmission element 1714 may, for example, include semiconductor memory, magnetic storage, optical storage, and/or other available forms of computer readable data storage. Storage and/or transmission element 1714 may be volatile or non-volatile. Examples of specific storage and/or transmission elements 1714 include radio-frequency identification (RFID) tags, read-only memory (ROM), random access memory (RAM), electrically erasable programmable read-only memory (EEPROM) (such as flash memory), and magnetic stripes.
[0159] In one embodiment, the storage and/or transmission element includes an RFID tag. The RFID tag may be affixed to and/or incorporated in the droplet actuator or droplet actuator cartridge. For example, where the substrate of the droplet actuator is made from a printed circuit board (PCB), the RFID tag may also be mounted on the PCB. The RFID tag may provide for wireless identification of the droplet actuator. For example, the RFID tag may transmit a unique identifier for each droplet actuator. RFID monitors, such as those manufactured by Texas Instruments (Dallas, Tex.), may track the location and use of the droplet actuator. In one embodiment, the invention provides a system in which a subject's RFID and a droplet actuator's RFID are scanned at a subject's bedside into a system which matches the subject with the droplet actuator. The subject's sample may be loaded onto the droplet actuator, for example, into a droplet actuator reservoir and/or into the droplet operations gap of the droplet actuator. The droplet actuator may be mounted on an instrument and used to execute an assay using the sample. Upon completion of the assay, assay results may be automatically associated with the subject. In some embodiments, the information may be automatically added to the laboratory information system or hospital information system or the subject's electronic medical records. Similar methods may be used in testing applications outside of the medical field.
[0160] In another example, the storage and/or transmission element includes a memory device, such as a random access memory (RAM) device, read-only memory (ROM) device, or a flash drive. For example, such a droplet actuator may be provided in the form of a peripheral connect device, such as a USB device, that plugs into a computer to power the droplet actuator and permit data exchange between the computer and the device. As another example, the droplet actuator can also be connected and powered by a personal digital assistant (PDA) or a smartphone or a mobile phone. Identifying information from the droplet actuator may be read by the computer, and output information from the assay may be stored on the computer and/or the USB device.
[0161] In another embodiment, the invention provides a system for conducting environmental studies, such as studies relating to pollution and/or biological or chemical warfare agents. The device may include a droplet actuator in an instrument associated with the droplet actuator including elements required to power the droplet actuator and/or control the droplet actuator. The system may also include elements for gathering other information, such as temperature, humidity, GPS location, and the like. Information including the results of the assay and the other information may be transmitted to a networked computer. Information including the results the assay and the other information may alternatively be stored on the droplet actuator device and information from multiple devices may be transported to an uploading station where the information may be aggregated onto a computer or a computer network.
[0162] In one embodiment, the invention provides a system for detecting and tracking the extent of a chemical or biological attack or release of a dangerous chemical. Droplet actuators may be installed at various locations throughout a target region, for example, on buildings, farms, water supply sources, buoys, weather balloons, etc. Droplet actuators may be installed on mobile devices, such as mobile robotic devices, airplanes, unmanned drones, and vehicle fleets (such as police cars, school buses, ambulances, military vehicles, oceangoing vessels, postal vehicles, commercial vehicles, etc.). Droplet actuators may be associated with GPS systems for determining coordinates of the droplet actuators when samples are taken. Tests may be executed using the droplet actuator devices, and results may be transmitted back to a central location, along with sample collection location information, for aggregation and analysis.
[0163] FIG. 18 illustrates another embodiment, droplet actuator 1724 is provided as part of a magnetic stripe card device 1800 . Card device 1800 includes a card 1805 with a magnetic stripe 1810 affixed thereto for receiving and storing data. A droplet actuator 1724 is also affixed to the card. Droplet actuator 1724 may include electrical contacts 1815 for electrically coupling droplet actuator 1724 to an instrument. Alternatively, droplet actuator 1724 may be electrically connected to wires on card 1805 . Wires on card 1805 may terminate in contacts, and these contacts may be electrically coupled to electrical contacts on the instrument so that the droplet actuator may be controlled by the instrument. Droplet actuator 1724 may include an opening 1820 or loading mechanism for loading a sample into droplet actuator 1724 in a manner which subjects the sample to droplet operations mediated by electrodes coupled to the electrical contacts and controlled by the instrument to which the card/droplet actuator is electrically coupled.
[0164] In some embodiments, the card may have the shape and size of a standard credit card, and magnetic stripe 1810 may have a location on card 1805 which is similar to the location of the magnetic stripe on a standard credit card. Magnetic stripe 1810 may be, for example, any magnetic stripe capable of storing data, such as those commonly used on magnetic stripe cards (e.g., credit cards, identity cards, and transportation tickets). Magnetic stripe 1810 may be read by physical contact and swiping past a reading head (not shown), as is well known. In one embodiment, the instrument is configured so that magnetic stripe 1810 may be read as the card is inserted into the instrument. Further, information from the assay may be written to magnetic stripe 1810 during and/or following the completion of the assay.
[0165] The instrument may be configured in a manner similar to an automated teller machine, in which the card is inserted by a user, a card reader device transports the card into an operational position in which the card electrical contacts are coupled to the instrument. Establishing the card in operational position may be controlled by a card insertion device and/or may be manually controlled. Further, in operational position, any detection region or window on the droplet actuator may be aligned with a detector on the instrument. In operational position, the instrument may control the execution of an assay on the droplet actuator, and then read and store information to and from the magnetic stripe. Information from magnetic stripe 1810 may be read by a magnetic stripe reader. An assay may be conducted, and information pertaining to assay results may be written to magnetic stripe 1810 . The instrument may be coupled to a network and may upload results from the assay to the network, e.g., into an electronic medical record system. The instrument may include an output device, such as a display and/or printer, which outputs information pertaining to assay results. In another embodiment, a magnetic stripe reader/writer at a subject's bedside is used to associate card 1800 with a specific subject, e.g., by reading a card identifier from magnetic stripe 1810 and copying the identifier into a subject record and/or by writing a subject identifier onto card 1800 . Magnetic stripe 1810 may also include information about the expiration date of card device 1800 , information about the assay type, instructions for a user for electronic display by the instrument, and software instructions for controlling the assay or selecting a software protocol on the instrument for controlling the assay. Further, printed material on card device 1800 may also include information about the expiration date of card device 1800 , information about the assay type, instructions for a user. In an alternative embodiment, the card is a smart card containing an integrated circuit actuator. The card may have metal contacts connecting the card physically to the reader. Similarly, the card may be a contactless card that uses a magnetic field or radio frequency (RFID) for proximity reading. A battery supply may be included on the card for self-contained execution of an assay.
[0166] As noted, the invention provides a droplet actuator with electronic storage and/or transmission element. Information that may be stored and/or transmitted by the electronic storage and/or transmission element includes, for example, sample identification information, test identification information (such as assay type), and subject identification information. Examples of subject identification information include medical history information, subject contact information, insurance information, and test results information. In short, the information may include any data of interest suited for the application in which it is used. Systems that use the droplet actuators of the invention that have data storage capability may, for example, provide the advantage of automated tracking, automated distribution, reduction in medical errors, and/or improved anonymity.
[0167] FIG. 19 is a functional diagram of a sample collection and analysis system 1900 of the invention. System 1900 utilizes droplet actuators 1724 of the invention that have data storage components 1714 . In this embodiment, sample collection system 1900 includes one or more kiosks 1915 for dispensing one or more droplet actuators 1724 . Kiosks 1915 may be standalone kiosks or may be provided as components of a computer network, such as a wide area network (WAN) or local area network (LAN). Kiosk 1915 may be located, for example, in a pharmacy, grocery store, mall, gas station, doctor's office, hospital, clinic, and/or any convenient location suited for collecting samples. An example method of using system 1900 may include, but is not limited to, the following steps:
[0168] Step 1: Using kiosk 1915 , a subject obtains a droplet actuator 1724 . For example, droplet actuator 1724 may be purchased by the subject using a credit card transaction. Droplet actuator 1724 is dispensed from kiosk 1915 . The subject may input identifying information into system 1900 using kiosk 1915 . Kiosk 1915 may include a keypad for inputting information, information may be collected from the subject's credit card or insurance card, and/or the subject may be provided with an identification card with information that is readable by kiosk 1915 . User information may, for example, include name, address, telephone, insurance information, physician information, etc. System 1900 may associate the subject's identifying information with identifying information from droplet actuator 1724 . A user-generated code or a kiosk-generated code may be provided during the transaction. In this way, the purchased droplet actuator 1724 may be associated with subject. This association may be stored locally within kiosk 1915 or, alternatively, the information is transferred to a networked computer via the networked system.
[0169] Step 2: The subject or a medical care provider may load a sample on droplet actuator 1724 . For example, a urine sample, blood sample, saliva sample, or stool sample may be loaded into a reservoir of droplet actuator 1724 . Non-medical samples may also be used, e.g., a drinking water sample, aquarium water sample, a swimming pool water sample, a pond water sample, a plant sample, and the like. Kiosk 1915 may dispense instructions and or sample collection devices for collecting and handling the sample. Droplet actuator 1724 may be sealed to prevent leakage of the sample. Droplet actuator 1724 may be placed in a sealed container to prevent leakage of the sample.
[0170] Step 3: The subject may return the droplet actuator 1724 that has a sample therein to the site of kiosk 1915 . Droplet actuator 1724 may be inserted into kiosk 1915 via any kind of receiving mechanism, such as a secure slot. Droplet actuator 1724 may be stored in a secure manner within kiosk 1915 until such time that it may be removed by an attendant. Droplet actuator 1724 may be stored in a temperature controlled environment within kiosk 1915 . Alternatively, droplet actuator 1724 may be provided to an attendant at the site of the kiosk, at a physician's office or elsewhere. In another embodiment, a mailing label, package, and/or instructions may be dispensed with droplet actuator 1724 , and droplet actuator may be mailed to a laboratory for processing.
[0171] Step 4: Droplet actuator 1724 is removed from kiosk 1915 by an attendant.
[0172] Step 5: Data storage device 1714 of droplet actuator 1724 may be scanned or otherwise read in order to extract the unique identification number and subject information. Alternatively, data storage device 1714 may include only a unique serial number, and the patient information may be stored at the local kiosk 1915 or at a centralized computer electronically coupled to the kiosk. The subject information may thus be matched to the serial number of the droplet actuator 1724 . In this way, the droplet actuator 1724 is automatically associated with the certain subject that has provided the sample.
[0173] Step 6: Sample within droplet actuator 1724 may be analyzed and the results automatically reported via, for example, telephone, email, and/or the subject accessing the results via kiosk 1915 (e.g., using a code). For example, results may be reported to the subject or the subject's medical care provider.
[0174] A similar process may be used in a hospital environment. For example, a subject identifier and droplet actuator identifier may be associated at a subject's bedside or via a hospital supply system. Associated information may be centrally stored and/or stored on storage and/or transmission element 1714 of droplet actuator 1724 .
[0175] A similar approach may be used for environmental studies, such as testing for contaminants in drinking water. Sample collection devices with unique serial numbers may be mailed to participants in the study. The serial numbers may, for example, be stored in an electronic format, such as an RFID actuator or in a physical format, such as a bar code. Users may load samples into the sample collection devices, and drop off the samples at local collection points (or ship them to a collection point) for analysis. The identifying information may be associated with the user's address. In this manner, certain geographical distributions of drinking water contamination may be identified. In a related embodiment, the users may take the sample collection devices to a kiosk analyzer, which controls droplet operations on the sample collection device and provides an output directly to the user. For example, a user may purchase a drinking water analysis collection device at a store, take it home and load it with a drinking water sample, bring it to a kiosk where it can be plugged in, permit the kiosk to run tests on the drinking water using a droplet actuator device that is part of the sample collection device, and provide the user with an output indicative of certain drinking water contaminants.
[0176] In yet another embodiment, kiosk 1915 may be reader instrument, and the user may insert droplet actuator 1724 into a reader slot, and kiosk 1915 may execute an assay using the droplet actuator. For example, a user may bring a water sample from home, obtain a droplet actuator from kiosk 1915 , load a droplet of water onto the droplet actuator, electronically couple the droplet actuator to kiosk, whereupon kiosk 1915 executes and assay and provides the user with results. As another example, a sample collection container may be mailed to a user, the user may collect the sample, such as a water sample, take the sample to kiosk 1915 , obtain a droplet actuator from kiosk 1915 , load a droplet of water onto the droplet actuator, couple the droplet actuator to kiosk, whereupon kiosk 1915 executes and assay and provides the user with results. Results may also be centrally stored for further analysis. In some cases, kiosk 1915 may be set up to receive biohazardous materials.
[0177] FIG. 20 is a functional diagram of a sample collection system 2000 of the invention. System 2000 utilizes droplet actuators 1724 with data storage components 1714 (see FIG. 17 ). Sample collection system 2000 includes distribution center 2010 , which may be, for example, a manufacturer facility or a warehouse distribution facility. Distribution center 2010 maintains an inventory of droplet actuators 1724 .
[0178] A server is provided by which one or more subjects or medical providers may place orders for droplet actuators 1724 via, for example, a computer in a subject's home, a medical care provider's office, pharmacy, clinic, and so on. Using any standard web browser or network interface application, the server facilitates the order placement and payment operations. For each transaction by which droplet actuator 1724 is ordered, an association may be made between droplet actuator identifying information and an ordering party's or subject's identifying information. This association may be provided via credit card information, purchase order number, other subject information such as name, address, email, and telephone, and/or a subject-generated or system-generated code. In this manner, droplet actuator 1724 may be associated with a certain subject. This association may be stored on web server or other networked computer and associated with assay results.
[0179] As will be appreciated by one of skill in the art, aspects of the invention may be embodied as a method, system, or computer program product. Accordingly, various aspects of the invention may take the form of hardware embodiments, software embodiments (including firmware, resident software, micro-code, etc.), or embodiments combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, the methods of the invention may take the form of a computer program product on a computer-usable storage medium having computer-usable program code embodied in the medium.
[0180] Any suitable computer useable medium may be utilized for software aspects of the invention. The computer-usable or computer-readable medium may be, for example but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, device, or propagation medium. More specific examples (a non-exhaustive list) of the computer-readable medium would include some or all of 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 transmission medium such as those supporting the Internet or an intranet, or a magnetic storage device. Note that the computer-usable or computer-readable medium could even be paper or another suitable medium upon which the program is printed, as the program can be electronically captured, via, for instance, optical scanning of the paper or other medium, then compiled, interpreted, or otherwise processed in a suitable manner, if necessary, and then stored in a computer memory. In the context of this document, a computer-usable or computer-readable medium may be any medium that can contain, store, communicate, propagate, or transport the program for use by or in connection with the instruction execution system, apparatus, or device.
[0181] Computer program code for carrying out operations of the invention may be written in an object oriented programming language such as Python, Java, Smalltalk, C++ or the like. However, the computer program code for carrying out operations of the invention may also be written in 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 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).
[0182] Certain aspects of invention are described with reference to various methods and method steps. It will be understood that each method step 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 methods.
[0183] The computer program instructions may also be stored in a computer-readable memory that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable memory produce an article of manufacture including instruction means which implement various aspects of the method steps.
[0184] The computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide steps for implementing various functions/acts specified in the methods of the invention.
CONCLUDING REMARKS
[0185] The foregoing detailed description of embodiments refers to the accompanying drawings, which illustrate specific embodiments of the invention. Other embodiments having different structures and operations do not depart from the scope of the present invention. The term “the invention” or the like is used with reference to certain specific examples of the many alternative aspects or embodiments of the applicants' invention set forth in this specification, and neither its use nor its absence is intended to limit the scope of the applicants' invention or the scope of the claims. This specification is divided into sections for the convenience of the reader only. Headings should not be construed as limiting of the scope of the invention. The definitions are intended as a part of the description of the invention. It will be understood that various details of the present invention may be changed without departing from the scope of the present invention. Furthermore, the foregoing description is for the purpose of illustration only, and not for the purpose of limitation, as the present invention is defined by the claims as set forth hereinafter.
|
The invention provides droplet actuators and droplet actuator cassettes including reagent storage capabilities, as well as methods of making and using the droplet actuators and cassettes. The invention also provides continuous flow channel elements and techniques for using electrodes to manipulate droplets in flowing streams. The invention also discloses methods of separating compounds on a droplet actuator. Various other aspects of the invention are also disclosed.
| 8
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a Continuation Application of U.S. patent application Ser. No. 10/359,734, filed on Feb. 7, 2003, incorporated herein by reference, which is a Continuation Application of U.S. patent application Ser. No. 08/671,873, filed on Jun. 28, 1996, now U.S. Pat. No. 6,542,150, also incorporated herein by reference. The present invention is related to application Ser. No. 08/673,793, entitled “METHOD AND APPARATUS FOR EXPANDING GRAPHICS IMAGES FOR LCD PANELS” filed Jun. 27, 1996, now U.S. Pat. No. 6,067,071, also incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention is in the field of portable computers, namely laptop, notebook, or similar portable computers with flat panel displays with or without SIMULSCAN™ capability. In particular, the present invention relates to displaying graphics data on fixed resolution LCD panel displays.
BACKGROUND OF THE INVENTION
[0003] Popularity of portable computer systems has driven computer designers to integrate more processing power, more memory capacity, and more peripherals into a single portable unit. Advances in core logic, a term known in the art to comprise support logic, and other common circuitry integrated into a chip or chipset, allows more functionality to be placed in smaller, lighter packages.
[0004] A primary element of a portable computer system is a display. Since Cathode Ray Tube (CRT) displays are relatively large and heavy, with high power requirements, other alternatives have actively been sought. Flat panel display technology represents a significant alternative to CRT display technology. Flat panel displays may have several advantages over CRT displays. Flat panel displays include a number of different display types, Liquid Crystal Display (LCD) being most commonly used. LCD displays may have advantages of being compact and relatively flat, consuming little power, and in many cases displaying color.
[0005] Typical disadvantages of LCD displays may be poor contrast in bright light—especially bright natural light, inconsistent performance in cold temperatures, and display resolutions which may be constrained by a fixed number of row elements and column elements. Among these limitations, fixed resolution may cause significant problems for LCD operation in a multimedia environment. Multimedia users may demand a monitor which can be configured for different display resolutions. Analog CRT displays may be easily configured for different resolutions.
[0006] Flat panel displays may typically comprise two glass plates pressed together with active elements sandwiched between. High resolution flat panel displays use matrix addressing to activate pixels. Conductive strips for rows may be embedded on one side of a panel and similar strips for columns are located on the other side. Panels may be activated on a row by row basis in sequence. This process may be described in more detail in a text entitled: “High Resolution Graphics Display Systems”, Peddie 1.994 (pp. 191-225), incorporated herein by reference, however the general nature of LCD addressing is known in the art.
[0007] LCD flat panel display resolution may be dictated by physical construction of an LCD. CRT displays have a continuous phosphor coating and may be illuminated by an analog signal driving an electron beam. Because of the analog nature of CRT, scaling display resolution is relatively simple. LCD displays have a fixed array of physical pixels which may be turned on or off by applying or removing a charge.
[0008] While resolution of a CRT may be changed by changing scanning frequency parameters, LCDs are limited by a fixed number of row and column elements. Fixed resolution LCD displays are particularly troublesome in multimedia systems. Such systems may require changes in display resolution to take full advantage of applications displaying high resolution graphics. In addition, for a manufacturer of display controllers to claim full VGA, SVGA, and XGA compatibility limitations of fixed panel resolution must be overcome.
TABLE 1 Vertical scanning frequencies for different graphics display modes Typical Vertical Scan Panel Type Resolution Frequency VGA Panel 640 × 480 25 Mhz SVGA Panel 800 × 600 40 Mhz XGA Panel 1024 × 768 65 Mhz
[0009] Like an analog CRT, an LCD panel may be controlled by a horizontal and vertical scanning signal. Data may be displayed in its respective screen position during an interval in time corresponding to when vertical and horizontal scan signals for a particular location coincide. Horizontal and vertical scan signals are set at a frequency proportional to display resolution. Table 1 contains vertical scanning frequencies for popular graphics display modes.
[0010] Typical vertical scanning frequencies may be 25 MHz for 640 pixels by 480 pixels display, 40 MHz for 800 pixels by 600 pixels, and 65 MHz for 1024 pixels by 768 pixels. New panels comprising 1280 pixels by 960 pixels may have an even higher vertical scanning frequency. A high resolution display therefore may have a higher scanning frequency than a relatively lower resolution display.
[0011] Most multimedia computers have the ability to select from one of several display resolutions. Common display resolutions may be 640 pixels by 480 pixels, 600 pixels by 800 pixels, and 1024 pixels by 768 pixels. A standard fixed resolution LCD display may be 600 pixels by 800 pixels. A standard universal VGA resolution may be 640 pixels by 480 pixels with 256 colors. When a low graphic resolution must be displayed on a fixed resolution LCD display certain problems may arise. To properly display all VGA modes in a portable computer environment with a fixed resolution LCD panel display, desired graphics resolution must be scaled to the panel resolution. Fewer problems are inherent in downscaling, when desired display resolution is larger than the panel. Upscaling however may present special problems.
[0012] Using the general principal stating high frequency is proportional to high resolution, some downscaling may be achieved by attempting to replicate lower scanning frequencies of low resolution display while maintaining native scanning resolution. On a fixed resolution display of 600 pixels by 800 pixels for example, a 640 pixel by 480 pixel resolution output may be scaled by lowering the frequency at which data is clocked to the display. This type of approach to expansion related problems may be considered synchronous. Synchronous approaches may have disadvantages for expanding certain resolutions.
[0013] Because of the relationship between scan frequencies for certain resolutions that need to be expanded, synchronous approaches to expansion may not be desirable. Visual anomalies such as flicker, and related line dropping may cause noticeable and annoying visual artifacts. Also, horizontal flicker may be noticed and is even more annoying as portions of the display shift from side to side. This is due to the inability of the expansion scheme to account for every line generated at one resolution to a corresponding line on a second resolution. Resolutions which divide evenly into each other may be best suited for synchronous approaches.
[0014] Asynchronous approaches may be necessary when the ratio of CRT display lines and LCD display lines, based on different desired display resolution and fixed resolution display capability, is non-integral and when it is generally considered desirable to decouple the time base upon which display data is generated from the time base upon which output display resolution is generated. Consider an example when 3 LCD display lines must be displayed for every 2 CRT lines.
[0015] Prior art methods use relatively expensive dual path approaches which may replicate hardware for each display sought to be driven. In addition to hardware costs, bandwidth requirements may be approximately doubled and available bandwidth cut by approximately half for a dual path approach. Other disadvantages of a dual path approach may be non-transparency of software. With a dual path approach, display related software may require separate modification to standard register contents, standard addresses or the like in order to operate at each resolution.
[0016] For transforming graphics resolutions, fewer problems are inherent in downscaling, when desired display resolution is larger than the panel. Upscaling however may present special problems. When attempting to display lower resolution graphics on a higher resolution, fixed resolution panel display a variety of compensation methods may be used. Compensation features may be made available through use of shadow registers and extension registers. Both compensation method and desired parameters, such as output resolution may be set through use of registers.
[0017] Some systems employ a compensation technique known as centering. With centering, a smaller resolution graphic image may be placed within a larger resolution display in the center of the display. One problem associated with centering a 640 pixel by 480 pixel display at full color within, for example, a 1024 pixel by 768 pixel display is limited bandwidth. On a display which supports 640 pixels by 480 pixels in native mode (e.g at native 640 pixel by 480 pixel timing of 25 Mhz) , there may be sufficient bandwidth to support 24 or 32 bits per pixel of color.
[0018] As frequency increases such as on a fixed panel 1024 pixel by 768 pixel display which does not support the native timing for 640 pixels by 480 pixels resolution, bandwidth requirements increase in proportion to increase in frequency between resolutions. Most 32 or 64 bit controller may only support 24 or 32 bit full color at a native resolution of 640 pixels by 480 pixels. Another problem with centering and prior art expansion techniques is the scope of programming required to support it. Many shadow registers must be programmed, and protection mechanisms must be in place to configure and then preserve the expanded display settings.
[0019] [0019]FIG. 1 is a diagram illustrating a prior art technique of centering. During centering, Graphics Window 200 with a resolution of 640 pixels by 480 pixels may be displayed on Fixed Resolution Panel 201 which is capable of displaying at a fixed resolution of 1024 pixels by 768 pixels. Graphics Window 200 may be generated by a software application such as a computer game with high resolution graphics. For consistency and compatibility purposes, such a computer game may generate a display with a resolution of 640 pixels by 480 pixels regardless of the resolution capability of the display.
[0020] Differences in size must be accommodated to physically center a smaller display within a larger resolution panel. Additionally, differences in normal VGA timing which may be around 25 Mhz, and native timing of an LCD panel which, for a 1024 pixel by 768 pixel display, may be around 65 Mhz must be accommodated. In other words, during centering, a panel must actively accommodate the difference between lower resolution graphics mode and higher resolution panel by generating blank pixels. The resulting display is often too small to be viewed acceptably. For a 1024 by 768 pixel panel there may be 9 or 10 inches of display surface of which one third may go unused during centering. Not only does this waste panel capability, but refresh rates are poor because of timing translation and often the displayed information is too small to read either in Windows™ or in DOS text mode. From an economic standpoint, a user pays a premium for the increased resolution of the panel display only to receive inferior performance.
[0021] Another compensation technique for vertical scaling is known as line replication. In line replication or stretching, every Nth line may be duplicated on a subsequent line. In text mode, blank line insertion may be used to evenly fill an entire panel.
[0022] Yet another problem arises when attempting to drive two display devices with different display resolutions either through a SIMULSCAN™ output or an auxiliary output. For example, if Microsoft™ Windows™ is running, a dual display mode may be activated by way of an icon as is done for SIMULSCAN™ displays. Requests may then be passed by Windows™ Graphic Driver Interface (GDI) to an appropriate display driver and hardware. Only one graphics resolution, however, may be selected for one or both displays at one time. In other words, separate display resolutions may not be desirable for each display in a particular SIMULSCAN™ environment. Thus, on a notebook system with an 800 pixel by 600 pixel LCD display, if a 640 pixel by 480 pixel resolution is chosen, for example, to drive an external LCD projection panel as a SIMULSCAN™ output, then the LCD output must either be “centered” as described earlier or otherwise accommodated.
[0023] Typically, fixed resolution panels present the most difficulties in graphics scaling since other elements may more often be flexible. Every resolution capable of being generated by a system must be capable of being displayed on a fixed panel for true compatibility. Some CRT based projection systems, however, may be inflexible as to timing and resolution parameters and thus must be used in their native resolutions only. This native resolution may present special difficulties as it may use non-standard timing or resolution.
[0024] A typical native resolution for projection CRT displays is 640 pixels by 480 pixels. Use of fixed resolution projection systems leads to problems with fixed resolution panels in cases where projection system resolution does not match panel resolution. In such a case, shutting off LCD panel display may be an undesirable alternative. Another undesirable alternative may be the dual path method previously described which allows independent display of any two resolutions.
[0025] When such multimedia display equipment is used with conventional portable computers, because of fixed resolution related problems, a single display resolution only may be displayed on both displays (internal or projected) at the same time. In many instances, it may be desirable to project presentation material on an external monitor while displaying other information (e.g., speaker's notes) on an internal display.
[0026] It may also be desirable to switch between internal and external displays, such that a speaker may preview an image prior to projection display. Furthermore, a need for two video displays containing different images may arise in other situations where computers are used, such as CAD systems, spreadsheets, and word processors. In particular, use of Windows™ may make it desirable to allow a user to open one window (or application) on a first video display (e.g., laptop flat panel display) and open another application on another display (e.g., external monitor) . Thus, for example, a user may be able to display a scheduler (daily organizer) program on one display while operating a word processing program on another.
[0027] Popular prior art approaches to providing multiple displays with different images driven by one computer such as in the dual path method previously described have disadvantages beyond mere hardware cost. In lap-top or notebook computers, dual path methods may increase power drain, weight and size in addition to cost. Minimizing power, cost, size, and weight is especially critical in highly competitive notebook computer markets.
[0028] Other methods to drive two displays involves two display signals sharing refresh rates. To faithfully provide two distinct display resolutions, it may be desirable to generate two separate signals for two video displays having different resolutions, pixel depths, and/or refresh rates. For example, it may be desirable to generate two displays in different graphics modes, or one display in a graphics mode and another in text mode.
[0029] Moreover, two different displays (e.g., flat panel display and CRT) may use refresh rates different from one another. Alternately, one display may provide improved performance operating at a particular refresh rate unavailable for the other display. In the context of upscaling an image to a fixed resolution display however, traditional methods such as interpolation may not be available or may be inefficient.
[0030] Interpolation is a well-known prior art technique used for upscaling video images. In an interpolation scheme, several adjacent pixels in a source video image are typically used to generate additional new pixels. During vertical interpolation of source image data, throughput performance problems may be encountered in a scan-line-dominant-order-of-storing scheme because vertical interpolation usually requires pixels from different scan lines. Accessing different scan lines may require retrieving data from different pages of display memory forcing a non-aligned or non-page mode read access. A non-page mode read access may require more clock cycles than a page mode access for memory locations within a pre-charged row. Thus average memory access time during vertical interpolation may be much higher than consecutive memory accesses within the same row. High average memory access time during vertical interpolation may result in a decrease in the overall throughput performance of a graphics controller chip.
[0031] To minimize number of accesses across different rows, a graphics controller chip may retrieve and store a previous scan line in a local memory element. For example, with respect to FIG. 2, a graphics controller chip may retrieve and store all pixels corresponding to scan line A-B and store retrieved pixels in a local memory located in a graphics controller chip. The graphics controller chip may then retrieve pixels corresponding to scan line C-D, and interpolate using pixels stored in local memory.
SUMMARY OF THE INVENTION
[0032] In a computer system with at least one fixed resolution panel display and a fixed resolution CRT display such as a projection display, a display controller may be used for outputting at least one asynchronous display resolution to a fixed resolution panel display. Display data may be received by the controller in one resolution, for example 640 pixels by 480 pixels. The display data may be output to a CRT display and a time base converter for asynchronously converting display data to a resolution which matches a fixed higher resolution panel which may be at a fixed resolution of 600 pixels by 800 pixels, 1024 pixels by 768 pixels or the like.
[0033] A time base converter for comparing different timing signals and controlling asynchronous output of display lines according to a predetermined relationship may receive timing input from vertical clock VCLK, dot clock DCLK, CRT horizontal refresh CRT HDSIP, and LCD horizontal refresh LCD HDISP signals. A Horizontal Discrete Time Oscillator may receive input from H SIZE CRT size of CRT horizontal line, H TOTAL LCD total horizontal lines for LCD, and may output a Horizontal Phase signal to a Polyphase Interpolator which may control interpolation of pixels received from a line buffer, from a first and second D-type flip-flop, and directly from a time base converter. A line buffer as described may also function as a vertical line filter. In addition, a signal representing LCD HDISP may be output from a Horizontal Discrete Time Oscillator and input to a time base converter such as described above. A Vertical Discrete Time Oscillator may receive inputs from N and D signals representing Numerator and Denominator respectively. Also, a Vertical Phase signal may be output to a Polyphase Interpolator such as described above. An End of Scan (EOS) signal may be input to a time base converter such as described above to control the end of a vertical scanning sequence. Output from a Polyphase Interpolator may be input to an LCD panel interface which may be used to drive an LCD panel.
[0034] A line buffer such as described may receive and store a scan line of display data and two flip-flop elements may be used to delay input of display data to a polyphase interpolator by one clock cycle for the flip-flop elements and one scan line cycle for the line buffer respectively. Thus, four adjacent pixels may be input simultaneously into a polyphase interpolator for upscaling in the following manner. Display data generated within core VGA logic may be output a time base converter.
[0035] A time base converter outputs display data to a CRT display, a line buffer, an input terminal of a polyphase interpolator, and a flip-flop element. Flip-flop element output may be input to another input terminal of a polyphase interpolator, line buffer output may be input to yet another input terminal of a polyphase interpolator and another flip-flop element. Finally flip-flop output associated with line buffer output may be input to a fourth input terminal of a polyphase interpolator.
[0036] Thus, four inputs with associated delays, create four pixels horizontally and vertically adjacent being input to a polyphase interpolator which may then upscale graphics data to desired output display resolution. Interpolation may be accomplished using a Discrete Cosine Transform upon input pixels. Interpolation may be used to upscale lower resolution display data to a fixed resolution panel of higher resolution.
[0037] In a computer system with a fixed resolution panel display, a display controller may be used for outputting at least one of a plurality of different graphics display resolutions to a fixed resolution panel display. Display data may be received by the controller in one resolution, for example 640 pixels by 480 pixels. The display data may be output to a fixed resolution panel which may be at a fixed resolution of 600 by 800 pixels, 1024 by 768 pixels or similar.
[0038] A line store buffer may receive and store a scan line of display data and two flip flop elements may be used top delay input of display data to a polyphase interpolator by one clock cycle for the flip flop elements and one scan line cycle for the line buffer respectively. Thus, four adjacent pixels may be input simultaneously into a polyphase interpolator for upscaling in the following manner. Display data generated within core VGA logic may be output to a line store buffer, an input terminal of a polyphase interpolator, and a flip flop element.
[0039] Flip flop element output may be input to another input terminal of a polyphase interpolator, line store output may be input to yet another input terminal of a polyphase interpolator and another flip flop element. Finally flip flop output associated with line store output may be input to a fourth input terminal of a polyphase interpolator. Thus, four inputs with associated delays, create four pixels horizontally and vertically adjacent being input to a polyphase interpolator which may then upscale graphics data to desired output display resolution. Interpolation may be accomplished using a Discrete Cosine Transform upon input pixels. Interpolation may be used to upscale lower resolution display data to a fixed resolution panel of higher resolution.
[0040] The display controller of the present invention may receive vertical scan clock VCLK signal from a digital PLL circuit. Variations in timing between native VCLK timing for a fixed resolution panel and timing for desired resolution may be synchronized in a PLL block. A clock divider circuit may generate new VCLK signals proportional to a ratio between the fixed resolution display panel and a desired display resolution. Control registers may contain values associated with fixed panel resolution and desired resolution leading to simplified interfacing. Rather than developing device drivers, programmers may set registers with values corresponding to desired operating parameters.
[0041] Display data may then be output to an analog CRT driver or an LCD panel driver. Control registers within the display controller may be used to store output resolution, input resolution, SIMULSCAN™ mode, and other parameters.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] [0042]FIG. 1 is a diagram illustrating a prior art technique of centering.
[0043] [0043]FIG. 2 is a diagram illustrating adjacent source pixels and pixels generated through interpolation.
[0044] [0044]FIG. 3 is a block diagram illustrating components associated with the asynchronous expansion circuit of the present invention.
[0045] [0045]FIG. 4 is a diagram illustrating a Discrete Time Oscillator of the present invention.
[0046] [0046]FIG. 5 is a timing diagram illustrating the timing relationship between lines generated for a CRT and lines generated for an LCD panel.
[0047] [0047]FIG. 6 is a diagram illustrating an embodiment of a Discrete Time Oscillator of the present invention.
[0048] [0048]FIG. 7 is a block diagram illustrating components associated with the expansion circuit of the present invention.
[0049] [0049]FIG. 8 is a diagram illustrating an embodiment of a Discrete Time Oscillator of the present invention.
[0050] [0050]FIG. 9 is a block diagram illustrating a VCO and clock dividers.
DETAILED DESCRIPTION OF THE INVENTION
[0051] The descriptions herein are by way of example only illustrating the preferred embodiment of the present invention. However, the method and apparatus of the present invention may be applied in a similar manner in other embodiments without departing from the spirit of the invention.
[0052] [0052]FIG. 2 is a diagram illustrating adjacent source pixels and pixels generated through interpolation. FIG. 2 shows pixels (A, B, C, and D) of the original source video image and pixels (E-P) which are generated by interpolation resulting in upscaling the original source video image. Pixel E may be generated, for example, by formula (⅔ A+⅓ B). If each pixel is represented in RGB format, RGB components of pixel E may be generated by using corresponding components of pixels A, B. Pixel K may similarly be generated using the formula (⅓ A+⅔ C) . Generation of pixels such as E, F may be termed horizontal interpolation as pixels E, F are generated using pixels A, B located horizontally. Generation of pixels such as G, K may be termed vertical interpolation.
[0053] [0053]FIG. 3 is a block diagram illustrating components associated with the asynchronous expansion circuit of the present invention. Expansion parameters used in the asynchronous expansion circuit of the present invention may be calculated as follows. Given the following parameters, H SIZE LCD —horizontal size of an LCD panel in pixels, H SIZE CRT —horizontal size of a CRT in pixels, V SIZE LCD —vertical size of the LCD in pixels, V SIZE CRT —vertical size of the CRT in pixels, H TOTAL CRT —horizontal total pixels for the CRT, V TOTAL CRT —vertical total pixels for the CRT, and F V =1/T V vertical frame rate or frequency, calculate frame clock rate F VCLK and T VCLK , vertical upscaling ratio, H TOTAL LCD and F DCLK and T DCLK , and reference parameters using equations 1-6.
[0054] For a given frame rate F V , F VCLK and T VCLK may be calculated as follows:
F VCLK =V TOTAL CRT ·H TOTAL CRT ·F V (1)
T VCLK =1 /F VCLK =T V /( V TOTAL CRT ·H TOTAL CRT ) (2)
[0055] To achieve proper upscaling, a ratio must be chosen which minimizes the size of the numerator and denominator such that:
N/D=V SIZE LCD /V SIZE CRT (3)
[0056] Next, H TOTAL LCD may be selected based on horizontal retrace requirements, and T DCLK may be selected and minimized using the following relationship:
H TOTAL CRT =D/N·T VCLK/T DCLK ·H TOTAL LCD (4)
[0057] Calculate other timing parameters for reference purposes using the relationships:
V TOTAL LCD =N/D·V TOTAL CRT (5)
T H LCD =H TOTAL LCD ·T DCLK (6)
[0058] To determine Vertical DTO 316 and Horizontal DTO 315 parameters, the following equation may be used:
PARAM/MODULO=( V SIZE CRT ·H TOTAL CRT )/(V SIZE LCD ·H TOTAL LCD ) (7)
[0059] PARAM may represent the P input to, for example, Horizontal DTO 315 . MODULO may represent the MOD Q input to Horizontal DTO 315 . When PARAM value reaches MODULO value, an output is generated which, in the case of Horizontal DTO 315 represents when sufficient HSIZE CRT 322 input has been received to fill the CRT, or a count equal to HTOTAL CRT 323 has been reached.
[0060] VGA core 300 represents a standard VGA controller known in the art for generating display data. VGA Core 300 may generate and output display data lines at a pixel frequency which corresponds to the display resolution for, in the preferred embodiment, a CRT projection panel. Lines 312 generated in RGB format at 24 bits per pixel in the preferred embodiment are output at a frequency 311 to CRT Driver 327 and Time Base Converter 313 . Lines 312 may also be generated at 32 bits per pixel. In the preferred embodiment, VGA Core 300 may generate display information at a frequency corresponding to 640 pixels by 480 pixels. CRT Driver 327 outputs lines to a CRT display 398 such as a projection screen which may employ standard CRT (RGB) display technology known in the art.
[0061] Time Base Converter 313 may receive inputs from VGA Core 300 , VCLK 311 , CRT HDISP 325 which is the horizontal retrace signal for the CRT, DCLK 326 or “Dot Clock” which is the rate at which pixels are output from VGA Core 300 , and Carry Out signal 321 and may use equations 1-6 to perform time base conversion between CRT lines and LCD lines in the following manner. Lines may be received at DCLK 326 proportional to CRT 398 resolution. Inside Time Base Converter 313 which also acts as a line store or line buffer, lines received at frequency 311 are compared against the lines required LCD panel display 399 frequency.
[0062] [0062]FIG. 5 illustrates the timing relationship between CRT lines and LCD lines. Since, for LCD panels of a higher resolution than CRT resolution, lines are required by LCD panel display 399 at a faster rate than lines are generated for CRT 398 , duplicate lines must be output to LCD panel display 399 . FIG. 5 illustrates how lines are asynchronously generated for LCD panel display 399 and CRT 398 . Since LCD panel display 399 is of a higher resolution than CRT 398 another line is required before the end of a line timing interval for CRT 398 . Line 312 in progress for CRT 398 will be repeated for LCD panel display 399 .
[0063] Display Data output from Time Base Converter 313 may be input to Vertical Filter/Line Buffer 314 , D-type Flip-flop 307 and Polyphase Interpolator 305 . Vertical Filter/Line Buffer 314 may receive display data from Time Base Converter 313 and filter display data using, for example, in the preferred embodiment, a Discrete Cosine Transform filter. Display data may be stored in Vertical Filter/Line Buffer 314 under control of Vertical Discrete Time Oscillator (DTO) 316 which may issue signal EOS 320 for signalling the end of a vertical scan. Display data output from Vertical Filter/Line Buffer 314 may be input to Polyphase Interpolator 305 and D-type Flip-flop 306 .
[0064] Horizontal DTO 315 and Vertical DTO 316 may be used to provide and control horizonal and vertical frequency related parameters such as H SIZE LCD , H SIZE CRT , V SIZE LCD , V SIZE CRT , H TOTAL CRT , and V TOTAL CRT . Horizonal DTO 315 receives HSIZE CRT signal 322 indicating size of a horizontal scan and HTOTAL CRT signal 323 indicating total number of horizontal scans. HPHASE 324 represents Horizontal Phase and may be input to Polyphase Interpolator 305 . Carry Out 321 from the comparison of HSIZE CRT 322 and HTOTAL CRT 323 of Horizontal DTO 315 may be input to Time Base Converter 313 and used to control the output of lines from Time Base Converter 313 .
[0065] Vertical DTO 316 receives D signal 317 and N signal 318 representing Denominator value D and Numerator value N in Equation 4. D signal 317 and N signal 318 may be programmed in registers or otherwise supplied by software depending on the relationships desired between parameters in Equation 4. Vertical Phase (VPH) signal 319 representing carry out is output to Polyphase Interpolator 305 .
[0066] Each D-type Flip-flop 306 and 307 may add an additional cycle of delay in the vertical direction such that Polyphase Interpolator 305 receives pixels X( 0 , 1 ), X( 0 , 0 ) , X( 1 , 0 ) , X( 1 , 1 ) . These four pixels represent two adjacent pixels in each horizontal and vertical direction. Pixels generated in Polyphase Interpolator 305 , are output to Panel Interface 309 which may be used to generate display information on corresponding LCD panel display 399 .
[0067] [0067]FIG. 4 is a diagram illustrating a circuit for generating VCLK 406 . VCO PLL 400 generates and maintains frequency stability of DCLK 405 . DCLK 405 may be input to VCLK DTO 401 and gate 402 . Input P 403 and input Q 404 may also be input to VCLK DTO 401 and are proportional to desired output frequency and input frequency respectively. DCLK 405 and carry out from DTO 401 may be input to gate 402 and may be used to generate VCLK 406 .
[0068] [0068]FIG. 5 is a timing diagram illustrating the timing relationship between lines generated for a CRT projection display and lines generated for a fixed resolution LCD panel. CRT HS signal 501 represents a horizontal scan signal for a CRT and is synchronized with the end of CRT horizontal retrace interval as shown by time 505 , 506 , and 507 . Times 505 , 506 , and 507 are illustrated as corresponding to CRT line generation. L 0 and L 1 are arbitrary designators use to compare timing for corresponding lines generated for both CRT display and LCD display.
[0069] L 0 represents line 0 and L 1 represents line one; L 0 and L 1 are reused as reference numbers for subsequent lines. By designating L 0 and L 1 accordingly, the relationship between L 0 generated for the CRT and L 0 generated for the LCD may be seen. Data for L 0 is replicated for a second LCD line during, for example, time 506 . Since the present invention discloses an asynchronous relationship between CRT and LCD displays, any number of lines displayed for the LCD during the time interval between time 505 and 506 would be replicated as LO.
[0070] CRT HDISP signal 502 is shown as active during the time when a horizontal line is being displayed and not active during the retrace interval when returning to begin the next line scan. LCD HS 503 represents a horizontal scan signal for an LCD panel and coincides with the end of the retrace interval of LCD HDISP signal 504 . LCD HDISP signal 504 is shown as active during the time when a horizontal line is being displayed and not active during the retrace interval when returning to begin the next scan. As shown in FIG. 5, three LCD lines may be displayed during an interval corresponding to display of two CRT lines. A scaling factor of 1.5 would result from a requirement to display 3 LCD lines for every 2 CRT lines.
[0071] Any number of LCD lines may be generated asynchronously as a function of CRT lines based on a ratio of CRT resolution and LCD panel fixed resolution in accordance with Equation (3). As display data for L 0 is being output as a CRT line, L 0 is being output as an LCD line. L 0 for the LCD is finished and a retrace interval begins before L 0 for the CRT is complete. Since L 0 for the CRT is still being output, then next line for the LCD begins to write L 0 again. Since display data for CRT lines and LCD lines are derived from a common data stream output from VGA Core 300 , only timing differences affect number of lines output to the LCD for each CRT line. Thus, within practical limitations, any number of LCD lines may be output asynchronously using display data originally generated as CRT output.
[0072] [0072]FIG. 6 is a diagram illustrating an embodiment of a Discrete Time Oscillator of the present invention. In order to implement Horizontal and Vertical DTO block of the present invention, a circuit of the kind illustrated in FIG. 6 may be used to perform a PLL function as well as a divide function. As background to FIG. 6, equation (8) describes the relationship between values P 603 , Q, F in 602 and F out 604 of FIG. 6:
f out =f in ( P/Q ) (8)
[0073] Value P 603 is input to accumulator 600 . Value P 603 represents the numerator of the rational expression on the right side of equation 1. Value P 603 may be proportional to the desired output frequency F out 604 . Denominator Q may be proportional to the input frequency F in 602 . In the preferred embodiment of the present invention, P 603 and Q may be proportional to vertical clock frequencies of desired display resolution and native display resolution respectively. Native display resolution means fixed panel display resolution.
[0074] F in 602 may be input to the clock terminal of gate 601 which, in the preferred embodiment, may be a flip-flop. The count output of accumulator 600 may be input to gate 601 . By indirectly coupling F in 602 through gate 601 , anomalies associated with dividing are minimized. As the count increments to value P 603 on each clock transition of F in 602 , carry out value representing mod Q is output as F out 604 .
[0075] [0075]FIG. 7 is a block diagram illustrating components associated with the expansion circuit of the present invention. VGA core 300 may generate display data one horizontal line at a time. Horizontal lines are output a pixel at a time at a frequency of VLCK 311 to Line Buffer 303 and D type Flip Flop 307 . Line Buffer 303 may store a line of display data and may represent one cycle of delay in the horizontal direction such that Line Buffer 303 may contain the previous line of data. Each D Flip Flop 306 and 307 may add an additional cycle of delay in the vertical direction such that Polyphase Interpolator 305 receives pixels X( 0 , 1 ), X( 0 , 0 ), X( 1 , 0 ), X( 1 , 1 ). These four pixels represent two adjacent pixels in each horizontal and vertical directions. Pixels generated in Polyphase Interpolator 305 , are output to CRT driver 308 and Panel interface 309 which may be used to generated display information on the corresponding display. Polyphase Interpolator 305 and Clock Divider 302 receive DCLK signal 310 from VCLK VCO & PLL block 301 . DCLK signal 310 represents the frequency at which data may be generated.
[0076] Clock Divider 302 may generate VCLK 311 at a value which represents a ratio between H sizeVGA and H sizeLCD . Thus, the ratio between H sizeVGA and H sizeLCD may be proportional to the ratio between DCLK 310 and VCLK 311 . The ratio of VCLK 311 and DCLK 310 may automatically set output scaling for the display. Control Logic 304 may store values corresponding to fixed display resolution and desired display resolution. By making values for fixed resolution and desired resolution settable in registers, output resolution is decoupled from a hardware implementation in core logic. Rather than write complex drivers on an individual basis for each display likely to be encountered, developers may simply set values in registers to drive displays of many types including fixed resolution displays. Polyphase Interpolator 305 may generate display lines automatically scaled to fit output size. Control Logic 304 may distribute control signals associated with register settings to VCLK VCO & PLL block 301 .
[0077] [0077]FIG. 8 is a diagram illustrating an embodiment of a Discrete Time Oscillator of the present invention. In order to implement VCLK VCO & PLL block 301 and Clock Divider 302 of the present invention, a circuit of the kind illustrated in FIG. 8 may be used to perform a PLL function as well as a divide function. As background to FIG. 8, equation (1) describes the relationship between values P 403 , Q, F in 402 and F out 404 of FIG. 8:
f out =f in ( P/Q ) (1)
[0078] Value P 403 is input to accumulator 400 . Value P 403 represents the numerator of the rational expression on the right side of equation 1. Value P 403 may be proportional to the desired output frequency F out 404 . Denominator Q may be proportional to the input frequency F in 402 . In the preferred embodiment of the present invention, P 403 and Q may be proportional to vertical clock frequencies of desired display resolution and native display resolution respectively. Native display resolution means fixed panel display resolution. Fin 402 may be input to the clock terminal of gate 401 which in the preferred embodiment may be a flip flop. The count output of accumulator 400 may be input to gate 401 . By indirectly coupling Fin 402 through gate 401 , anomalies associated with dividing are minimized. As the count increments to value P 403 on each clock transition of F in 402 , carry out value representing mod Q is output as F out 404 .
[0079] [0079]FIG. 9 is a block diagram illustrating a VCO and clock dividers. VCO 500 may generate DCLK 505 at a native frequency proportional to the scanning frequency for a fixed panel LCD which may be in use. DCLK 505 may be input to DTO divider 501 for generation of VCLK 503 according to a ratio P/Q as in equation (1). Ratio P/Q may represent the relationship between desired output frequency, which may be proportional to output resolution, and input frequency represented in this embodiment by DCLK 505 , which may be proportional to a fixed resolution. VCLK may be output from DTO divider 501 at a frequency proportional to ratio P/Q as in equation (1) and input to DTO divider 502 and other circuits within the controller of the present invention. DTO divider 502 may be used to generate MVA™ clock MCLK 504 . MCLK 504 may be used to further scale an MVA™ window within the main scaled graphics display. Since MVA™ window size may be changed during use and since color depth of an MVA™ window may be greater than background color depth, separate “scaling within scaling” must be performed for MVA™ display.
[0080] While the preferred embodiment and alternative embodiments have been disclosed and described in detail herein, it may be apparent to those skilled in the art that various changes in form and detail may be made without departing from the spirit and scope of the invention. For example, while interpolation in the preferred embodiment may comprise a polyphase interpolator, the present invention could be practiced with virtually any interpolation means.
[0081] Similarly, while output is drawn to a fixed resolution CRT projection panel and a fixed resolution LCD panel, the present invention could be practiced on any system which requires asynchronous display timing for multiple displays operating from the same display data stream. Moreover, although the preferred embodiment is drawn to an integrated circuit, the present invention may be applied to a series of integrated circuits, a chipset, or in other circuitry within a computer system without departing from the spirit and scope of the present invention.
|
A display controller in a computer system controls the asynchronous output of graphics display data in a computer system having at least one fixed resolution flat panel display. Fixed panel displays may have problems displaying non-native resolutions particularly at lower resolutions. The controller of the present invention uses a time base converter, horizontal and vertical Discrete Time Oscillators (DTO), and polyphase interpolator, which may be Discrete Cosine Transform (DCT)-based to expand graphics display data asynchronously from native resolution to at least one resolution suitable for display on a fixed resolution panel. Graphics data may also be output asynchronously to a CRT. Time base converter receives frequency related input parameters and generates at least one asynchronous output at the desired output resolution.
| 6
|
BACKGROUND OF THE INVENTION
This invention relates to tufting machines and more particularly to hand-held tufting machines using pneumatic power for driving the reciprocating needle.
Hand-held tufting machines of this general class are universally used as mending tools for correcting faults in tufted fabric such as carpeting. For example, if for some reason, such as a broken yarn, one or two needles of a tufting machine do not form stitching in the fabric, the missing stitches are inserted by the use of the hand-held units known as mending guns. Known prior art mending guns are illustrated in U.S. Pat. Nos. 2,753,820; 2,837,045; 2,887,076; 3,142,276; 3,144,844; 3,225,723; and 3,645,219. Other uses of such guns are found in the manufacture of customized rugs.
Because of the ready availability of a supply of compressed air in carpet mills many, if not most, of the current mending guns are pneumatically driven, the gun having a small pneumatic rotary turbine motor within the handle for reciprocatably driving the needle. However, such a motor is a costly item relative to the cost of the entire gun, being in the range of approximately 50 percent of the overall cost. Thus, it is highly desirable that some alternative means for driving the needle be found.
SUMMARY OF THE INVENTION
The present invention provides a pneumatically powered mending gun that does not use a rotary pneumatic motor. In place of the motor the present invention provides an inexpensive piston drive construction. The piston reciprocates within a pivotably mounted housing that cyclically pivots in alternate directions with each stroke of the piston to open and close air ports in the piston housing for ingress and egress of air therein, the piston being eccentrically connected to a crank that drives the needle. Thus, the piston is double acting and as the piston reaches the end of its stroke at each end of the piston housing, the piston housing has pivoted into a position to receive high pressure air at the end reached by the piston thereby to drive the piston in the reverse direction, and thus the needle. The invention can be applied to conventional mending guns with little modification thereto, and with elimination of the motor at great savings.
According to the principles of the present invention the piston housing is pivotably mounted intermediate the ports on a bracket that includes a pair of spaced ports disposed at opposite ends of the fulcrum, one port of each pair being an inlet and the other being an outlet and being on opposite sides of the normal piston housing center line, each bracket port being disposed to register with the respective housing port when the housing has pivoted to its extreme position at opposite sides of the center line. Compressed air, which is conventionally used for blowing yarn through the hollow needle used in such guns, is directed to each bracket inlet port, the air entering each inlet port communicating with the interior of the piston housing at each end when the respective port is in registration with the adjacent housing port. When the inlet port registers with the housing port at one end, the outlet port at the other end registers with the other housing port. Consequently, pressurized air entering the housing at one end drives the piston in a first direction to drive the crank to which it is eccentrically connected. This pivots the piston housing to a position where the other end communicates with and receives pressurized air, the first end of the piston housing then being disposed for releasing its charge of air to the corresponding exhaust port.
Consequently, it is a primary object of the present invention to provide a simple inexpensive pneumatic needle drive for a hand-held tufting machine and thereby eliminate the need for the relatively expensive rotary pneumatic motor.
It is another object of the present invention to drive the needle of a hand-held tufting machine pneumatically through a piston/cylinder assembly, the assembly being mounted for pivotable movement for porting air alternately to opposite ends of the piston.
It is a further object of the present invention to provide in a hand-held tufting mending gun a piston/cylinder drive assembly, air being supplied to opposite ends of the piston alternately to drive the piston in both directions and the assembly being mounted for movement to port air to the appropriate end of the piston when the piston approaches the limit of its travel at the corresponding end.
It is a still further object of the present invention to provide in a hand-held tufting machine a piston/cylinder drive assembly, the piston being eccentrically connected to a crank for driving the needle of the machine and the piston housing being pivotably mounted on a bracket having inlet and outlet air ports for communicating with the interior of the housing at each end, air being alternatively admitted and exhausted from each end of the piston housing as the housing is caused to pivot by the action of the piston.
BRIEF DESCRIPTION OF THE DRAWINGS
The particular features and advantages of the invention as well as other objects will become apparent from the following description taken in connection with the accompanying drawings, in which:
FIG. 1 is a side elevational view of a hand-held tufting mending gun incorporating the features of the present invention;
FIG. 2 is a disassembled perspective view of the mending gun of FIG. 1;
FIG. 3 is a diagrammatic view illustrating the action of the piston/cylinder assembly for valving air for driving the piston; and
FIG. 4 is a cross sectional view taken substantially through a speed reducing mechanism for reducing the speed of the mending gun needle.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, a hand-held tufting machine mending gun generally indicated at 10 is illustrated comprising a housing 12 to which a handle 14 is secured. The handle is substantially hollow and includes a fitting 16 at the bottom for connection of the gun to a high pressure source of air. In the prior art mending guns a rotary pneumatic motor (not illustrated) is positioned within the handle and the air flow from the source to the motor is opened and closed by a valve controlled by an operator influenced lever 18. The same or a similar operator influenced lever may be utilized in the handle of the gun of the present invention for opening and closing the passage of high pressure air to the needle carrier and the piston/cylinder assembly as hereinafter described.
The housing 12 is a substantially inverted L-shaped member having a hollow 20 at the top and a tapered open top channel 22 opening into the hollow and extending out the leg 24 of the L-shaped housing 12, the channel being deeper between the hollow and a pair of upright ledges 26 that at the free end of the leg 24. For reasons which will become apparent the wall forming the hollow is open at 28 oppositely to the channel over an angle of approximately 90 degrees. The housing is sealed at the top intermediate the hollow and the interior of the handle and to this end a tight fitting disk-shaped plug 30 having an upstanding pin 32 may be inserted into the top of the housing, the pin extending upwardly into the hollow. It is visualized that rather than a separate plug 30, the housing would have a floor formed between the hollow and the handle 14, such as at 31, and the pin 32 would then be secured to the floor. Positioned about the top portion of the pin 32 is a bearing member 34 of a conventional type such as a ball bearing. A disk 36 having a central aperture 38 fitting about the bearing 36 is positioned for rotation relatively to the pin 32 and includes an eccentrically disposed tapped hole 40.
Threadedly received within the hole 40 of the disk 36 is a crank pin 42 having an enlarged shoulder 44 adjacent the end remote from the disk 36. Journally disposed about the pin 42 between the disk and the shoulder 44 are a pair of crank arms 46 and 48, the pin extending through an aperture in each arm. As hereinafter described, the crank arm 46 is a needle drive crank arm and the crank arm 48 is the disk driving crank arm.
Disposed above the housing 12 is a lever 50 in the form of a substantially rectangular block having a follower slot 52 open at one end of the block. The slot 52 has a width substantially equal to the diameter of the shoulder 44 and is positioned about the shoulder. The block lever 50 also includes an aperture 54 which is aligned with a bore 56 in a housing cover 58 positioned on the housing 12. The housing cover 58 comprises a substantially flat plate member 60 having three upstanding walls 62, 64, 66 in the form of a U-shaped frame at one end thereof, the bore 56 being substantially centrally disposed on the plate 60. A pair of counterbored holes 68 are formed in the plate 60 for receiving a pair of filister head screws 70 which are threadedly received within holes 72 in the top of the housing 12 at opposite sides of the channel 22. A pair of spaced pegs 74 on the top of the housing 12 are received within guide holes 76 formed in the plate 60 to further aid in securing the housing cover 58 to the housing 12. Secured within the bore 56 are the outer races of a pair of ball bearings 78, the inner races thereof securely receiving a shaft 80. The bottom portion of the shaft 80 is received within the aperture 54 of the block 50 and secured by set screws 82, while the upper end of the shaft 80 is threaded and secured to the center of a yarn feed disk 84. Thus, when the disk 36 is rotated so to is the disk 84.
Positioned above the disk 84 between the walls 62, 66 is a yarn feed support member 86 in the form of a substantially L-shaped block, the upstanding leg being bifucated. In the vicinity of the intersection of the legs of the member 86 below the bifucation, the member has a through bore 88 for receiving a support shaft sleeve 90. A support rod 92 is positioned within the sleeve 90 which is also received within a first bore 94 in a feed roller drive support member 96 having a second bore 98 spaced from the first bore. The sleeve 90 after passing through the bore 94 is further received within a yarn guide collar 100 having a tubular guide member 102 fixed to the periphery thereof. The rod 92 extends through a hole 104 in the wall 62 and through the members 86, 100, 96 and 90 intermediate the walls 62, 66, and is threadedly secured into a tapped hole 106 in the wall 66. The lower leg of the member 86 includes a tapped hole 108 spaced from the bore 88 for receiving a threaded rod 110 which is also threaded through the walls 62, 66. A knurled wheel 112, 114 is secured on each end of the rod and a third knurled wheel 116 is threadedly rotatably positioned on the rod 110 interior of and adjacent the wall 62. Thus, loosening the wheel 116 on the rod permits the member 86 to translate laterally as the rod 110 is rotated by means of one of the wheels 112, 114.
A link 118 is secured by a screw 120 between the upstanding bifucated legs of the member 86 and carries a small axle 122 which rotatably supports a knurled idler roller 124. The idler 124 meshes with a knurled drive roller 126 carried on one end of a feed shaft 128 supported by bearings 130 in the bore 98 of the support member 96. The other end of the shaft 128 has a wheel 132 fastened thereto, the wheel 132 having a groove in which on "O" ring 134 is trained. A spring 136 is fastened at one end to the link 118 at the location of the shaft 122, and at its other end to the bottom of the block 86 to urge the link downwardly so the "O" ring engages and rides on the disk 84. The position of the "O" ring on the disk controls the rotational speed of the roller 126 and thus the amount of yarn pulled through the guide 102, the position being controlled by the location of the member 86 of the rod 110.
Secured on top of the leg 24 of the housing 12 in the channel 22 is a hollow substantially cylindrical guide barrel 138 having an elongated open slot 140 along the top parallel to the axis of the barrel. The barrel is secured by screws 142, or the like, tapped into the underside of the barrel but not extending into the hollow. A pair of screws 144 extend through knurled wheels 146 and through axle members 148 and are threadedly received through the sides of the barrel to rotatably mount the wheels 146 on the barrel for guiding the gun as it is fed along the work.
Positioned within the open front end of the barrel 138 is a projecting tab 150 formed on the rear of a needle guide holder 152 having a through aperture within which a needle guide 154 is secured. The guide holder 152 is secured within the barrel by means of the screws 144 which are threadedly received within tapped holes in the tab 150. Received in the rear of the barrel and slidable within the hollow of the barrel is a shuttle 156 which is a cylindrical member having a flat formed on its upper surface. A stud 158 is received within an aperture in the end of the crank arm 46 remote from the connection thereof to the disk 36 and is threadedly received in a tapped hole in the flat surface at the rear of the shuttle 156 so that as the disk 36 rotates the shuttle reciprocates within the barrel 138. A hollow cylindrical needle carrier 160 having a stud 162 extends through a flat spacer 164 and is secured to the shuttle for movement therewith by means of a set screw 166. Secured in the front of the needle carrier 160 is a collet 168 for retaining a hollow needle 170 which extends through the needle guide 154. At the rear thereof the needle carrier 160 receives a valve member 172 which is connected to a hose 174 by means of a hose fitting 176 and a yarn guide 178 is angularly disposed on the needle carrier. Yarn from the nip between the rollers 124, 126 is adapted to be threaded through the guide 178, through the hollow of the needle and out the point, and air from the handle 14, flowing through the hose 174, acts to draw the yarn fed by the rollers 124, 126 through the needle to form loops in the work.
In accordance with the invention the disk 36 is driven by a piston/cylinder assembly 180 mounted on the gun. To this end, an L-shaped bracket 182 is secured at one leg 181 to the rear of the wall 64 of the housing cover 58. The other leg 183 of the bracket 182 includes a substantially centrally disposed aperture 184 for receiving a stud 186 mounted on the top side of a substantially rectangular shaped housing 188 forming the container for the piston of the piston/cylinder assembly 180. The housing 188 preferably is bronze and slidably pivots against the bottom surface of the leg 183, which may include frictionless slide pads (not illustrated) of Teflon or other such material.
Although the housing 188 is rectangular for purposes of sliding, the interior thereof is cylindrical as is the piston, hence it is denoted a piston/cylinder assembly. Formed in the upper surface of the housing 188 are a pair of spaced holes 190, 192 which are substantially aligned along the axis of the housing and the piston rod 194 and open into the interior of the housing. The piston travel within the housing 188 is between the location of the holes 190 and 192 as the outer limits. Similarly sized holes 195, 196, 198, 200 are formed through the leg 183 of the bracket 182, the holes 195, 196 and 198, 200 being spaced substantially equal from the center line of the aperture 184 as the respective hole 190 and 192 is to the center line of the stud 186, so that the hole 190 may be aligned with either of the holes 195, 196 and the hole 192 can be aligned with either of the holes 198, 200. The holes 195 and 198 are disposed on opposite sides of the normal center line of the housing 188 from the holes 196, 200, that normal position being when the stud 186, the piston rod 194 and the axis of the needle drive crank arm 46 are aligned. When the hole 190 is aligned with the hole 195, the hole 192 is aligned with the hole 200, and vise versa. The piston rod 194 may be connected to the disk drive crank arm 48 by an upstanding block member 202 formed with the crank arm 48. First and second air lines 204 and 206 communicating with the housing handle 14 are fitted to respective holes 196, 200 to feed pressurized air into the inlet holes, the holes 195, 198 acting as outlet holes.
It should be clear that when the hole 190 is aligned with the hole 196 air entering the hole 196 is received within the head end of the housing 188 and acts on the head end of the piston to drive the piston and thus the piston rod toward the needle mounted side of the gun. Since the hole 192 is then aligned with the hole 198, air in the piston rod end or tail end of the housing exhausts through the hole 198 to atmosphere. This rotates the disk 36 through the eccentrically mounted pin 42 to drive the needle outwardly from the guide 152. As this occurs the housing pivots relative to the bracket 182 about the stud 186 since the disk, due to momentum, contines to rotate. This changes the alignment of the holes so that the hole 192 becomes aligned with the hole 200 and the hole 195 aligns with the hole 190. Thus, air enters the housing at the tail end of the piston to drive the piston in the opposite direction as air exhausts to atmosphere through holes 190 and 195 from the head end of the housing 188. Thus, the piston drives the disk 38 continuously when air is directed by valve 18 through the hoses 204 and 206.
Since the needle speed of the construction heretofore disclosed is equal to the reciprocating speed of the piston rod 194, it may be too fast for practical mending operation. Thus, it is proposed to include a speed reducer intermediate the piston/cylinder assembly and the needle. To this end the disk 36 is replaced by a reducing box 220 having a first disk 222 including a downwardly extending eccentric crank pin 224 for connecting to the piston crank arm 48. The disk 222 is journally mounted in a housing 226 and includes a sun gear 228 centrally fixedly mounted thereon. The sun gear 228 meshes with one or more planet gears 230 journalled on an intermediate disk 232 fixed to the housing 226 as by set screws 234. The gears 230 mesh with a ring gear 236 having internal teeth journalled in the housing 226 and which is fixed to a driven disk 238. A crank pin 240 is eccentrically mounted on the disk 238 for connecting to the crank arm 46 for driving the needle shuttle 156. Thus, rotation of the disk 222 effects rotation of the disk 238 at a reduced speed relative to the disk 222. By varying the number of teeth on the various gears the speed of the needle can be preselected.
Numerous alterations of the structure herein disclosed will suggest themselves to those skilled in the art. However, it is to be understood that the present disclosure relates to the preferred embodiment of the invention which is for purposes of illustration only and not to be construed as a limitation of the invention. All such modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims.
|
A hand-held tufting mending gun has a piston within a cylinder pivotably mounted on a plate, the piston rod being eccentrically connected to a crank pin on a rotatable drive disk. The plate has an inlet port and an outlet port for registering cyclically with a respective port at each end of the cylinder. When an inlet port registers with a cylinder port at one end, the other cylinder port registers with the opposite outlet port. Also eccentrically connected to the drive disk is a needle driving crank arm for reciprocating a shuttle carrying a hollow needle carrier supporting a hollow needle. A high pressure air source fed to the gun housing is directed to the inlet ports and to the needle carrier, the latter for blowing the yarn through the hollow needle. Air entering the inlet ports feeds first one cylinder port and then the other to drive the piston, and exhausts from the unfed end of the cylinder through the cooperating outlet port.
| 3
|
FIELD OF THE INVENTION
[0001] The present invention relates to a dual-mode hybrid high occupancy capacity vehicle (HHOCV) whose on-road electrical energy and power is primarily derived from an electrical storage device whose electrical energy and power is replenished from a unique application of an existing electrical energy power source.
BACKGROUND OF THE INVENTION
[0002] Various alternative energy vehicle systems are now commercially available for urban use. Alternative in this context is compared to conventional internal combustion engines that use gasoline, diesel, natural gas, propane or other standard non-electric medium as its fuel source. The most ubiquitous of these vehicle systems is the gasoline-electric hybrid system where an electric motor is used to supplement the gasoline engine. The electric motor receives the bulk of its electrical energy and power from a battery pack that is charged during deceleration (regenerative braking) of the vehicle or by the gasoline engine. Recently, a plug-in version of the gasoline-electric hybrid vehicle has been made available that adds electrical energy storage capacity and charging of that additional storage capacity via a residential convenience 120 VAC outlet. The next logical step is the use of this alternative hybrid technology to replace multiple gasoline driven individual automobiles with a mass transit system composed of high occupancy vehicles with the same or better access to the road systems and without requiring new and costly charging stations for their batteries. This invention satisfies this next step as well as providing overall higher total efficiency.
SUMMARY OF THE INVENTION
[0003] A unique method of recharging high energy and high power density storage devices, from existing facilities is offered. The new recharging method claimed here is by a pantograph-type power collection system from high voltage direct current overhead catenary line for light rail, high-speed train, trolley or comparable power sources at 300-700 VDC at up to 3000 A. The invention would utilize a safe and efficient battery system that takes charge at a much faster rate than conventional lead-acid- or lithium-based-batteries and is superior in nameplate cycles for deep (i.e. greater than 80 percent) depth-of-discharge as well as in power/energy density. The invention may be added on to existing high occupancy capacity vehicles or included in original designs. The faster charge rate and greater depth-of-discharge of the electric energy and power storage devices allows the system to charge for a shorter period of time and draw more total energy than conventional counterparts. This enables the (HHOCV) system claimed here to obtain its recharge of the all-electric mode charge-depleting batteries and/or capacitors from a pantograph which extends upward to make a connection with a direct current catenary line. As typical catenary systems operate at approximately 300-700 V direct current (VDC) or greater, the efficiency through which the recharging occurs is vastly greater than with multiple 120 VAC convenience receptacles for individual automobiles and does not require a voltage rectification circuit. Further, the ability to recharge by pantograph connection to a typical light rail/catenary type system allows for the vehicle to make convenient and efficient quick recharging stops, coordinated so as not to result in physical or electrical-load-obstruction of the light rail or trolley cars or system. The HHOCV invention described herein may either recharge by coordinating with, be a replacement/substitute for, or seamlessly mesh with the light rail/catenary substations through the use of a system compatible load shedding controller such that the occasional HHOCV recharging will not impact the design margin of the original rail/catenary substations. These and the advantages described in the abstract above form the basis for the invention described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 . Catenary, Ground, Single Mode Bus, Pantograph—A pantograph 1 a is affixed to the top of a single-mode hybrid high occupancy capacity vehicle (HHOCV) to form a dual mode HHOCV capable of drawing electrical power 1 b from an overhead catenary 1 c . The HHOCV also includes an external electrical conductor capable of establishing electrical ground.
[0005] FIG. 2 . Power Input vs. Recharging Time Comparison—Power input vs. recharging time as a function of various capacity battery systems for 300 and 600 VDC. 2 a shows the power line available from a standard commercially available recharging unit at 36 kW [1]. 2 b is the power line for a custom recharging station at 70 kW [2]. 2 c is the power line for the technology represented here at 2.1 MW. As an example comparison, a 150 Ah battery at 600 V requires 157 minutes to charge from the 36 kW system, 78 minutes from the 70 kW system and less than 2 minutes with the 2.1 MW system proposed here. [1] Enova Systems 36 kW off-board charging system, Model FCS36; [2] Tindo Custom Recharging Unit, 400 VAC-3Ø, 100 A Input; 386 VDC, 200 A, 70 kW output.
[0006] FIG. 3 . Flow Diagram—The catenary provides power to the series/parallel switching hardware and heat exchanger. The battery system monitors the state-of-charge, regulating the battery charge/capacitance device input and output. The flow diagram indicates how the primary power drive (variable DC motor), and secondary power drive (Backup Combustion Engine/Generator, low speed/high torque transmission) are configured. It also indicates how the Backup Combustion Engine/Generator interacts between the primary and secondary power drives and torque sensing hardware.
DETAILED DESCRIPTION OF THE INVENTION
[0007] This invention embodies the coupling of an HHOCV to a light rail or trolley car catenary or comparable energy and power delivery system, as a novel energy and power source for substantial and quick energy and power transfer to onboard electrical energy storage devices. The time and frequency of recharging depend on the conventional fuel consumption reduction desired, physical route characteristics (resultant battery discharge) and emissions reduction desired. When or if the petroleum-fueled engine is desired or required to operate, the fuel savings should be even higher, due to the all-electric components assuming the peak torque conditions, allowing the internal combustion engine to remain at or close to constant revolutions per minute (rpm). Further, the incorporation and partial supplementation or use of capacitors during peak power or torque demand will substantially extend the energy available from the batteries.
[0008] In practice, the HHOCV would drive under an existing catenary line (e.g. in a yard or spur area), raise the pantograph, verify the vehicle ground, and charge the onboard electrical energy devices using essentially the maintenance power of the system during the intermittent zero or low demand on the design load for a given substation's primary source. The HHOCV controller would ensure that the superposition of multiple HHOCV's recharging simultaneously would not overcome the design load of each respective substation and together, their primary. Similar power sources to the light rail, such as 3 rd rail, are considered derivative or an obvious extension of the invention described here.
[0009] A conventional light rail system whose electrical power is derived by catenary also forms part of the basis for this invention with respect to the dual interlock for grounding. This dual interlock will assure that a ground is made and the vehicle is safely grounded.
[0010] The switching of the batteries from series to parallel for faster charging and the affect on the charging time due to this change is as shown in FIG. 2 (line 2 c ) which is new art with respect to speed and efficiency of energy transfer. The onboard recharging and regulation circuitry (Controller— FIG. 3 ) will sense available power from the 300-700 VDC catenary for an acceptably quick and safe charge. This process is also new art because very significant power (up to 10 MW) can be transferred to onboard electrical energy and power storage devices. This art is further enhanced by the type of batteries (Li-ion, Ni-metal hydride, molten salt) and their configuration that may be used in conjunction with the catenary as a high energy transfer source for recharging.
[0011] A combustion engine powered generator will provide emergency power to the direct variable drive DC motor or electric motor if battery/capacitance device power is accidentally depleted. Torque sensing hardware will transfer battery/capacitance device power to the electric motor-torque transmission in high torque situations or reverse mode.
[0012] Since light rail systems in large metropolitan areas already exist adjacent to established bus routes, this invention will be immediately functional.
[0000]
Potential Existing Catenary Systems
Sacramento, CA
Houston, TX
San Jose, CA
Charlotte, NC
Los Angeles, CA
Miami, FL
San Diego, CA
New York, NY
Phoenix, AZ
Boston, MA
Denver, CO
Newark, NJ
San Francisco, CA
Pittsburg, PA
Seattle, WA
Philadelphia, PA
Portland, OR
Baltimore, MD
Salt Lake City, UT
Toronto, Canada
St. Louis, MO
Montreal, Canada
Dallas-Ft. Worth, TX
Mexico City, Mexico
Chicago, IL
[0013] ENERGY STORAGE. The energy storage is embodied within the charge-depleting battery and/or capacitance devices. The energy storage system enables the acceptance of electric power in the range of 0 to 3,000 ADC at a potential of from 300 to 700 VDC. It is the greater than 0.5 MW power that defines “industrial” power and at the highest range of low voltage that represents the 300 to 700 VDC potential. This storage rate is over two orders of magnitude above that which is possible via residential and commercial power sources. This allows the dual-mode hybrid vehicle to travel independent of its interconnection to the primary energy source.
[0014] Further, the presently existing infrastructure of these railway stations from which the incomparable energy transfer may take place, can occur without modification to the existing infrastructure facilities. The present and future electrical capacity of these railway electrical substations that feed the electrical energy to the railway stations is fixed. The existing infrastructure to supply these existing railway substations is therefore static and subject only to maintenance. The existing infrastructure to supply these existing railway substations with capacities up to 10 MW exists in a range of distributed substations. This electrical energy transfer rate is unimpeded throughout the contiguous interconnection of the existing catenary-rail system. The load factor (the period of time a system is used divided by the time available) is far less than unity. The load factor is even less at the railway lines where the dual-mode hybrid vehicle listed would take energy from this existing system. The novel use of the dual-mode hybrid vehicle is its ability to operate Off-Track on any line that is less frequented by the existing railway system vehicles and receives its energy at a high rate of storage so as not to impact the existing operations and most importantly receive this energy at a rate no greater than the draw of the existing railway facilities in order to have no impact whatsoever on the existing infrastructure that feeds the existing railway substations. The presently existing energy transfer capability of the existing substations that feed electrical energy to the existing railway facilities and equipment is the source from which we envision the dual-mode hybrid vehicle claimed will obtain its electrical energy. The charge depleting batteries and/or capacitors are located within the dual mode hybrid vehicle and are sized to accept energy at nearly the maximum rate allowed by the existing railway system substations to reduce charging time “On Catenary”. The charge rate of these charge depleting batteries and/or capacitors is controlled such that their rate of energy transfer (power) may be matched to the existing substation limitation whether by temporary or permanent reduced capacity of the individual section. The energy transfer range is presently envisioned as from near zero to as high as 2,100 kW.
[0015] This example describes accepting charge below the operating margin for a 3,000 kW or greater rated substation. If for some unknown reason the energy transfer capability of the line is affected during charging or recharge, the controller within the hybrid vehicle will reduce the energy transfer rate until the energy balance is restored (voltage drops are returned to normal ranges or current rate of change is returned to normal values or the monitored DC waveform returns to that expected of an ANSI class 31 device) or the transfer rate is diminished to zero at which time the hybrid vehicle would disengage. Regardless of the energy transfer rate set to charge or recharge the depleting batteries and/or capacitors contained within the dual mode hybrid vehicle, the novel approach to energy transfer is this dual mode hybrid vehicle controller never takes energy above the transfer capacity of the line where the hybrid vehicle is temporarily connected “On Track”.
[0016] Embodied within the energy storage claimed is the conventional storage capability. The conventional storage capability is capable of accepting the lower energy storage rate. This lower energy storage rate remains over one order of magnitude greater than that which is possible via residential and/or commercial power sources. This conventional storage capability is limited only by the capability of the existing railway catenary substations to provide power to the overhead catenary during intermittent periods of maximum system demand.
[0017] Embodied within the energy storage claim and the conventional storage capability listed, there exists the On/Off Catenary energy storage. Significant to these claims are the capability of the dual-mode hybrid vehicle to absorb energy at the rates listed (On Catenary) where electrical power is obtained from the existing railway catenary system at the reduced rate, but also to disengage from the existing catenary (Off Catenary) and travel on existing roadways utilizing the energy so derived from the lower energy storage capable catenary. The lower energy storage capable catenary provides for transporting freight and personnel at significantly reduced impact to the environment (little when operating via the diesel generator to no local pollution) when operating via the electric motor/generator. This approach provides a higher efficiency than capable from any residential and/or commercial energy source due both to the higher transfer rate and optimization of the battery energy using the tempering capability of the capacitance devices. Also embodied within the energy storage and the conventional storage capability claimed, there exists the Battery/Capacitor storage dependencies. Significant to this claim is the tempering capability of the capacitance devices, which allows the batteries to discharge at a more moderate rate when taking advantage of dynamic braking along the roadway route. It is envisioned that the battery efficiency will be improved by 12 percent due to this tempering effect even with the more moderate transfer rate.
[0018] Embodied within the energy storage claimed is the novel storage capability. The novel storage capability is capable of accepting the higher and highest energy storage rate. This higher energy storage rate is over two orders of magnitude greater than that which is possible via residential and/or commercial power sources. The conventional storage capability is limited only by existing railway catenary substations which provide power to the overhead catenary at or above 10 MW.
[0019] Embodied within the energy storage is the novel storage capability claimed in that there exists the On/Off Catenary energy storage. Significant to this claim is the capability of the dual-mode hybrid vehicle to absorb energy at the rates listed (On Catenary) where electrical power is obtained from the existing railway catenary system at the full rate of at or above 10 MW, but also to disengage from the existing catenary (Off Catenary) and travel on existing roadways utilizing the energy so derived from the maximum energy storage capable catenary. The maximum energy storage capable catenary provides for transporting freight and personnel at an even more significantly reduced impact to the environment (little when operating via the diesel generator to no local pollution) when operating via the electric motor/generator, higher efficiency than capable from any residential and/or commercial energy source due both to the higher transfer rate and optimization of the battery energy using the tempering capability of the capacitance devices. Also embodied within the energy storage and the novel storage capability is the Battery/Capacitor storage dependencies. Significant to this claim is the tempering capability of the capacitance devices, which allows the batteries to discharge at a more moderate rate when taking advantage of dynamic braking along the roadway route. It is envisioned that the battery efficiency will be improved by 17 percent due to this tempering effect with the higher transfer rate.
[0020] CATENARY SYSTEM. The catenary system claimed is embodied within the existing railway electric distribution system that presently exists at twenty-six (26) Catenary Systems identified previously within the United States, Mexico, and Canada. These existing catenary systems are just as important a claim for the delivery of the electrical energy at an incomparable transfer rate as is the retrofitted or constructed high occupancy dual-mode hybrid vehicle for receiving these extraordinary amounts of portable power. The catenary system is the source of the electric power to these charge-depleting battery and/or capacitance devices contained within these high occupancy dual-mode hybrid vehicles. The catenary system enables the delivery of electric power in the range of 0 to 3,000 ADC at a potential of from 300 to 700 VDC distributed throughout the previously listed locations and embedded within the working infrastructure wherein no additional equipment, increases in capability or special provisions for attachment are required outside that contained within the dual-mode hybrid vehicle. This delivery rate of the catenary system is over two orders of magnitude above that which is possible via residential and commercial power sources. This claim allows the dual-mode hybrid vehicle to receive sufficient energy from the existing infrastructure to travel independent of this interconnection.
[0021] Embodied within the catenary system claimed is the presently existing locations of these railway stations from which the incomparable energy transfer may take place due to convenient locations. The locations of these railway stations where the stated energy transfer capability of electric power in the range of 0 to 3,000 ADC at a potential of from 300 to 700 VDC exists today are distributed throughout these previously listed locations approximately one-mile apart providing easy and convenient access to the energy source. The novel locations at which the dual-mode hybrid vehicle would receive this energy would be at electrified section lines (required due to the catenary-rail provisions required for operation of the existing railway systems) used as “setouts” by the existing railways vehicles.
[0022] CONTROLLER. The controller system claimed is a novel combination of control modes which will sense and allow energy transfer to storage systems within the hybrid vehicle to match seamlessly and not adversely impact the existing operations of the various existing section locations, the existing infrastructure upon which this existing electric railway system is built, and the energy transfer limitations that may be encountered during operating conditions. The control mode Efficiency, improves efficiency to further the considerable economy of scale already present within the system. The control mode Depth-of-Discharge, limits depth of discharge to prevent battery polarity reversal and also keeps track of nameplate cycles and monitors various conditions of the battery (temperature, charge and discharge status, cell condition, reverse charge, equal charge, equal voltage, etc.) all of which affect and/or monitor/prolong battery health. The control mode Distance, is an override to maximize the distance the hybrid vehicle may cover without regard to efficiency should such be warranted. The control mode Heat Transfer, utilizes the waste heat from the batteries for comfort control or minimizes the waste heat from the batteries during operation or charging/recharging cycles or cools by ducting and air circulation of the batteries for prolonged life. Any combination of these waste heat mode capabilities may be used dependent on the outcome of interest. The control mode Grounding and Safety Interlocks, ensures that the grounding condition is met (via mechanical interlocks) prior to charging, ensures the grounding condition is removed only when the pantograph has retracted and is in its locked position, and ensures the grounding condition has been removed prior to moving of the hybrid vehicle.
[0023] Series/Parallel. The control mode Battery/Capacitor—Series/Parallel, controls the rate of charge of the battery/capacitor systems as well as discharge and regenerative braking for further energy savings. This mode also senses when the system is connecting to a high power capacity spur substation such that the batteries need/should be connected into a parallel configuration for faster charging and later back to a series connection for matching the operating voltage during normal operating modes. This mode can also change the series/parallel configuration of the batteries and capacitors as a coarse setting for speed control or torque control of the dual-mode hybrid vehicle. In conjunction with the controller, the series/parallel system is capable of providing a recharging rate of twelve times the battery capacity (12C) for 180 Ah capacities and up to 60 C for battery capacities of 90 Ah, both at 600 V. Ref line A in FIG. 2 , for the power (at 600V) which is less than envisioned with the 700 VDC system claimed here. A further advantage of the high current capability when in parallel mode and taking power at a high rate from the catenary is in the melting of electrolyte solids toward their molten phase for battery operation. Specifically, when utilizing molten salt or thermal rechargeable batteries, that utilize materials such as Ni—NaAlCl 4 (Na—NiCl 4 ), Na—S or Li—S are inactive in their solid phase and require substantial heat from resistive electrical heating or comparable to change the electrolyte from a solid to molten phase. The NaAlCl 4 melts at 157° C. and has an average operating temperature of 270-350° C. The melting procedure requires at least 24 hours from a 230 VAC, 15.5 A circuit (85 kWh) per module; but merely minutes from the high voltage and current capability of the existing catenaries. Lastly, another advantage of high current is its ability to recharge a system that switches the battery cells or capacitors from a series operating connection to a full or partial parallel recharging connection. Such parallel recharging is advantageous as it reduces loss and recharge time due to one unhealthy cell.
[0024] Active Heat Exchanger. Embodied within the controller and incorporating thermal transfer devices along the distributed batteries are the constituents of an active heat exchanger system for vastly increasing the charge and discharge rate of these batteries by removal of the internal heat generated during these functions. The heat may be used in numerous fashions dependent on the seasons for passenger comfort but critical to the charge/discharge efficiency and overall battery life will be maintaining individual battery cell temperatures that demands an active in lieu of passive heat exchanger system.
[0025] Equipment Based Embodiments of Claims 1 c and 4 a. A single variable electric drive motor/generator is the sole mechanical power source for the HHOCV receiving electrical power either from the internal combustion engine generator or the batteries/capacitors all in conjunction with the controller which is auctioneering for the better of the two electric sources based on its operating mode. This single variable electric drive motor/generator doubles as a regeneration source to charge the batteries/capacitors during braking and deceleration. The low-speed/high-torque transmission will allow the internal combustion engine to remain as small as possible and use the least liquid fuel. Any shifting required will be determined by the controller in conjunction with the torque sensing hardware shown on FIG. 3 .
|
The invention presents a dual-mode hybrid high occupancy capacity vehicle (HHOCV) with a novel electrical energy and power storage application, electrical energy and power source and charging system in conjunction with additional methods to maximize the energy and rate of use such that the overall system is far superior to multiple personal transportation vehicles and roadway based catenary mass transit systems, including, but not limited to petroleum-only fueled high occupancy capacity vehicles. The HHOCV exhibits a novel battery charging system by taking advantage of existing track/trolley/catenary facilities for electrically charging its electrical storage media at a high energy rate so as to minimize disruption of such charging services, and is not confined by physical boundaries or limitations and may travel off the power source to the existing common roadways returning only to be recharged. The design incorporates software controllers and other devices to maintain the energy transfer rate and is of such physical size that the overall invention may either be retrofitted to existing buses or designed within new high occupancy vehicles.
| 8
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] A method of manufacturing a TFT panel, and more particularly, to a method of manufacturing a LTPS TFT OLED panel.
[0003] 2. Description of the Prior Art
[0004] In general, low temperature poly crystalline silicon thin film transistor (LTPS TFT) array manufacturing needs about six to nine photo-masks to process a photolithograph etching process, which is more complex than five photo-masks required to manufacture the hydrogenated amorphous silicon thin film transistor (α-Si:H TFT). In addition, the active matrix organic light-emitting diode (AMOLED) needs seven to ten photo-masks, because of the need to manufacture an LTPS TFT array and a pixel define layer (PDL).
[0005] Please refer to FIG. 1 . FIG. 1 is schematic diagram of a traditional OLED TFT structure. In the prior art, a glass substructure 102 is provided, with an insulator layer 104 and amorphous silicon film (not shown) deposited on the glass substructure 102 . The amorphous silicon film then re-crystallizes to polycrystalline silicon after an excimer laser annealing (ELA) process. Then, an active layer 106 pattern is etched on the polycrystalline silicon, and a gate insulator layer 108 is deposited on the active layer 106 and the insulator layer 104 .
[0006] Moreover, a gate metal 110 is etched by a metal etching process, a second mask, and a second PEP. The gate metal 100 is a self-alignment mask and the boron ion doping process proceeds on the active layer 106 , forming a source 103 and a drain 105 on the corresponding sides of the gate metal 110 . In the prior art, a capacitance (Cst) 113 is formed on a poly silicon lower panel 107 , the gate insulator layer 108 and a metal upper panel 111 by the above-mentioned first PEP and the second PEP individually. Then, an inter-layer dielectric (ILD) 112 is deposited on the glass substructure 102 to cover the gate metal 110 , the metal upper panel 111 , and the gate insulator layer 108 . The particle ILD and the gate insulator layer 108 of the source 103 and the drain 105 are then removed by a third photo-mask and a third PEP to define a corresponding via hole 115 . Furthermore, a metal forming process is performed utilizing a fourth photo-mask, and the fourth mask etches a data line and a drain metal on the via hole 115 of metal layer 114 for electrically contacting the source 103 and the drain 105 . A flat passivation layer 116 is forming on the metal layer 114 and the ILD 112 using a fifth photo-mask and a fifth PEP, and the passivation layer 116 on the metal layer 114 which electrically contacts the drain 105 is removed. An ITO transparent electrode film (not shown) is formed on the passivation layer 116 , and a sixth photo-mask and a sixth PEP are used to define a suitable shape for the transparent electrode 118 . Then, a pixel define layer (PDL) 120 is doped and is etched by a seven photo-mask and a seven PEP. Finally, a LED (not shown) is formed on the transparent electrode 118 to complete the traditional OLED panel 100 .
[0007] In the prior art, seven photo-masks are needed to complete the above-mentioned OLED. The process is complex and the use of too many masks increases the cost and increases the misalignment, thereby decreasing the yield. That is why decreasing the number of the photo-masks is an important issue in the monitor manufacturing industry.
SUMMARY OF THE INVENTION
[0008] The present invention relates to a method of manufacturing an AMOLED to solve the above-mentioned problems.
[0009] The present invention provides an embodiment relating to a method of manufacturing an AMOLED panel. The method comprises providing a substrate, forming a TFT on the substrate, forming an inter-layer insulator layer, forming a plurality of via holes, forming a metal layer which electrically contacts a source and a drain, and forming a transparent electrode, a pixel define layer and a LED.
[0010] The present invention omits the passivation layer, dopes the transparent electrode on the metal layer and the ILD, and needs only six photo-masks. If the metal layer and the transparent electrode are made by the same PEP, the present invention only needs five photo-masks. Therefore, the present invention could decrease costs and simplify the manufacturing process.
[0011] These and other objectives of the present invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is schematic diagram of a traditional OLED TFT structure.
[0013] FIGS. 2 to 6 are schematic diagrams of manufacturing an AMOLED according to the present invention.
[0014] FIG. 7 is schematic diagram of forming the transparent electrode and metal layer using the same photo-mask according to the second embodiment.
DETAILED DESCRIPTION
[0015] Please refer to FIGS. 2 to 6 . FIGS. 2 to 6 are schematic diagrams of manufacturing an AMOLED according to the present invention. Firstly, FIG. 2 illustrates providing a glass substructure 202 as a lower base, forming a buffer insulator layer 204 and an amorphous silicon film (not shown) on the glass substructure 202 , shooting lasers and annealing, such that the amorphous silicon film (not shown) becomes a polycrystalline silicon film. A desired pattern is then etched on an active layer 206 utilizing a first photo-mask and a first PEP, wherein each pixel area forms a poly silicon lower panel 207 as a result of the first PEP.
[0016] Please refer to FIG. 3 , a gate insulator layer 208 deposited on the active layer 206 and the buffer insulator layer 204 . Then, a first metal film (not shown) is deposited on the gate insulator layer 208 using a second photo-mask and a second PEP forms patterns of a scan line (not shown), a gate metal 210 , and a metal upper panel 211 . A capacitance (Cst) 213 forms from the poly silicon lower panel 207 , the gate insulator layer 208 and the metal upper panel 211 . After that, the gate metal 210 is used as a self-alignment mask for performing a boron ion doping process, and the result forms a source 203 and drain 205 on the corresponding sides of the gate metal 210 . Moreover, a silica or sensitization material is smeared on the gate metal 210 , the metal upper panel 211 , and the gate insulator layer 208 through a spin on glass (SOG) process, which forms a flat inter-layer dielectric (ILD) 212 . Because of the SOG process, a drive array of the lower base has a better flat effect and the organic material ladder cover is better, too.
[0017] Please refer to FIG. 4 , which illustrates removing partial of the ILD 212 and the gate insulator layer 208 on the source 203 and drain 205 using a third photo-mask and a third PEP. Please refer FIG. 5 , which illustrates performing a second metal film etching process using a fourth photo-mask and a fourth PEP to etch a data line and a metal layer 214 on a via hole 215 surface, where the data line and the metal layer 214 electrically contact the source 203 and the drain 205 individually. Then, ITO or IZO is formed as a transparent electrode layer (not shown) on the metal layer 214 and the ILD 212 , using a fifth photo-mask and a fifth PEP for defining a suitably shaped transparent electrode 218 .
[0018] Please refer to FIG. 6 , which illustrates spinning on glass (SOG) by silica smearing a pixel define layer (PDL) 220 on the metal layer 214 , the transparent electrode 218 and the ILD 212 , using a sixth photo-mask and a sixth PEP to form a suitably shaped pixel define layer 220 . Finally, an organic light emitting diode (OLED) is formed on the transparent electrode 218 to complete the OLED panel 600 . Of note, if the transparent electrode 218 cover of this embodiment is wider than the metal layer 214 which electrically contacts the drain 205 , the light of the OLED 222 emits up and down to be a bottom emission LED panel or a top and bottom emission OLED.
[0019] Otherwise, please refer to FIG. 7 . FIG. 7 is a schematic diagram of forming the transparent electrode and metal layer using the same photo-mask according to the second embodiment. The difference between the second embodiment and the above-mentioned embodiment is the use of the same fourth photo-mask and fourth PEP after forming a metal layer 714 and a transparent electrode 718 to etch the data line and the same pattern of the metal layer 714 and the transparent electrode 718 . In addition, the metal layer 714 and the transparent electrode 718 electrically contact the source 203 and the drain 205 . Because of the transparent electrode 718 and the metal layer 714 having the same shape and the metal layer having a reflective effect, the metal layer 714 reflects the LED light to form a top emission LED panel. Finally, the pixel define layer and LED are formed in the same way as mentioned above. Thus, the second embodiment only needs five masks.
[0020] Compared to the prior art, the present invention omits the passivation layer, dopes the transparent electrode on the metal layer and the ILD, and needs only six photo-masks. If the metal layer and the transparent electrode are made by the same PEP, the present invention only needs five photo-masks. Since the number of the photo-mask is less than the prior art, the present invention is able to decrease manufacturing costs and simplify the manufacturing process. In addition, the present invention can be applied in a low temperature polycrystalline silicon TFT (LTPS TFT) array LCD panel manufacturing process. This not only simplifies the photo-mask, but also forms the reflecting, penetrating or half-reflecting-half-penetrating LCD using different corresponding positions of the metal layer and the transparent electrode.
[0021] Those skilled in the art will readily observe that numerous modifications and alterations of the device and method may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims.
|
The present invention relating to a method of manufacturing an AMOLED panel. The method comprises providing a substrate, forming a TFT on the substrate, forming an inter-layer insulator layer, forming a plurality of via holes, forming a metal layer which electrically contacts a source and a drain, forming a transparent electrode, a pixel define layer and a LED. Because the present invention omits a passivation layer, the cost decreases and the process is simpler.
| 7
|
RELATIONSHIP TO OTHER APPLICATIONS AND PATENTS
[0001] The present application claims priority from pending U.S. Provisional Patent Application, Ser. No. 62/020,618, filed Jul. 3, 2014.
FIELD OF THE INVENTION
[0002] The present invention relates to a system of implements mutually and separably joinable for easy transport and subsequent use; more particularly, to such a system comprising nesting buckets (also referred to herein as “pails”) of the nature of those used in children's play at the beach, a carrying caddy for use therewith, and one or more shovels removably attached to the caddy; and most particularly to such a system wherein the buckets and shovels further comprise specialized modifications to facilitate their being carried together and used separately in a beach or picnic setting. The system may be further configured to serve as a cooler for carrying foods and/or beverages, a tray for serving food and/or beverages, and may include a collapsible beach chair. (As used herein, “nesting” or “nestible” should be taken to mean configured to be capable of being nestingly and separably assembled into a unit, and “nested” should be taken to mean actually assembled thusly.)
BACKGROUND OF THE INVENTION
[0003] Many people enjoy leisure-time activities, frequently family-oriented, at lakeside and/or oceanside beaches or parks. Children enjoy digging in the sand and making sand constructions, which may be facilitated by the use of one or more buckets and simple shovels. In attending to such activities, families typically carry along various types of food and drink, which may be facilitated by the capability of keeping such food and drinks either warm or cool during a holding period before consumption. Handling food and drink during eating may be facilitated by providing level surfaces, not naturally available at beaches or parks, upon which to place food and drink securely. One or more lightweight collapsible chairs are also desirable for comfortable seating, as at a beach.
[0004] Carrying all such paraphernalia as individual items can be cumbersome, restrictive, and fatiguing. What is needed in the art is a system for the combined and easy transporting by one person of nested buckets having integral features for holding food receptacles and for tempering food being carried in the buckets; an encompassing caddy; at least one shovel; optionally at least one collapsible chair; and apparatus for unifying these elements into an easily transportable system.
SUMMARY OF THE INVENTION
[0005] A system of implements mutually and separably joinable for easy transport as a unit and subsequent use individually in accordance with the present invention comprises a plurality of nestible buckets, preferably decreasing in height and diameter such that the buckets may be nested, one within the next. At least one of the buckets has a carrying handle, preferably a flexible strap defining a bail. At least one of the buckets includes a bucket bottom having the underside thereof defining a small table when the bucket is inverted; the underside surface may be formed with one or more depressions to receive and support any of various food and drink containers. At least one of the buckets may be modified to accept heating or cooling means for tempering carried food during a holding period before consumption. The nested buckets preferably are gathered in a closable shroud or caddy. A lightweight collapsible beach chair optionally is removably attachable to the caddy. At least one shovel is removably attachable to the caddy.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The features described herein can be better understood with reference to the drawings described below. The drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention. Like numerals are used to indicate like parts throughout the various views, wherein:
[0007] FIG. 1 is an elevational view of three exemplary nesting buckets in accordance with the present invention;
[0008] FIG. 2 is an end elevational view of a caddy for carrying and storing the nesting buckets shown in FIG. 1 and having a plurality of shovels removably attached to the caddy;
[0009] FIG. 3 is a plan view showing the three buckets of FIG. 1 in nested conformation;
[0010] FIG. 4 is a plan view of a first embodiment of the underside of the largest bucket shown in FIG. 1 ;
[0011] FIG. 5 is a plan view of a second embodiment of the underside of the largest bucket shown in FIG. 1 ;
[0012] FIG. 6 is a plan view of an embodiment of an exemplary self-closing strap for use as a handle with any of the three buckets shown in FIG. 1 ;
[0013] FIG. 7 is an elevational front side view of the caddy and shovels shown in FIG. 2 ;
[0014] FIG. 8 is an elevational back side view of the caddy and shovels shown in FIG. 2 ;
[0015] FIG. 9 is an elevational end view of an optional system in accordance with the present invention; and
[0016] FIG. 10 is an elevational side view of the system shown in FIG. 9 .
DETAILED DESCRIPTION OF THE INVENTION
[0017] Referring now to FIGS. 1 through 10 , in a system 10 in accordance with the present invention, a plurality 12 of nesting buckets are here shown exemplarily as three buckets 12 a,b,c . Other numbers of buckets are fully anticipated by the invention including only one bucket. Preferably, from outer bucket 12 a to inner bucket 12 c , each bucket is incrementally smaller in height and diameter to allow for the nesting of the buckets into a single unit 12 that can be carried by a user with, for example, a strap 14 secured to largest bucket 12 a.
[0018] A caddy 16 is provided to store and carry the nested buckets 12 . Caddy 16 thus substantially surrounds the outermost bucket in the set. Caddy 16 may comprise one or more pockets 18 of various sizes usable for storage and may also comprise one or more attachment slots 20 configured to receive the handle of a shovel 22 or other object. Once shovel 22 is secured in a slot 20 , it may be strapped down to caddy 16 by means of a locking strap 24 , which may comprise a hook-and-loop fastener, locking snap, or any other suitable means for closing such a locking strap around a shovel handle. Caddy 16 may further include a shoulder strap 26 or handle for carrying caddy 16 with buckets. As seen in FIG. 7 , caddy 16 may comprise a pair of D-rings 28 that are non-removably secured to strap 26 via eyes in strap 26 .
[0019] The present invention is not limited to only the arrangement shown in FIG. 7 , but may include alternative means for securing a strap or handle to the caddy, for example as shown in FIG. 2 , comprising a pair of D-rings 30 and a clasp 32 secured around the corresponding D-rings of the caddy and strap. This arrangement allows for strap 26 to be removed from caddy 16 when the strap is not in use, or for strap 26 to be replaced by an alternate strap or handle.
[0020] Caddy 16 may be configured with tapered dimensions such that an opening at the top of the caddy is larger than an opening at the bottom. Tapering the dimensions in such a manner prevents the bucket or buckets from sliding through the bottom of an open-bottom caddy. Caddy 16 may be formed of any desired material, e.g., a canvas material, such as the material used for a canvas tote bag. Caddy 16 alternatively may be formed of other suitable natural or synthetic material.
[0021] System 10 is further configured to temper food and beverages being carried in one of buckets 12 a,b,c . Preferably, the smallest bucket 12 c in the set of buckets 12 (i.e. the top bucket in the set of nested buckets) comprises a tempering chamber 13 at the bottom of the bucket. Tempering chamber 13 may be provided with removable tempering means either cold or hot, e.g., ice or a heated element (not shown), separated from the food or beverages by a divider 15 . Thus, the tempering means on the bottom is separated from the rest of the bucket, leaving a dry compartment on top for storing items such as food or beverages that are intended to be kept cold or warm at a non-ambient temperature during transport of the food or beverages, or while they are being held for later consumption. Such a tempering chamber and divider may be configured to be inserted into any of the buckets. In another embodiment of the present invention, smallest bucket 12 c may itself serve as a cooler with its own lid (not shown) and compartments for drinks and/or ice and food which are separated by a divider.
[0022] Referring to FIGS. 4 and 5 , the bottom 21 of at least one, and preferably each, bucket 12 a,b,c , when overturned, defines a flat surface which can act as a small tray or table. Further, the bottoms of any or all of buckets 12 a,b,c may be formed with one or more shaped indentations 23 a,b,c that can function as cup holders or food/tray holders (food containers). In an exemplary embodiment shown in FIG. 5 , indentations include one indentation that is a small rectangle 23 a for holding an item such as a juice box, another indentation that is a larger rectangle 23 b for holding a plate, and a third indentation 23 c that is round for holding an item such as a cup or soda can. Additional or alternative indentations 23 may be formed in bottoms 21 as desired.
[0023] As noted above, one or more of buckets 12 a,b,c may be configured with a strap 14 . A currently preferred embodiment of a strap in accordance with the present invention is shown in FIG. 6 , as described below. Strap 14 is preferably formed from a nylon material.
[0024] Preferably, each bucket comprises a plurality of openings 25 in the lip 27 of the bucket, through which strap 14 may be inserted to secure strap 14 to the bucket. Each bucket further comprises a tunnel portion (not shown) in the bottom of the bucket through which the strap or handle is to be inserted between the opposing openings 25 .
[0025] Strap 14 may also comprise means to detach the strap from the bucket. In one exemplary embodiment shown in FIG. 6 , one end 14 a of continuous strap 14 comprises a double sided hook-and-loop material (A), and the opposite end 14 b of strap 14 comprises two corresponding portions of hook material B and loop material C. Portion A may be inserted between Portions B and C in order to secure the two ends of the strap together, for example, near the top of the arc of the strap in FIG. 1 . If the user wishes to remove the strap from the bucket, the two ends can be detached in known fashion and the strap removed from the openings in the lip of the bucket and the tunnel in the base of the bucket. The strap can be also reinserted for further use. In alternative embodiments, the strap may be made from an alternative material that is suitable for use as a strap, and the ends of the strap can be attached to each other using an alternative attachment means.
[0026] FIGS. 9 and 10 show an alternate arrangement for transporting caddy 16 containing buckets 12 by securing caddy 16 and shovels 22 to an optional collapsible beach chair 40 . Caddy 16 may be configured with a plurality of closable loops or straps 42 that are secured to caddy 16 . Straps 42 may include hook-and-loop fasteners or other suitable means for opening and closing such straps. Straps 42 are configured to go around a section of a beach chair, such as the plastic or metal frame 46 of the chair, so that a user can removably attach the caddy to the beach chair. One or more shoulder straps 48 are removably attached to frame 46 , forming thereby system 10 in accordance with the present invention. This arrangement allows the user to carry the caddy, shovels, and bucket kit in combination with the beach chair, by carrying the beach chair in a fashion similar to a back pack. Other components that may be combined in a system in accordance with the present invention include but are not limited to one or more towels and an umbrella (not shown).
[0027] The present invention therefore greatly increases the convenience for beachgoers or picnickers by providing an all-encompassing system that allows the user to carry together and store all of the items to be brought along as a single, transportable kit or unit.
[0028] While the invention has been described by reference to various specific embodiments, it should be understood that numerous changes may be made within the spirit and scope of the inventive concepts described. Accordingly, it is intended that the invention not be limited to the described embodiments, but will have full scope defined by the language of the following claims.
|
A system of implements mutually and separably joined as a carrying unit for easy transport and subsequent use, the implements comprising a plurality of nestible buckets, a caddy removably receiving of the plurality of nestible buckets, optionally a collapsible chair removably attached to the caddy, at least one shovel removably attached to the caddy, and a carrying strap. Preferably, one of the buckets is modified to constitute a chamber for tempering food contained in the bucket at a non-ambient temperature during a holding period.
| 0
|
This application is a continuation of U.S. Ser. No. 12/611,373 filed Nov. 3, 2009, now U.S. Pat. No. 8,003,702 which is a divisional of U.S. Ser. No. 11/865,437 filed Oct. 1, 2007, now U.S. Pat. No. 7,622,495 which claims priority from U.S. Provisional application Ser. No. 60/848,642, filed Oct. 3, 2006. These prior applications are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to a novel family of substituted aryl compounds, pharmaceutical formulations containing them, use of the compounds in the manufacture of medicaments for treating various diseases, and methods of treating these diseases.
BACKGROUND OF THE INVENTION
The present invention relates to novel compounds for inhibiting glycogen synthase kinase-3 (GSK3β) and/or modulators of NMDA channel activities and their use in regulating biological conditions mediated by GSK3β activity and or NMDA channel activity and, more particularly, to the use of such compounds in the treatment of biological conditions such as neurodegenerative diseases, type II diabetes, cancer and affective disorders. The present invention further relates to methods of treating neurodegenerative disorders using GSK3β inhibitors and NMDA modulators.
Synonyms for GSK3β include Tau protein kinase I (TPK I), FA (Factor A) kinase, kinase FA and ATP-citrate lyase kinase (ACLK). GSK3 exists in two isoforms, i.e. GSK3α and GSK3β, and is a proline-directed serine/threonine kinase originally identified as an enzyme that phosphorylates glycogen synthase. However, it has been demonstrated that GSK3β phosphorylates numerous proteins in vitro such as glycogen synthase, phosphatase inhibitor 1-2, the type-II subunit of cAMP-dependent protein kinase, the G-subunit of phosphatase-1, ATP-citrate lyase, acetyl coenzyme A carboxylase, myelin basic protein, a microtubule-associated protein, a neurofilament protein, an N-CAM cell adhesion molecule, nerve growth factor receptor, c-Jun transcription factor, JunD transcription factor, c-Myb transcription factor, c-Myc transcription factor, L-Myc transcription factor, adenomatous polyposis coli tumor suppressor protein, Tau protein and β-catenin.
GSK3β inhibitors may act to increase the survival of neurons subjected to aberrantly high levels of excitation induced by the neurotransmitter glutamate (Nonaka, S., et al., Proc. Natl. Acad. Sci. USA, 95(3):2642-7, 1998). Glutamate-induced neuronal excitotoxicity is also believed to be a major cause of neurodegeneration associated with acute damage, such as in cerebral ischemia, traumatic brain injury and bacterial infection. Furthermore, it is believed that excessive glutamate signaling is a factor in the chronic neuronal damage seen in diseases such as Alzheimer's, Huntington's, Parkinson's, AIDS associated dementia, amyotrophic lateral sclerosis (ALS) and multiple sclerosis (MS) (Thomas, R J., J. Am. Geriatr Soc., 43:1279-89, 1995.
N-methyl-D-aspartate receptors are critical for neuronal plasticity and survival, whereas their excessive activation produces excitotoxicity and may accelerate neurodegeneration. Stimulation of NMDARs in vitro (cultured rat hippocampal or cortical neurons) and in the adult mouse brain in vivo disinhibited GSK3S via protein phosphatase 1(PP1)-mediated dephosphorylation of GSK3β at the serine 9 residue (Szatmari, E., et al, J. Biol. Chem., 280(11):37526-35, 2005). NMDA-triggered GSK3β activation was mediated by NMDAR that contained the NR2B subunit. These data suggest existence of a feedback loop between GSK3β and PP1 that results in amplification of PP1 activation by GSK3β. The excessive activation of NR2B-PP1-GSK3β-PP1 circuitry may contribute to the neurodegeneration induced by excessive NMDA. GSK3R inhibitors might mimic the action of certain hormones and growth factors, such as insulin, which use the GSK3β pathway.
GSK3β is considered to be an important player in the pathogenesis of Alzheimer's disease. GSK-3 was identified as one of the kinases that phosphorylate Tau, a microtubule-associated protein, which is responsible for the formation of paired helical filaments (PHF), an early characteristic of Alzheimer's disease. Apparently, abnormal Tau hyperphosphorylation is the cause for destabilization of microtubules and PHF formation. Consequently, GSK-3 inhibitors are believed to be potentially useful for treatment of these and other neurodegenerative disorders. Indeed, disregulation of GSK-3 activity has been recently implicated in several CNS disorders and neurodegenerative diseases, including schizophrenia (Beasley, C., et al., Neurosci Lett., 302(20):117-20, 2001; Kozlovsky, N., et al., Eur. Neuropsychopharmacol, 12:13-25, 2002), stroke, and Alzheimer's disease (AD) (Ghat, R. V. and Budd, S. L., Neurosignals, 11:251-61, 2002; Hernandez, F., et al., J. Neurochem., 83:1529-33, 2002; Lucas, J. J., et al., EMBO J, 20:15):27-39, 2001; Mandelkow, E. M., et al., FEBS Lett., 314(21):315-21, 1992).
It thus would be desirable to provide a class of GSK3β inhibitors that would be useful in the treatment of diseases mediated through GSK3β activity such as bipolar disorder (in particular manic depression), diabetes, Alzheimer's disease, leukopenia, FTDP-17 (Fronto-temporal dementia associated with Parkinson's disease), cortico-basal degeneration, progressive supranuclear palsy, multiple system atrophy, Pick's disease, Niemann Pick's disease type C, Dementia Pugilistica, dementia with tangles only, dementia with tangles and calcification, Down syndrome, myotonic dystrophy, Parkinson's Disease, Amyotrophic Lateral Sclerosis (ALS), Parkinsonism-dementia complex of Guam, AIDS related dementia, Postencephalic Parkinsonism, prion diseases with tangles, subacute sclerosing panencephalitis, frontal lobe degeneration (FLD), argyrophilic grains disease, subacute sclerotizing panencephalitis (SSPE) (late complication of viral infections in the central nervous system), inflammatory diseases, cancer, dermatological disorders such as baldness, neuronal damage, schizophrenia, pain, in particular neuropathic pain. GSK3β inhibitors can also be used to inhibit sperm motility and can therefore be used as male contraceptives.
Ions such as glutamate play a key role in processes related to chronic pain and neurotoxicity, primarily by acting through N-methyl-D-aspartate receptors. Thus, inhibition of such action, by employing ion channel antagonists or negative modulators, can be beneficial in the treatment and control of CNS diseases. NMDA receptor activity produces synaptic plasticity in the central nervous system that affects processes for learning and memory, including long-term potentiation and long-term depression (Dingledine R., Crit. Rev. Neurobiol., 4(1):196, 1988). However, prolonged activation of NMDA receptor under pathological conditions (such as cerebral ischemia and traumatic injury) causes neuronal cell death (Rothman S. M. and Olney J. W., Trends Neurosci., 18(2):57 8, 1995). NMDA receptor-mediated excitotoxicity may contribute to the etiology or progression of several neurodegenerative diseases, such as Parkinson's disease and Alzheimer's disease. Since open channel blockers of NMDA receptors were shown, in the late 1980s, to have potential for therapy of ischemic stroke, the receptor has been considered an attractive therapeutic target for the development of neuroprotective agents. Unfortunately, the development of these compounds as neuroprotectants is often limited by their psychiatric side-effects associated with their undesired pharmacodynamic properties such as slow dissociation from the receptor (Muir K. W. and Lees K. R., Stroke, 26(3):503 13, 1995).
Known NMDA antagonists include ketamine, dextromophan, and 3-(2-carboxypiperazin-4-yl)-propyl-1-phosphonic acid (“CPP”). Although these compounds have been reported (J. D. Kristensen, et al., Pain, 51:249 253 (1992); P. K. Eide, et al., Pain, 61:221 228 (1995); D. J. Knox, et al., Anaesth. Intensive Care 23:620 622 (1995); and M. B. Max, et al., Clin. Neuropharmacol. 18:360 368 (1995)) to produce symptomatic relief in a number of neuropathies including postherpetic neuralgia, central pain from spinal cord injury, and phantom limb pain, widespread use of these compounds is precluded by their undesirable side effects. Such side effects at analgesic doses include psychotomimetic effects such as dizziness, headache, hallucinations, dysphoria, and disturbances of cognitive and motor function. Additionally, more severe hallucinations, sedation, and ataxia are produced at doses only marginally higher than analgesic doses. Thus, it would be desirable to provide novel NMDA modulators that are absent of undesirable side effects or that produce fewer and/or milder side effects.
NMDA receptors are heteromeric assemblies of subunits, of which two major subunit families designated NR1 and NR2 have been cloned. Without being bound by theory, it is generally believed that the various functional NMDA receptors in the mammalian central nervous system (“CNS”) are only formed by combinations of NR1 and NR2 subunits, which respectively express glycine and glutamate recognition sites. The NR2 subunit family is in turn divided into four individual subunit types: NR2A, NR2B, NR2c and NR2D. Ishii, T., et al., J. Biol. Chem., 268:2836-2843 (1993), and Laurie, D. J., et al., Mol. Brain. Res., 51:23-32 (1997) describe how the various resulting combinations produce a variety of NMDA receptors differing in physiological and pharmacological properties such as ion gating properties, magnesium sensitivity, pharmacological profile, as well as in anatomical distribution.
SUMMARY OF THE INVENTION
The invention relates to compounds and their salts having the formula (I):
wherein
each R 1 , R 2 and R 3 independently is selected from hydrogen, carboxy, nitro, C 1 -C 4 alkylsulfonyl, aminosulfonyl, C 1 -C 4 alkyl aminosulfonyl, halogen, cyano, C 1-4 alkyl, C 1-4 alkoxy, NR′R″, aryl, aryl-C 1-4 alkyl, or aryl-C 1-4 alkoxy, and each of R′ and R″ is independently H or C 1-4 alkyl, or R′=R″═ClCH 2 CH 2 , or NR′R″ constitutes a saturated heterocyclic ring containing 3-8 ring members;
X is:
—(CH 2 ) n —Y—
wherein Y is: >NH, >C═O, >C═S or none; n is 0-4; any carbon of the —(CH 2 ) n — may be substituted by 1-2 substituents independently selected from among halogen, carboxy, C 1-4 alkyl, C 1-4 alkoxy, OH, NH 2 or acyl,
Ar is a kynurenine/kynuramine metabolite of a 3-indole:
or a 3-indole:
wherein each R 5 independently is hydrogen, halogen, C 1-4 alkyl, C 1-4 , alkoxy, OH, NR′R″ as defined above, nitro, aryl, aryl-C 1-4 alkyl, or aryl-C 1-4 alkoxy;
with the provisos that:
if X is —(CH 2 ) 2 —NH—, Ar is 3-indole, R 1 is 4-methylsulfonyl and R 3 and each R 5 is hydrogen, then R 2 cannot be 2-nitro;
if X is unsubstituted —(CH 2 ) 2 —NH—, Ar is 3-indole, R 1 is 4-nitro and R 3 and each R 5 is hydrogen, then R 2 cannot be 2-bromo;
if X is substituted or unsubstituted —(CH 2 ) 2 —NH— and Ar is 3-indole or 2-aminobenzoyl, then R 1 and R 2 cannot be 2,4-dinitro;
and if X is unsubstituted —(CH 2 ) 2 —NH—, Ar is 3-indole, an R 5 is 5-methoxy, then R 1 and R 2 cannot be 2,4-dinitro.
In another aspect, the invention provides a pharmaceutical formulation that comprises at least one pharmaceutically acceptable diluent, preservative, solubilizer, emulsifier, adjuvant, and/or carrier, and at least one member of the group consisting of the compounds of the invention as defined above and pharmaceutically acceptable salts thereof.
In yet another aspect, the invention comprises the administration of an effective amount of at least one of the compounds of the invention as defined above and pharmaceutically acceptable salts thereof, for the prevention or treatment of a disease, disorder or biological condition which is mediated by GSK3β activity or NMDA channel activity or associated with excess GSK3β or NMDA activity.
DETAILED DESCRIPTION OF THE INVENTION
Compounds of the present invention are based on indole and its metabolites. The amino acid tryptophan and other indole derivatives such as melatonin are converted biologically through the “kynurenine pathway” (Beadle, G. W., et al., Proc. Natl. Acad. Sci. USA, 33:155-8, 1947, see Heidelberger, C., et al., J. Biol. Chem., 179:143, 1949). Over 95% of all dietary tryptophan is metabolized to kynurenines (Wolf, H., J. Clin. Lab. Invest., 136(Suppl):1-86, 1974). In peripheral tissues, particularly the liver, the indole ring of tryptophan or melatonin is modified by either tryptophan dioxygenase or indoleamine 2,3-dioxygenase, which results in the formation of formylkynurenine or N1-acetyl-N2-formyl-5-methoxykynuramine (AFMK), respectively. Formylase then rapidly converts formylkynurenine to L-kynurenine which is the key compound in the kynurenine pathway (Mehler & Knox 1950) and AFMK to N1-acetyl-5-methoxykynuramine (AMK).
The invention relates to compounds and their salts having the formula (I):
wherein
each of R 1 , R 2 and R 3 independently is selected from hydrogen, carboxy, nitro, C 1 -C 4 alkylsulfonyl, aminosulfonyl, C 1 -C 4 alkyl aminosulfonyl, halogen, cyano, C 1-4 alkyl, C 1-4 alkoxy, NR′R″, aryl, aryl-C 1-4 alkyl, or aryl-C 1-4 alkoxy, and each of R′ and R″ is independently H or C 1-4 alkyl, or R′═R″═ClCH 2 CH 2 , or NR′R″ constitutes a saturated heterocyclic ring containing 3-8 ring members;
X is:
—(CH 2 ) n —Y—
wherein Y is: >NH, >C═O, >C═S or none; n is 0-4; any carbon of the —(CH 2 ) n — may be substituted by 1-2 substituents independently selected from among halogen, carboxy, C 1-4 alkyl, C 1-4 alkoxy, OH, NH 2 or acyl,
Ar is a 3-indole:
or a kynurenine/kynuramine metabolite thereof:
wherein each R 5 independently is hydrogen, halogen, C 1-4 alkyl, C 1-4 alkoxy, OH, NR′R″ as defined above, nitro, aryl, aryl-C 1-4 alkyl, or aryl-C 1-4 alkoxy; with the provisos that:
if X is —(CH 2 ) 2 —NH—, Ar is 3-indole, R 1 is 4-methylsulfonyl and R 3 and each R 5 is hydrogen, then R 2 cannot be 2-nitro;
if X is unsubstituted —(CH 2 ) 2 —NH—, Ar is 3-indole, R 1 is 4-nitro and R 3 and each R 5 is hydrogen, then R 2 cannot be 2-bromo; and
if X is substituted or unsubstituted —(CH 2 ) 2 —NH— and Ar is 3-indole or 2-aminobenzoyl, then R 1 and R 2 cannot be 2,4-dinitro;
and if X is unsubstituted —(CH 2 ) 2 —NH—, Ar is 3-indole, an R 5 is 5-methoxy, then R 1 and R 2 cannot be 2,4-dinitro.
In preferred embodiments, Y is >NH, each of R 1 , R 2 and R 3 is independently selected from hydrogen, carboxy, nitro, C 1 -C 4 alkylsulfonyl, halogen and cyano, and each R 5 independently is selected from hydrogen and C 1-4 alkoxy.
Preferred compounds within the generic class of compounds set forth above include 2-(2-aminobenzoyl)-N-2-nitro-4-methylsulfonyl-phenylethylamine; N-(4-methylsulfonyl-2-nitrophenyl)-5-methoxytryptamine; N-(2-bromo-4-nitrophenyl)-5-methoxytryptamine; N-(4-bromo-2-nitrophenyl)-5-methoxytryptamine; N-(2-cyano-4-nitrophenyl)-5-methoxytryptamine; 2-(2-aminobenzoyl)-N-2-bromo-4-nitro-phenylethylamine; 2-(2-aminobenzoyl)-N-2-nitro-4-bromo-phenylethylamine; 2-(2-aminobenzoyl)-N-2-nitro-4-cyano-phenylethylamine; N-(2-nitrophenyl)-tryptamine; N-(4-carboxy-2-nitrophenyl)-tryptamine; N-(2-carboxy-4-nitrophenyl)-tryptamine; N-(2-nitrophenyl)-5-methoxytryptamine; N-(4-carboxy-2-nitrophenyl)-5-methoxytryptamine; N-(2-carboxy-4-nitrophenyl)-5-methoxytryptamine; N-(2-cyano-4-nitrophenyl)-tryptamine; N-(2-nitro-4-bromophenyl)-tryptamine, N-(3,4-dicyanophenyl)-tryptamine, N-(3,4-dicyanophenyl)-5-methoxytruptamine and 2-(2-aminobenzoyl)-N-2-nitrophenylethylamine.
Particularly preferred compounds include N-(4-methylsulfonyl-2-nitrophenyl)-5-methoxytryptamine; N-(2-nitrophenyl)-5-methoxytryptamine; N-(2-cyano-4-nitrophenyl)-tryptamine; 2-(2-aminobenzoyl)-N-2-nitro-4-methylsulfonyl-phenylethylamine; and N-(2-nitrophenyl)-tryptamine.
In another aspect, the invention provides a pharmaceutical formulation that comprises at least one pharmaceutically acceptable diluent, preservative, solubilizer, emulsifier, adjuvant, and/or carrier, and at least one member of the group consisting of the compounds of the invention as defined above and pharmaceutically acceptable salts thereof.
A pharmaceutical formulation according to the invention is preferably characterized by at least one of the following features:
(i) it is adapted for oral, rectal, parenteral, transbuccal, topical, intrapulmonary (e.g. by inhalation), intranasal or transdermal administration; (ii) it is in unit dosage form, each unit dosage comprising an amount of at least one compound of formula (I) which is within the range of about 0.001-about 100 mg/kg; (iii) it is a controlled release formulation, wherein at least one compound of formula (I) is released at a predetermined controlled rate.
The amount of a compound of formula (I) useful in treating a disease or disorder can vary with the nature and severity of the condition to be treated, the particular method of administration selected, the frequency of administration, the age, sex, weight and general condition of the patient and other factors evident to those of skill in the art. Generally, if the unit dosage is to be administered orally, a dose within the range of about 0.01 mg/kg-about 50 mg/kg daily, preferably within the range of about 0.05 mg-about 10 mg/kg, is effective. A more preferred dosage for oral administration is within the range of about 0.5-about 10 mg/kg daily. If the compound is to be administered parenterally or transdermally, a unit dosage within the range of about 0.005-about 15 mg/kg generally is desirable.
For oral administration, the pharmaceutical formulations may be utilized as, e.g., tablets, orally disintegrating tablets, capsules, emulsions, solutions, syrups or suspensions. For parenteral administration, the formulations can be utilized as ampoules, or otherwise as suspensions, solutions or emulsions in aqueous or oily vehicles. The need for suspending, stabilizing and/or dispersing agents will, of course, take account of the fact of the solubility or otherwise of the active compounds, in the vehicles that are used in the particular embodiments. The formulations additionally can contain physiologically compatible preservatives and antioxidants. In the formulations for topical application, e.g. creams, lotions or pastes, the active ingredient can be mixed with conventional oleaginous or emulsifying excipients.
The pharmaceutical formulations also can be utilized as suppositories with conventional suppository bases such as cocoa butter or other glycerides. Alternatively, the formulations can be made available in a depot form, which will release the active composition slowly in the body, over a pre-selected time period.
The compounds of the invention also can be administered by using conventional transbuccal, intranasal, intrapulmonary or transdermal delivery systems.
The compounds of formula (I) or their salts can be administered in combination with other therapeutic agents, especially compounds that act as anxiolytics, tranquilizers, analgesics, mood stabilizers, anti-Parkinson's agents (dopaminergic and non-dopaminergic drugs), anti-Alzheimer's drugs or anti-diabetic agents. “In combination” as used herein is intended to mean either that the compounds of the invention are physically combined with one or more additional therapeutic agents or that they are administered in separate physical forms but sufficiently close in time that both act within the body within a given time period. Examples of suitable anxiolytics which can be administered in combination with the compounds of formula I include flunitrazepam, diazepam and alprazolam; suitable tranquilizers include clonazepam, zolpidem, trazodone and melatonin; suitable analgesics include aspirin, ibuprofen and diclofenac; suitable mood stabilizers include lithium, sodium valproate and carbamazepine; suitable anti-Parkinon's agents include levodopa/carbidopa, cabergolline, pergolide, pramipexole, ropinirol, entacapone (COMT inhibitor), selegiline and rasagiline (MAO-B inhibitors); and suitable anti-diabetic agents include metformin, acarbose and glipizide. These known therapeutic agents can be physically combined with the compounds of the present invention or administered in combination with the compounds of the present invention but in separate physical form.
The compounds of formula I and their salts are administered to inhibit GSK3β activity or NMDA channel activity in animals or humans. More particularly, the compounds can be administered to prevent or to treat diseases, disorders or conditions which are mediated through GSK3β activity or NMDA channel activity or associated with excess GSK3β activity or NMDA channel activity. Such diseases, disorders and conditions, include central nervous system (CNS) disorders and traumas and neurodegenerative diseases, such as bipolar disorder (particularly manic-depressive disorder), Alzheimer's disease, Parkinson's disease, FTDP-17 (frontal-temporal dementia associated with Parkinson's disease), cortico-basal degeneration, progressive supranuclear palsy, multiple system atrophy, Pick's disease, Niemann Pick's disease type C, Dementia Pugilistica, dementia with tangles only, dementia with tangles and calcification, Parkinsonism-dementia complex of Guam, AIDS-related dementia, postencepalic Parkinsonism, prion diseases with tangles, Amyotrophic Lateral Sclerosis (ALS) subacute sclerosing panencephalitis, frontal lobe degeneration (FLD), argyrophilic grains disease, subacute sclerotizing panencephalitis (SSPE) (late complication of viral infections in the central nervous system), neuronal damage and schizophrenia; diabetes; leukopenia; Down Syndrome; myotonic dystrophy; inflammatory diseases; cancer and other proliferative disorders; dermatological disorders, such as baldness; cancer; pain, including neuropathic pain and chronic pain; migraines, psychiatric diseases, such as depression; anxiety; and stroke.
The invention is further illustrated by the following examples which are provided for illustrative purposes only and are not intended to be limiting.
EXAMPLE 1
2-(2-aminobenzoyl)-N-2-nitro-4-methylsulfonyl-phenylethylamine
General procedure for the synthesis of 2-(2-aminobenzoyl)-N-2-nitro-4-methylsulfonyl-phenylethylamine
In a 100 ml three-necked round-bottom flask kept under an argon atmosphere, 250 mg (1.14 mmoles, 1 eq) of methyl-4-fluoro-3-nitrobenzensulfone were dissolved in 20 ml of ethanol. Kynuramine dihydrobromide 371 mg (1 eq) was then added under magnetic stirring in one portion. After 15 minutes Na 2 CO 3 326 mg (3 eq) was added to the reaction.
The reaction course was followed by HPLC-MS that, after 6 hours, showed complete conversion. The yellow precipitate was then collected by filtration, washed with water and cold EtOH and then dried under vacuum at 40° C.
The desired product was recovered as a yellow solid (300 mg). 1H NMR (DMSO-d 6 , 400 MHz) δ 3.20 (s, 3H, SO 2 CH 3 ), 3.38 (br t, J=6.8 Hz, 2H, NHCH 2 CH 2 ), 3.77-3.81 (m, 2H, NHCH 2 CH 2 ), 6.51-6.55 (m, 1H, aromatic H), 6.76 (dd, J 1 =1.2 Hz, J 2 =8.4 Hz, 1H, aromatic H), 7.22-7.27 (m, 3H, 1 aromatic H+NH 2 ), 7.35 (d, J=9.6 Hz, 1H, aromatic H), 7.76 (dd, J 1 =1.4 Hz, J 2 =8.4 Hz, 1H, aromatic H), 7.92 (dd, J 1 =2.1 Hz, J 2 =9.0 Hz, 1H, aromatic H), 8.49 (d, J=2.1 Hz, 1H, aromatic H), 8.72 (br t, J=5.9 Hz, 1H, NHCH 2 CH 2 ).
EXAMPLE 2
N-(4-methylsulfonyl-2-nitrophenyl)-5-methoxytryptamine
General procedure for the synthesis of N-(4-methylsulfonyl-2-nitrophenyl)-5-methoxytryptamine
In a 100 ml three-necked round-bottom flask kept under an argon atmosphere, 483 mg (2.20 mmoles, leg) of methyl-4-fluoro-3-nitrobenzensulfone were dissolved in 40 ml of ethanol. 5-methoxytryptamine hydrochloride 500 mg (leg) was then added under magnetic stirring in one portion. After 15 minutes Na 2 CO 3 466 mg (2 eq) was added to the reaction. The reaction was heated to 50° C. using an oil bath. The reaction course was followed by HPLC-MS that, after 3 hours, showed complete conversion. The orange precipitate was collected by filtration, washed with water and cold EtOH and then dried under vacuum at 40° C. The desired product was recovered as an orange solid (350 mg).
1 H NMR (DMSO-d 6 , 400 MHz) δ 3.05 (t, J=7.1 Hz, 2H, NHCH 2 CH 2 ), 3.20 (s, 3H, SO 2 CH 3 ), 3.71-3.75 (m, 5H, OCH 3 +NHCH 2 CH 2 ), 6.71 (dd, J 1 =2.6 Hz, J 2 =8.8 Hz, 1H, aromatic H), 7.07 (d, J=2.4 Hz, 1H, aromatic H), 722-7.24 (m, 2H, aromatic H), 7.28 (d, J=9.0 Hz, 1H, aromatic H), 7.89 (dd, J 1 =2.0 Hz, J 2 =8.9 Hz, 1H, aromatic H), 8.47 (d, J=2.6 Hz, 1H, aromatic H), 8.64 (br t, J=5.7 Hz, 1H, NHCH 2 CH 2 ) 10.73 (br s, 1H, NH).
EXAMPLE 3
N-(2-bromo-4-nitrophenyl)-5-methoxytryptamine
EXAMPLE 4
N-(4-bromo-2-nitrophenyl)-5-methoxytryptamine
EXAMPLE 5
N-(2-cyano-4-nitrophenyl)-5-methoxytryptamine
General procedure for the synthesis of N-(2-bromo-4-nitrophenyl)-5-methoxytryptamine, N-(4-bromo-2-nitrophenyl)-5-methoxytryptamine and N-(2-cyano-4-nitrophenyl)-5-methoxytryptamine
1 equivalent of 1-fluoro-2R 1 -4R 2 -benzene was reacted in ethanol, at room temperature, with 1 equivalent of 5-methoxytryptamine, to yield the desired product, as follows:
(N-(2-bromo-4-nitrophenyl)-5-methoxytryptamine): R 1 ═Br, R 2 ═NO 2 ; reaction time 3 h; yield referred to chromatographed product: 70% (N-(4-bromo-2-nitrophenyl)-5-methoxytryptamine): R 1 ═NO 2 , R 2 ═Br; reaction time 3 h; yield referred to isolated product (collected by filtration): 50% N-(2-cyano-4-nitrophenyl)-5-methoxytryptamine): R 1 ═CN, R 2 ═NO 2 ; reaction time 3 h; yield referred to isolated product (collected by filtration): 50%
NMR spectra of compounds N-(2-bromo-4-nitrophenyl)-5-methoxytryptamine, N-(4-bromo-2-nitrophenyl)-5-methoxytryptamine and N-(2-cyano-4-nitrophenyl)-5-methoxytryptamine
N-(2-bromo-4-nitrophenyl)-5-methoxytryptamine
1 H NMR (DMSO-d 6 , 400 MHz) δ 2.96 (t, J=7.7 Hz, 2H, CH 2 ), 3.54-3.59 (m, 2H, CH 2 —NH), 3.74 (s, 3H, OCH 3 ), 6.62 (br t, J=5.8 Hz, 1H, CH 2 —NH), 6.70 (dd, J=2.5 Hz, J 2 =8.7 Hz, 1H, aromatic H), 6.83 (d, J=9.2 Hz, 1H, aromatic H), 7.03 (d, J=2.2 Hz, 1H, aromatic H), 7.18-7.22 (m, 2H, aromatic H), 8.04 (dd, J 1 =2.2 Hz, J 2 =9.2 Hz, 1H, aromatic H), 8.25 (d, J=2.5 Hz, 1H, aromatic H), 10.69 (br s, 1H, NH).
N-(4-bromo-2-nitrophenyl)-5-methoxytryptamine
1 H NMR (DMSO-d 6 , 400 MHz) δ 3.01 (t, 2H, J=6.9 Hz, CH 2 ), 3.59-3.64 (m, 2H, CH 2 —NH), 3.73 (s, 3H, OCH 3 ), 6.70 (dd, J 1 =2.8 Hz, J 2 =8.7 Hz, 1H, aromatic H), 7.03-7.07 (m, 2H, aromatic H), 7.19-7.22 (m, 2H, aromatic H), 7.60 (dd, J 1 =2.1 Hz, J 2 =9.6 Hz, 1H, aromatic H), 8.11 (d, J=2.8 Hz, 1H, aromatic H), 8.20 (br t, J=5.6 Hz, 1H, CH 2 —NH), 10.71 (br s, 1H, NH).
N-(2-cyano-4-nitrophenyl)-5-methoxytryptamine
1 H NMR (DMSO-d 6 , 400 MHz) δ 2.97 (t, 2H, J=7.4 Hz, CH 2 ), 3.58-3.63 (m, 2H, CH 2 —NH), 3.76 (s, 3H, OCH 3 ), 6.71 (dd, J 1 =2.5 Hz, J 2 =8.8 Hz, 1H, aromatic H), 6.93 (d, J=9.6 Hz, 1H, aromatic H), 7.04 (d, J=2.2 Hz, 1H, aromatic H), 7.17-7.23 (m, 2H, aromatic H), 7.59 (br t, J=6.0 Hz, 1H, CH 2 —NH), 8.15 (dd, J 1 =3.0 Hz, J 2 =9.4 Hz, 1H, aromatic H), 8.41 (d, J=2.9 Hz, 1H, aromatic H), 10.70 (br s, 1H, NH).
EXAMPLE 6
2-(2-aminobenzoyl)-N-2-bromo-4-nitro-phenylethylamine
EXAMPLE 7
2-(2-aminobenzoyl)-N-2-nitro-4-bromo-phenylethylamine
EXAMPLE 8
2-(2-aminobenzoyl)-N-2-nitro-4-cyano-phenylethylamine
General procedure for the synthesis of 2-(2-aminobenzoyl)-N-2-bromo-4-nitro-phenylethylamine, 2-(2-aminobenzoyl)-N-2-nitro-4-bromo-phenylethylamine and 2-(2-aminobenzoyl)-N-2-nitro-4-cyano-phenylethylamine
3×125 mg (3×1 equiv) of kynuramine dihydrobromide were dissolved under an argon atmosphere in 3×1 ml of absolute ethanol in three different flasks of a Carousel parallel synthesizer. Triethylamine (3×0.1 ml, 3×2 equiv) was also added in each flask. 2-Bromo-1-fluoro-4-nitrobenzene (85 mg, 1 equiv), 4-bromo-1-fluoro-2-nitrobenzene (85 mg, 1 equiv) and 2-fluoro-5-nitrobenzonitrile (65 mg, 1 equiv) were then added respectively in one of the three parallel flasks (A, B and C) and the obtained mixtures were allowed to react at room temperature under magnetic stirring. The course of the reactions was followed by TLC (dichloromethane as the eluent). Reactions A, B and C were all completed after 16 hours. The three reaction mixtures were then concentrated under reduced pressure and the resulting residues were purified by column chromatography on silica gel (approx. 10 grams) by using dichloromethane as the eluent.
2(2-aminobenzoyl)-N-2-bromo-4-nitro-phenylethylamine was obtained as a yellow solid in 30% yield, 2(2-aminobenzoyl)-N-2-nitro-4-bromo-phenylethylamine was collected as an orange solid in 40% yield and 2(2-aminobenzoyl)-N-2-nitro-4-cyano-phenylethylamine was isolated as a yellow solid in 40% yield.
EXAMPLE 9
N-(2-Nitrophenyl)-tryptamine
Procedure:
In a 250 ml round bottom flask DMF (1 eq.), tryptamine (1 eq.), 2-nitrofluorobenzene (1 eq.) were taken and stirred for 10 min. Then potassium carbonate (1.1 eq.) was added at room temperature. The stirring was continued for 2 hours. TLC was monitored. The reaction mixture was poured into ice water and stirred for 15 min. The resultant solid was filtered and washed with water. The crude material was crystallized from methanol. The yield was 60%.
NMR: (CDCl 2 ) δ 3.2 (t, 2H, CH 2 ), 3.6 (t, 2H, CH 2 NH), 6.6 (t, 1H, 4′-H), 6.8 (d, 1H, 7-H), 7.1-7.3 (m, 3H, 2-H, 5-H, 6-H), 7.4 (m, 2H, 4-H, 6′-H), 7.6 (d, 1H, 5′-H) 8.1 (m, 3H, 3′-H, 2×NH).
EXAMPLE 10
N-(4-Carboxy-2-nitrophenyl)-tryptamine
Procedure:
In a 250 ml round bottom flask DMF (10 eq.), tryptamine (1 eq.), and 4-carboxy-2-nitrofluorobenzene (1 eq.) were added and stirred for 10 min. Then potassium carbonate (2.5 eq.) was added at room temperature. The stirring was continued for 2 hrs. TLC was monitored. The reaction mixture was poured into ice water, neutralized with acetic acid to pH=5 and stirred for 15 min. The resultant solid was filtered and washed with water. The crude material was crystallized from toluene. The yield was 50%.
NMR: (CDCl 3 ) δ 3.3 (t, 2H, CH 2 ), 3.5 (t, 2H, CH 2 NH), 6.8 (d, 1H, 6′-H), 7.2 (m, 2H, 5-H, 6-H), 7.4 (d, 1H, 7-H), 7.6 (d, 1H, 4-H), 8.0 (d, 1H, 5′-H), 8.4 (bs, 1H, NH), 8.6 (s, 1H, NH), 8.8 (s, 1H, 3′-H).
EXAMPLE 11
N-(2-Carboxy-4-nitrophenyl)-tryptamine
Procedure:
In a 250 ml round bottom flask DMF (10 eq.), tryptamine (1 eq.), 2-carboxy-4-nitrofluorobenzene (1 eq.) were added and stirred for 10 min. Then potassium carbonate (2.5 eq.) was added at room temperature. The stirring was continued for 2 hrs. TLC was monitored. The reaction mixture was poured into ice water, neutralized with acetic acid to pH=5 and stirred for 15 min. The resultant solid was filtered and washed with water. The crude material was crystallized from toluene. The yield was 50%.
NMR: (CDCl 3 ) δ 3.1 (t, 2H, CH 2 ), 3.6 (t, 2H, CH 2 NH), 6.7 (d, 1H, 5′-H), 7.0 (m, 3H, 2-H, 5-H, 6-H), 7.4 (d, 1H, 7-H), 7.5 (d, 1H, 4-H), 8.1 (d, 1H, 4′-H), 8.8 (d, 1H, 3′-H), 8.9 (bs, 1H, NH), 10.4 (s, 1H, NH).
EXAMPLE 12
N-(2-Nitrophenyl)-5-methoxytryptamine
Procedure:
In a 250 ml round bottom flask DMF (10 eq.), 5-methoxy-tryptamine (1 eq.) and 2-nitrofluorobenzene (1 eq.) were added and stirred for 10 min. Then potassium carbonate (1.1 eq.) was added at room temperature. The stirring was continued for 2 hrs. TLC was monitored. The reaction mixture was poured into ice water and stirred for 15 min. The resultant solid was filtered and washed with water. The crude material was crystallized from methanol. The yield was 60%.
NMR: (CDCl 3 ) δ 3.2 (t, 2H, CH 2 ), 3.6 (t, 2H, CH 2 NH), 3.8 (s, 3H, OCH 3 ), 6.6 (t, 1H, 4′-H), 6.8 (d, 2H, 6-H, 7-H), 7.0 (d, 1H, 4-H), 7.1 (s, 1H, 2-H), 7.3 (d, 1H, 6′-H), 7.9 (bs, 1H, NH), 8.2 (m, 2H, 3′-H, NH).
EXAMPLE 13
N-(4-Carboxy-2-nitrophenyl)-5-methoxytryptamine
Procedure:
In a 250 ml round bottom flask DMF (10 eq.), 5-methoxytryptamine (1 eq.) and 4-carboxy-2-nitrofluorobenzene (1 eq.) were added and stirred for 10 min. Then potassium carbonate (2.5 eq.) was added at room temperature. The stirring was continued for 2 hrs. TLC was monitored. The reaction mixture was poured into ice water, neutralized with acetic acid to pH=5 and stirred for 15 min. The resultant solid was filtered and washed with water. The crude material was crystallized from toluene. The yield was 40%.
NMR: (CDCl 3 ) δ 3.5 (m, 4H, 2×CH 2 ), 3.8 (s, 3H, OCH 2 ), 6.7 (d, 1H, 6′-H), 6.9 (bs, 1H, 7-H), 6.95 (s, 1H, 2H), 7.1 (s, 1H, 4-H), 7.3 (d, 1H, 5′-H), 8.0 (bs, 1H, 6-H), 8.4 (bs, 1H, 3′-H), 8.8 (s, 1H, NH), 10.4 (s, 1H, NH).
EXAMPLE 14
N-(2-Carboxy-4-nitrophenyl)-5-methoxytryptamine
Procedure:
In a 250 ml round bottom flask DMF (10 eq.), 5-methoxytryptamine (1 eq.), 2-carboxy-4-nitrofluorobenzene (1 eq.) were added and stirred for 10 min. Then potassium carbonate (2.5 eq.) was added at room temperature. The stirring continued for 2 hrs. TLC was monitored. The reaction mixture was poured into ice water, neutralized with acetic acid to pH=5 and stirred for 15 min. The resultant solid was filtered and washed with water. The crude material was crystallized from toluene. The yield was 40%.
NMR: (CDCl 3 ) δ 3.1 (t, 2H, CH 2 ), 3.6 (t, 2H, NH), 3.8 (s, 3H, OCH 3 ), 6.6 (m, 2H, 4-H, 5′-H), 6.7 (m, 5H, Ar—H), 8.1 (d, 1H, 5-H), 8.7 (d, 1H, 3′-H), 8.9 (bs, 1H, NH), 10.5 (s, 1H, NH).
EXAMPLE 15
N-(2-cyano-4-nitrophenyl)-tryptamine
EXAMPLE 16
N-(2-nitro-4-bromophenyl)-tryptamine
General procedure for the synthesis of N-(2-nitro-4-bromophenyl)-tryptamine and N-(2-cyano-4-nitrophenyl)-tryptamine
2×500 mg (2×1 equiv) of tryptamine were dissolved under an argon atmosphere in 2×2 ml of absolute ethanol in three different flasks of a Carousel parallel synthesizer. 4-bromo-1-fluoro-2-nitrobenzene (690 mg, 1 equiv) and 2-fluoro-5-nitrobenzonitrile (520 mg, 1 equiv) were added, respectively, in one of the two parallel flasks (A and B) and the obtained mixtures were allowed to react at room temperature under magnetic stirring. The course of the reactions was followed by TLC (dichloromethane as the eluent). Reactions A and B were completed after 8 and 2 hours, respectively. The two mixtures were then diluted with ca. 15 ml of diethyl ether and the resulting precipitates were collected by filtration and washed with additional Et 2 O. TLC analyses showed in all precipitates residual traces of starting materials, thus each reaction mixture was purified by column chromatography on silica gel (approx. 20 grams). A mixture of petroleum ether/dichloromethane (8:2) was used until the starting nitroaromatic derivatives were eluted; subsequently, the target products were eluted by using dichloromethane. N-(2-nitro-4-bromophenyl)-tryptamine was collected as a red solid in 55% yield and finally N-(2-cyano-4-nitrophenyl)-tryptamine was obtained as a yellow solid in 40% yield.
NMR spectra of compounds, N-(2-nitro-4-bromophenyl)-tryptamine and N-(2-cyano-4-nitrophenyl)-tryptamine
N-(2-nitro-4-bromophenyl)-tryptamine
1 H NMR (DMSO-d 5 , 400 MHz) δ 3.07 (t, 2H, J=6.9 Hz, CH 2 ), 3.62-3.68 (m, 2H, CH 2 —NH), 6.98 (t, J=6.9 Hz, 1H, aromatic H), 7.06-7.10 (m, 2H, aromatic H), 7.26 (br s, 1H, aromatic H), 7.35 (d, J=8.0 Hz, 1H, aromatic H), 7.58 (d, J=8.3 Hz, 1H, aromatic H), 7.62 (dd, J 1 =2.2 Hz, J 2 =8.8 Hz, 1H, aromatic H), 8.13 (d, J=2.2 Hz, 1H, aromatic H), 8.20 (br t, J=5.4 Hz, 1H, CH 2 —NH), 10.87 (br s, 1H, NH).
N-(2-cyano-4-nitrophenyl)-tryptamine
1 H NMR (DMSO-d 6 , 400 MHz) δ 3.01 (t, 2H, J=7.2 Hz, CH 2 ), 3.59-3.64 (m, 2H, CH 2 —NH), 6.93 (d, J=9.6 Hz, 1H, aromatic H), 6.99 (t, J=7.4 Hz, 1H, aromatic H), 7.08 (t, J=6.9 Hz, 1H, aromatic H), 7.21 (br s, 1H, aromatic H), 7.34 (d, J=8.0 Hz, 1H, aromatic H), 7.55-7.60 (m, 2H, aromatic H+CH 2 —NH), 8.15 (dd, J 1 =2.1 Hz, J 2 =9.5 Hz, 1H, aromatic H), 8.39 (d, J=2.1 Hz, 1H, aromatic H), 10.85 (br s, 1H, NH).
EXAMPLE 17
N-(3,4-dicyanophenyl)-tryptamine
General procedure for the synthesis of N-(3,4-dicyanophenyl)-tryptamine
Under an argon atmosphere, a 100 ml three-necked round-bottom flask was charged with tryptamine (1.10 g, 1 equiv.) dissolved in EtOH (12 ml). To the solution 4-fluoro-phtahalonitrile (1.00 g, 1 equiv.) was then added in one portion. The resulting mixture was allowed to react under magnetic stirring for 25 h at room temperature. The reaction course was followed by TLC and HPLC-MS. The solvent was then removed by rotary evaporation and the crude product was chromatographed over a silica gel column by eluting with dichloromethane. The product was recovered as an off-white solid (880 mg, yield 35%).
1 H NMR (CDCl 3 , 400 MHz) δ 3.13 (t, J=6.3 Hz, 2H, CH 2 CH 2 NH), 3.51-3.56 (m, 2H, CH 2 CH 2 NH), 4.54 (br t, J=5.3 Hz, 1H, CH 2 CH 2 NH), 6.69 (dd, J 1 =2.3 Hz, J 2 =8.6 Hz, 1H, aromatic H), 6.79 (d, J=2.5 Hz, 1H, aromatic H), 7.06 (d, J=2.3 Hz, 1H, aromatic H), 7.14-7.18 (m, 1H, aromatic H), 7.23-7.27 (m, 1H, aromatic H), 7.41 (br d, J=8.1 Hz, 1H, aromatic H), 7.46 (d, J=8.8 Hz, 1H, aromatic H), 7.57 (br d, J=8.1 Hz, 1H, aromatic H), 8.08 (br s, 1H, NH).
EXAMPLE 18
N-(3,4-dicyanophenyl)-5-methoxytryptamine
General procedure for the synthesis of N-(3,4-dicyanophenyl)-5-methoxytryptamine
Under an argon atmosphere, a 100 ml three-necked round bottom flask was charged with 5-methoxytryptamine (1.33 g, 1 equiv.) dissolved in hot EtOH (20 ml). The solution was then cooled to room temperature and 4-fluoro-phtahalonitrile (1.00 g, 1 equiv.), was added in one portion. The resulting mixture was allowed to react under magnetic stirring for 20 h at room temperature. The reaction course was followed by TLC and HPLC-MS. The solvent was then removed by rotary evaporation and the crude product was chromatographed over a silica gel column by eluting with dichloromethane. The product was recovered as a white solid (490 mg, yield 22%).
1 H NMR (CDCl 3 , 400 MHz) δ 3.09 (t, J=6.6 Hz, 2H, CH 2 CH 2 NH), 3.50-3.54 (m, 2H, CH 2 CH 2 NH), 3.85 (s, 3H, OCH 3 ), 4.55 (br t, J=5.1 Hz, 1H, CH 2 CH 2 NH), 6.69 (dd, J 1 =2.3 Hz, J 2 =8.8 Hz, 1H, aromatic H), 6.80 (d, J=2.8 Hz, 1H, aromatic H), 6.90 (dd, J 1 =2.0 Hz, J 2 =8.8 Hz, 1H, aromatic H), 6.98 (d, J=2.9 Hz, 1H, aromatic H), 7.03 (d, J=2.3 Hz, 1H, aromatic H), 7.30 (d, J=8.8 Hz, 1H, aromatic H), 7.47 (d, J=8.8 Hz, 1H, aromatic H), 7.97 (br s, 1H, NH).
EXAMPLE 19
2-(2-aminobenzoyl)-N-2-nitrophenylethylamine
2 ml of 2-nitro-fluorobenzene were reacted in 20 ml DMF, at room temperature, with 5 g of kynuramine and 3 g of potassium carbonate, to yield the desired product; reaction time was 2 h. The reaction mixture was placed in 250 ml of water and stirred. It was extracted into ethylacetate (2×100 ml), ethylacetate layer was washed twice with water (50 ml), dried with sodium sulphate and the solvent was distilled off. The crude material was purified by column chromatography run with ethylacetate and hexane mixture (1:9).
Yield referred was 500 mg.
1 H NMR (DMSO-d 6 , 500 MHz) δ 3.35 (t, 2H, NHCH 2 CH 2 , J=6.6 Hz), 3.69 (q, 2H, NHCH 2 CH 2 , J=6.4 Hz), 6.52 (t, 1H, aromatic, J=7.6 Hz), 6.68 (t, 1H, aromatic, J=7.8 Hz), 6.75 (d, 1H, aromatic, J=8.3 Hz), 7.13 (d, 1H, aromatic, J=8.7 Hz), 7.23 (m, 3H, 1 aromatic H+NH 2 ), 7.55 (t, 1H, aromatic, J=7.8 Hz), 7.77 (d, 1H, aromatic, J=8.1 Hz), 8.06 (d, 1H, aromatic, J=8.7 Hz), 8.23 (t, 1H, NHCH 2 CH 2 , J=5.6 Hz)
BIOLOGICAL TESTING OF COMPOUNDS OF THE INVENTION
Experiment 1
Evaluation of GSK3β Activity
Compounds were evaluated for inhibition against purified GSK3β. GSK3β was expressed in and purified from insect Sf9 cells. Compounds (10 μM) were assayed; following a 1/100 dilution of the enzyme in 1 mg/ml BSA, 10 mM DTT, with 5 μl of 40 μM GS-2 peptide as a substrate, in a buffer, in the presence of 15 μM [γ- 32 P]ATP (3000 Ci/mmol; 1 mCi/ml) in a final volume of 30 μl. After 30-min incubation at 30° C., 25-μl aliquots of supernatant were spotted onto 2.5×3 cm pieces of Whatman P81 phosphocellulose paper, and, 20 s later, the filters were washed five times (for at least 5 min each time) in a solution of 10 ml of phosphoric acid/liter of water. The wet filters were counted in the presence of 1 ml of scintillation fluid. Table 1 presents the GSK3S activity inhibition by compounds of the present patent application.
TABLE 1
GSK3β Activity
Inhibition
Tested Substance
IC50
N-(2-Nitrophenyl)-tryptamine
9.9 μM
N-(2-cyano-4-nitrophenyl)-tryptamine
12.7 μM
N-(2-Nitrophenyl)-5-methoxytryptamine
14.1 μM
N-(2-Carboxy-4-nitrophenyl)-tryptamine
14.2 μM
N-(3,4-dicyanophenyl)-tryptamine
14.8 μM
N-(3,4-dicyanophenyl)-5-methoxytryptamine
16.8 μM
2-(2-aminobenzoyl)-N-2-
18.5 μM
nitrophenylethylamine
N-(4-Carboxy-2-nitrophenyl)-5-
21.7 μM
methoxytryptamine
2-(2-aminobenzoyl)-N-2-nitro-4-
29.3 μM
cyano-phenylethylamine
This experiment revealed that N-(2-Nitrophenyl)-tryptamine, N-(2-cyano-4-nitrophenyl)-tryptamine, N-(2-nitrophenyl)-5-methoxytryptamine, N-(2-carboxy-4-nitrophenyl)-tryptamine, N-(3,4-dicyanophenyl)-tryptamine, N-(3,4-dicyanophenyl)-5-methoxytryptamine, N-(4-carboxy-2-nitrophenyl)-5-methoxytryptamine and 2-(2-aminobenzoyl)-N-2-nitro-4-cyano-phenylethylamine have a significant inhibiting activity on GSK3β activity.
Experiment 2
Evaluation of Anti-Parkinsonian Activity Using MPTP-Treated Mice with/without a Sub Threshold Dose of L-DOPA
Animals: six month old male C57 BL/6 mice, weighing 22-25 g were used. Following arrival at the laboratory, the mice were allowed to acclimatize for two weeks in a room with controlled temperature (21±1° C.), and a constant light-dark schedule (12 hr on/12 hr off, lights on between 06.00 and 18.00 hrs). Free access to food and water was maintained throughout. They were housed in groups of 12 animals and tested only during the hours of light (08.00-15.00 hrs). All testing was performed in a normally lighted room. Each test chamber (i.e. activity test cage) was placed in a soundproofed wooden box with 12 cm thick walls and front panels and had a dimmed lighting.
Behavioural measurements and apparatus: An automated device, consisting of macrolon rodent test cages (40×25×15 cm), each placed within two series of infra-red beams (at two different heights, one low and one high, 2 and 8 cm, respectively, above the surface of the sawdust, 1 cm deep), was used to measure spontaneous and/or drug-induced motor activity of 1-methyl 4-phenyl 1,2,3,6-tetrahydropyridine (MPTP) and control mice. The following parameters were measured: LOCOMOTION was measured by the low grid of infrared beams. Counts were registered only when the mouse in the horizontal plane, ambulating around the test-cage. REARING was registered throughout the time when at least one high level beam was interrupted, i.e. the number of counts registered was proportional to the amount of time spent rearing. TOTAL ACTIVITY was measured by a sensor (a pick-up similar to a gramophone needle, mounted on a lever with a counterweight) with which the test cage was constantly in contact. The sensor registered all types of vibration received from the test cage, such as those produced both by locomotion and rearing as well as shaking, tremors, scratching and grooming.
Behavioral measurements (locomotion, rearing and total activity): Twelve days after MPTP injections (2×40 mg/kg, s.c., 24 hr interval), the mice were administered orally with the different compounds at 3 mg/kg or vehicle (0.1% Tween-80 in 1% methylcellulose) and immediately thereafter placed in the activity test chambers and their motor behaviors were monitored for 60 min. After 60 min, the mice were injected with 5 mg/kg L-Dopa (s.c) and then replaced in the test chamber and activity measurements maintained for an additional 300 min.
Table 2 presents the locomotion, rearing and total activity counts of MPTP-treated and control mice administered either tested substances or vehicle administered with a sub threshold dose of L-Dopa.
TABLE 2
TOTAL
TREATMENT
LOCOMOTION
REARING
ACTIVITY
Vehicle
100%
100%
100%
MPTP + vehicle
16%
25%
46%
MPTP + N-(4-bromo-2-
16%
24%
46%
nitrophenyl)-5-
methoxytryptamine
MPTP + 2-(2-
17.6%
25%
45%
aminobenzoyl)-N-2-
nitrophenylethylamine
MPTP + N-(2-carboxy-4-
16%
25%
45%
nitrophenyl)-tryptamine
MPTP + N-(3,4-
18%
25%
47%
dicyanophenyl)-tryptamine
MPTP + N-(3,4-
19%
27%
48%
dicyanophenyl)-5-
methoxytryptamine
MPTP + 2-(2-aminobenzoyl)-
17%
29%
46%
N-2-nitro-4-cyano-
phenylethylamine
MPTP + N-(4-Carboxy-
22%
30%
46%
2-nitrophenyl)-5-
methoxytryptamine
MPTP + N-(4-methylsulfonyl-
41%
74%
70%
2-nitropheny)-5-
methoxytryptamine
MPTP + N-(2-nitrophenyl)-5-
44%
90%
73%
methoxytryptamine
MPTP + N-(2-cyano-4-
52%
98%
73%
nitrophenyl)-tryptamine
MPTP + 2-(2-
54%
100%
72%
aminobenzoyl)-N-2-nitro-4-
methylsulfonyl-
phenylethylamine
MPTP + N-(2-Nitrophenyl)-
53%
100%
90%
tryptamine
2(2-aminobenzoyl)-N-2-nitro-4-methylsulfonyl-phenylethylamine, N-(4-methylsulfonyl-2-nitrophenyl)-5-methoxytryptamine, N-(2-nitrophenyl)-5-methoxytryptamine, N-(2-nitrophenyl)-tryptamine and N-(2-cyano-4-nitrophenyl)-tryptamine (3 mg/kg) significantly reversed the motor deficits of MPTP-treated mice when combined with a sub-threshold (inactive) dose of L-Dopa.
Experiment 3
Electrophysiological Characterisation of NMDA-Activated Currents in Freshly Isolated Hippocampal Neurones of Rat
Isolation of hippocampal neurons: Wistar rats (12-14 days) were decapitated without anesthesia and the hippocampus was removed. It was manually cut into slices (0.2-0.4 mm), in a solution containing (mM): 150 NaCl; 5 KCL; 1.25 NaH 2 PO 4 ; 2 CaCl 2 ; 2 MgCl 2 ; 26 NaHCO 3 ; 20 glucose. Slices were preincubated in this solution for 30 min at room temperature. The enzymatic treatment proceeded in the same solution with lower Ca 2+ concentration (0.5 mm) containing 0.4 mg/ml protease from aspergillus oryzae . The incubation in the enzyme solution proceeded at 32° C. within 10 min. Slices were kept subsequently in enzyme-free solution containing normal Ca 2 ±concentration and used within 6-8 h for obtaining isolated neurons. Throughout the entire procedure the solutions were continuously saturated with a 95% O 2 and 5% CO 2 gas mixture to maintain pH of 7.4. For cell dissociation the slice was transferred into the extracellular solution containing (mM): 150 NaCl; 5 KCl; 2 CaCl 2 ; 10 n-2-hydroxyethylpiperazine-n′-2-ethanesulphonic acid (Hepes); pH adjusted with NaOH to 7.4. Single cells were isolated from CA and CA3 zones of hippocampal slices by vibrodissociation method. They had a diameter 10-15 μm and preserved a small part of dendritic tree. After isolation they were usually suitable for the recording for 1-2 h.
Salines and chemicals: The contents of the extracellular solution was as follows (in mM): 130 NaCl, 5KCl, 2CaCl 2 , 20 n-2-hydroxyethylpiperazine-n′-2-ethansulfonic acid (Hepes); 0.1 μm TTX, 10 μm glycine, 300 mm 1-aspartate; pH was adjusted with NaOH to 7.4.
The contents of the intracellular solution were as follows (in mM): 110 CsF, 20 Tris-HCl (pH=7.2). L-aspartate and glycine solutions were prepared on the day of experiment.
The tested substances were dissolved in DMSO.
Current recording and data analysis: The drug-containing solutions were applied by the fast “concentration clamp” method using “jumping table” set-up. The currents were recorded with patch clamp technique in the whole-cell configuration. Recording of the currents was performed using EPC-7 L/M patch-clamp amplifier.
NMDA-activated currents: The currents were filtered at 3 kHz (three-pole active Bessel filter) digitally sampled at the rate 6000 μs per point for NMDA activated currents. NMDA-induced transmembrane currents were measured in the presence of 10 μM glycine and 300 μM L-aspartate in the control and test solutions. The currents were recorded at holding potential −70 mV.
Calculations: The inhibition of current at 1 μM of the substance was averaged at least for 4 cells. The effect of substance was measured as the mean ratio I/Io where I was the current under the action of substance and Io was the current in control conditions.
The action of 1 μM tested substances on NMDA-activated currents are shown in Table 3.
TABLE 3
Tested Substance
% Inhibition
(1 μM)
Peak Current
Steady State Current
N-(3,4-dicyanophenyl)-
93.4%
66.4%
tryptamine
N-(2-Nitrophenyl)-
90.93%
66.83%
tryptamine
N-(2-Carboxy-4-
76.7%
70.4%
nitrophenyl)-tryptamine
N-(4-Carboxy-2-
89.92%
74.14%
nitrophenyl)-5-
methoxytryptamine
N-(2-Nitrophenyl)-5-
78%
77.3%
methoxytryptamine
N-(4-bromo-2-
104.2%
78.18%
nitrophenyl)-5-
methoxytryptamine
N-(3,4-dicyanophenyl)-5-
84.4%
78.4%
methoxytryptamine
N-(2-cyano-4-
83.1%
82.44%
nitrophenyl)-tryptamine
N-(2-nitro-4-bromophenyl)-
95.8%
83%
tryptamine
N-(2-bromo-4-nitrophenyl)-
91.53%
86.57%
5-methoxytryptamine
2-(2-aminobenzoyl)-N-2-
85.95%
87.24%
nitro-4-cyano-
phenylethylamine
N-(2-cyano-4-nitrophenyl)-
96.21%
88.21%
5-methoxytryptamine
2-(2-aminobenzoyl)-N-
90.85%
88.77%
2-nitro-4-bromo-
phenylethylamine
2-(2-aminobenzoyl)-N-
86.23%
90.78%
2-bromo-4-nitro-
phenylethylamine
N-(4-Carboxy-2-
101.6%
92.84%
nitrophenyl)-tryptamine
N-(2-Carboxy-4-
84%
93.6%
nitrophenyl)-5-
methoxytryptamine
This experiment revealed that N-(3,4-dicyanophenyl)-tryptamine, N-(2-nitrophenyl)-tryptamine, N-(2-carboxy-4-nitrophenyl)-tryptamine, N-(4-carboxy-2-nitrophenyl)-5-methoxytryptamine, N-(2-nitrophenyl)-5-methoxytryptamine, N-(4-bromo-2-nitrophenyl)-5-methoxytryptamine, N-(3,4-dicyanophenyl)-5-methoxytryptamine, N-(2-cyano-4-nitrophenyl)-tryptamine and N-(2-nitro-4-bromophenyl)-tryptamine have a significant blocking activity on NMDA-activated currents.
|
This invention is directed to substituted aryl compounds, which are linked to a substituted indole moiety by various linkers, and the kynurenine/kynuramine-like metabolites of these agents, their preparation and pharmaceutical compositions containing these compounds. This invention further is directed to the pharmaceutical use of the compounds for inhibiting GSK3β kinase and/or modulating N-methyl-D-aspartate (NMDA) channel activities for the treatment of neurodegenerative and other disorders.
| 2
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of U.S. patent application Ser. No. 11/149,047, filed Jun. 8, 2005, which is a continuation-in-part of U.S. patent application Ser. No. 10/633,155 (now U.S. Pat. No. 6,910,832), filed Jul. 31, 2003. The entire contents of those applications are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention generally relates to systems for the support of surface structures. More specifically the present invention relates to improvements to hybrid foundation systems comprised of piles and engaging cementious components, and to the methods and processes for preparing them.
BACKGROUND OF THE INVENTION
[0003] The construction of surface structures based on the rising concern for sustainable use of materials and developable lands leads in many cases to the use of minimal ground impact foundation technologies. These technologies reduce the effects of excavation and site manipulation, thereby limiting environmental impacts to surface and subsurface water flows, and soil biological functions. They also reduce erosion by curbing the volume of excavated materials, and can in many cases provide similar structural function with less material than traditional foundation solutions.
[0004] In developing these technologies for widespread use, and therefore the greatest overall environmental benefit, cost reductions are imperative. These costs can be reduced through the development of alternate component parts, or the development of more efficient means of production.
[0005] The present invention is a result of these development efforts.
[0006] Disclosure of U.S. Pat. Nos. 5,039,256 and 6,578,333 are hereby incorporated for reference. Please also refer to U.S. Pat. No. 7,076,925, incorporated herein by reference.
OBJECTS AND SUMMARY OF THE PRESENT INVENTION
[0007] An object of this invention is to provide an improved foundation that is applicable to a wide variety of site and soil conditions, architectural typologies, loading conditions.
[0008] A further object of this invention is to provide an improved foundation that is installed with less excavation than conventional foundation systems.
[0009] An object of this invention is to provide an improved foundation that preserves the inherent structural integrity, moisture content, and biological life of its engaged soil.
[0010] An object of this invention is to provide an improved foundation that can be used as a standardized construction component.
[0011] An object of this invention is to provide an improved foundation that has some replaceable and maintainable parts.
[0012] An object of this invention is to provide an improved foundation that can withstand frost and expanding soil conditions without jeopardizing structural function.
[0013] An object of this invention is to provide an improved foundation that requires substantially less resources than current methods require.
[0014] An object of this invention is to provide an improved process for preparing a cementious structural foundation body through which piles are driven, but without the use of embedded sleeves or selectively re-enforcing elements.
[0015] The above and other objects of the present invention are realized in a novel foundation system and method based on selectively constructed diamond piers. A novel casting method is employed to create the piers, using tapered inserts and a bifurcated mold with selectively arranged openings, mounts and the like. The casting uses a cementious material with re-enforcing elements dispersed evenly therewith. The resulting cast pier is advantageously shaped for selective positioning in many different soil conditions to become a supporting foundation.
[0016] The forgoing features of the present invention are more fully described in the following detailed discussion of the specific illustrated embodiments, and in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
[0017] For a more complete understanding of the specific embodiments, FIGS. 1-6 are provided as illustrations relating to the practice of the present invention, wherein:
[0018] FIG. 1 is a section view of the primary components used in the inventive process to create the first embodiment, including a tapered dowel and a top and bottom casting form with specific features;
[0019] FIG. 2 is a side view of the components of FIG. 1 assembled with secondary components in preparation for the creation of the first embodiment;
[0020] FIG. 3 is a perspective view of the first embodiment depicting the resulting structural body created by the components in FIG. 1 , and having a cut away section which reveals the specific features;
[0021] FIG. 4 is a section view of a modified version of the primary components of FIG. 1 used now in the inventive process to create a second embodiment;
[0022] FIG. 5 is a side view of the two structural bodies the two embodiments installed in a given soil with driven piles, and including a diagram of the reactions and forces at work in the soil in relation to the shape of the bases of the embodiments and the anchoring action of the piles; and
[0023] FIG. 6 illustrates the diameters sequence and relationships necessary for the proper application of the inventive process.
DETAILED DESCRIPTION OF THE INVENTION
[0024] The present invention is an improved structural component for use in hybridized cementious head and driven pile foundation systems whereby (sleeveless) cavities for receiving driven battered piles are created within a cast structural body, shaped at its base in a pyramidal or wedge configuration to facilitate its structural integration with the surrounding soil. The cavities are created through an inventive process involving the use of a tapered dowel component and specifically shaped openings in a casting form, dimensioned and prepared for the insertion and removal of these dowels and the subsequent curing of an appropriately configured cavity and adequately re-enforced surrounding structural body. The process avoids the inclusion of sleeves or independent retaining support structures, in part, by using a cementious material with dispersed steel re-enforcing fibers. These fibers enhance the tensile strength of the resulting pier, vastly simplifying the design.
[0025] In the following discussion, like numerals are used to indicate common elements depicted in various views.
First Embodiment
[0026] Referring now to FIG. 1 , views of the primary components used in the inventive process to create the first embodiment are shown. There is a section view of a two part thermoplastic form 1 a . and 1 b , with side flanges 2 including a flange male and female interlock 3 a and 3 b . The form 1 b . has a square shaped top 4 , though this could be of any desired geometry, circular, rectangular, triangular, with a centered hole 5 for the placement of an embedded anchor bolt (see component 14 , FIGS. 2 and 3 ). The form 1 a . has an open end 6 for receiving a poured, curable cementious medium, and the subsequent placement of a pyramidal shaped plug 7 . The use of this plug 7 will be more fully described in FIGS. 2 and 3 , and in the example description. The main walls of the forms la. and 1 b . are angled at approximately 45 degrees relative to the side flanges 2 and/or the top square plane 4 . These sides contain round holes 8 in form 1 b , and opposing, corresponding dimpled round holes 9 in form 1 a. The tapered dowels 10 are of specific, continually reducing diameter to fit within the form holes 8 & 9 . The dowels may be solid in cross section or hollow provided the wall thickness, after tapering, is sufficient for casting purposes. The upper diameter 10 a . (shaded) corresponds with the form hole 9 , and will tighten to perform a pressure fit within that hole.
[0027] As the forms age and the pressure fit is worn loose, a locking clamp 11 may be used to provide the same function whereby the tapered dowel is inserted in the form assembly through hole 9 and into and through hole 8 but will only reach to a certain depth. The lower diameter 10 b . corresponds with the diameter of form hole 8 . At the thinner end of the dowel is a tapping point 12 , the function of which, along with the specific positioning of the dowel within the forms, will be described in the discussion of FIG. 2 .
[0028] FIG. 2 is a side view of the components of FIG. 1 assembled in preparation for the casting of the first embodiment. In the inventive process, form 1 b is attached by any ordinary mechanical means to a casting base 13 . This base may be of wood, steel, plastic or any suitable material to provide a firm platform for the placement of the forms on a casting table or work surface. The casting base has a hole 13 a . drilled a partial distance into the base specific to the desired final protrusion height of an anchor bolt 14 . (This bolt function will become obvious in the discussion of FIG. 3 .) Forms 1 a and 1 b are now clamped together along the side flanges 2 in any number of appropriate spots necessary to keep the forms interlocked throughout the pouring and curing process, and by any standard mechanical clamping device 15 known in general industry.
[0029] The tapered dowel 10 is then inserted through the dimple hole 9 and with its lower end through the round hole 8 . The pressure fitting of the larger diameter section of the dowel 10 a . restricts the extent to which the dowel protrudes from hole 8 . This establishes a sufficient distance, measured from the tapping point 12 of the dowel to the casting base below, to allow the free swing of a hammer or other tapping tool to strike the point and deliver an axial impact force to the dowel. The tapping point may be marred and deformed over time by repeated strikes, therefore its diameter is substantially less than that of the thinnest end of the dowel. In this fashion, deformities of the tapping point will not restrict the removal of the dowel through the cured cavity it will subsequently create.
[0030] Once the tapered dowels have been inserted (at least 2) into the form assembly, the next step involves the pouring of a cementious, curable matrix 6 a into the forms from above, through the top hole 6 . The matrix is made up of an appropriate curable medium, and in contrast to previous art or traditional pours of cementious structural bodies, no specifically configured reinforcing rod or pre-placed tensioning element is employed. The strength and mix of this medium will be more fully described in FIG. 3 . Once poured, the plugging element 7 is placed into the receiving hole 6 , and the cast body is allowed to begin its curing process. At this point the casting base may be shaken or vibrated to ensure uniform flow of the cementious medium, and additional matrix may be added through the top if necessary, and re-plugged.
[0031] The dowels will be removed during the curing process, (recognizing that for some cement, curing extends long after form extraction) but before the forms are removed from the cast body. The forms are removed after the concrete has “set,” i.e., that it can survive intact form removal. The taper of the dowels facilitates this removal as they will be extracted up and out of the forms such that the moving dowel will slide a continuously thinner diameter through the partially cured or cured cavity it has created. To facilitate its removal, the dowel may be rotated about its longitudinal axis to break any chemical bonds that may begin to form during the curing process of the medium. This rotating step may be done once or repeated several times as the variability in the setting chemistry unfolds. Assuming a set time of twenty-four hours, rotation should be performed every two hours, for the first eight hours. It may also not be necessary at all to rotate the dowel, and the it may be extracted cleanly with the simple tap on the tapping point to break any chemical bonds, and the dowel removed with a subsequent upward sliding extraction motion just prior to form removal. This rotation and extraction process can be done by hand or by mechanical or robotic means.
[0032] Once fully cured, with the dowels extracted, the forms are unclamped, the plug removed and the upper form 1 a. is lifted off the cast body. The casting base and form 1 b . assembly is then rolled to one side and the cast structural body pulled or gravity dropped from the form. The forms and components may then be cleaned and re-assembled for a subsequent casting. The resulting structural component is shown in FIG. 3 .
[0033] FIG. 3 is a perspective view of the cast structural body 16 now rotated to its application orientation with the anchor bolt 14 on top, and revealing a cut away section of one of the cast cavities 17 created by the tapered dowel. Theses cavities will receive driven piles 18 . These piles have a continuous constant diameter, smaller than the most restrictive cross-section of the tapered cavity at its lowest end. You can see at this lower end of the longitudinal cavity, the recess 19 created by the dimple hole shape in the casting form 1 a . of FIG. 1 . This recess provides protection against the breaking of the cured surface cementious material, typically referred to as a surface spall, under the loading action of the pile.
[0034] Under load, a vertical force would be applied downward on the structural body, forcing the pile, which is embedded in surrounding earth, up against the upper edge of the lower end of the cavity. This load would typically cause a surface spall since the interlocking nature of the cementious medium cannot restrain this exposed section of the body from separating and lifting away. If such a spall occurs, it leads to further spalling since a new surface has been exposed, which, similarly, cannot resist the strain of the pile.
[0035] By creating the recess 19 , the upward force of the pile is applied at a point 19 a , at a distance sufficiently setback from the surface, and thereby contained by enough surrounding medium, to resist breaking within the loading parameters of the specific structural body. As applied, this dimpling technique may be increased and varied by increasing its depth within the cast body, depending on the scale of loads anticipated and the relative interlocking strength of the curable matrix employed.
[0036] The matrix depicted herein shows a multitude of corrugated steel fibers 20 within the binding medium. Unlike the use of these fibers in other traditional cementious applications in industry, where they are employed as secondary re-enforcing, these fibers comprise the primary re-enforcing elements within the structural body. This fact is integral with the inventive process described in the discussion of FIG. 2 , since the use of these fibers directly within the matrix eliminates the costly and time consuming step of forming and placing specifically shaped re-enforcing rod components within the casting forms, and allows for easier placement, rotation and extraction of the cavity creating tapered dowels.
[0037] These fibers, through their corrugated shape and inherent tensile characteristics, significantly enhance the interlocking strength of the cured cementious medium. The proportion of fibers to matrix volume can be varied, and, as with the recessed dimple 19 , may be adjusted to the loading requirements and mix medium anticipated. A suitable matrix composition includes corrugated steel fibers, one inch in length having a one-tenth inch width, 20 mils (0.020 inches) thick, and height of corrugation around 50 mils (0.050 inches). dispersed in the concrete at a ratio of one pound fiber to fifty pounds of concrete. This results, on a volumetric basis, in three pounds of steel fiber in one cubic foot of concrete. Per se, well-known industry standard mixtures of portland cement, water and stone are adequate for this application.
[0038] FIG. 3 also reveals the shape 21 of the base of the structural body created by the plug shown in FIG. 2 . This angle shape, is similar in angular degree and function to the main sides of the cast body, which relate specifically as perpendicular planes the angle of the dowels and subsequent driven piles. The pitch of the angle may be varied and may take single or multiple forms, creating, but not limited to, conical, pyramidal or wedge shapes. Its function will be more fully defined in the discussion of FIG. 5 .
[0039] FIG. 3 also depicts a conventional bracket attachment 22 , which is bolted to the cast anchor bolt 14 . This anchor bolt provides a flexible means of structural load transfer between the structural body and attached bracket.
Second Embodiment
[0040] FIG. 4 is a variation on the first embodiment, creating a more rectilinear shaped structural body 30 , which may be cast as a block to support point loads as in the first embodiment, but is more naturally employed as a continuous or longitudinal section of fixed width and utilizing a series of paired cast cavities along its length. In this application, rather than a top and bottom form, side forms 31 a and 31 b are employed. They are connected at the top and base by a restricting element 32 preventing the lateral outward movement of the forms under internal side pressures from the cementious pour. These restricting cleats are common in industry and do not represent an inventive step. The wedge block 33 is employed similar to the plug element 7 in FIG. 2 . It is continuous along the full length of the forms, and will generate the necessary base shape 34 in the final cast body. The forms have round holes 8 in a section of the form shaped to be perpendicular to the axis of the dowel, and dimpled holes 9 .
[0041] These forms may be made of any suitable structurally stiff material which can withstand the internal forces of the curing cementious material, and be re-used for repeatable castings. Again a tapered dowel 10 is used, complete with the necessary tapping point, and appropriate diameters corresponding to the form holes.
[0042] In casting the rectilinear structural body 30 , the assembled forms, dowels and wedge block must be “book-ended” with rigid panels 35 which will restrict the flow of the cementious material. These may be integral to the side forms, or, as depicted, simply secondary components attached by some mechanical means to the side forms or restricted from movement by weights or other means external to the panels to keep them from movement during the pour and subsequent curing. It is possible as well to form an entire self contained shape such as a square or rectangle with a series of interconnected side forms and cast not a discreet block 30 , but a continuous perimeter shape such as would employed for a continuous perimeter foundation.
[0043] FIG. 5 shows the function of the wedge or pyramidal shape at the base of either embodiment, now installed with the application of driven piles into a surrounding soil. The installation involves clearing an appropriately sized opening for placing the pier. Piles are initially tapped slightly into the ground, positioning and orienting the pier. Using a sequential rotational process (e.g., clockwise), once oriented correctly, the piles are collectively driven into the ground slowly increasing their ground penetration until the necessary depth is achieved.
[0044] The shapes at the base of each embodiment act to cleave the soil when it heaves under frost or expansive soil conditions. In a traditional application, a foundation typically rests a flat horizontal surface against a given soil bearing area. If soils below this foundation heave, the foundation is lifted and this is undesirable as it can lead to concrete cracking, differential settlements and structural failure. In order to alleviate such a heaving soil pushing up against a conventional foundation, the horizontal flat base is typically set deeper in the soil, below what is referred to as the frost line (in the case of freeze thaw regions) or below the heaving line (in areas where silts and clay soils are subject to volumetric change to the addition (or deletion) of moisture). This step leads to the extensive excavation that causes dramatic impacts to building sites and surrounding areas.
[0045] The structural bodies 30 and 16 depicted are examples of minimal impact foundation systems which are typically installed in surface soils with little or no excavation well above region frost or heaving lines 80 . The cleaving shapes 21 and 34 address the problem of heave. In the diagram the number 50 represents the first soil movement that takes place when a soil begins to heave.
[0046] In this application, the upward pushing force of the soil, (a volumetric expansion at the molecular level which translates to true volumetric change in the soil medium) first tries to lift the cast structural component. The component is of course restricted from upward movement by the anchoring action of the driven piles 18 . They are still well below the heaving soil and “fight” to keep the cast component in place. But something must move since the molecular changes in the soil will not be stopped. Since there is no flat horizontal surface for the soil to push against directly, the result is that the soil spreads away from the specifically shaped cast body—it is cleaved to the side as shown in the arrow 60 . As the soil heaving works its way incrementally downward (due to the nature of freezing temperatures or moisture permeating the soil) the process continues, as in heave areas 51 & 52 and the resulting sideways motions 61 & 62 .
[0047] Having established this pattern of movement, the soil will continue to work in this way heaving away, but not directly against, the cast body, while the pins keep the system anchored in place. In this type of application, it is imperative that the lower ends of the driven pins are below the frost or heaving line in order to maintain anchoring resistance. Also, where the wedge configuration is internalized such as in the second embodiment 34 or the very center of the base of the first embodiment, that the depth 70 created by the plug or wedge block used in the casting process, is at least equal or greater than the estimated vertical heave displacement of a given site soil.
[0048] FIG. 6 again diagramatically shows the relationships between the relative diameters of the system components, where the driven piles 18 are of a constant cross section and a have a diameter x and; the tapered dowels 10 have, near the thinner end, a diameter 10 b just larger than the pile=x+c, and at the larger end, a diameter also larger than the pile but more so=x+c+c. These diameters correspond to the round hole in a given casting form 8 =x+c+c, and the dimpled hole 9 =x+c. When cast to create a tapered cavity 17 , the pile will be allowed a free sliding motion through the cavity without binding.
[0049] A variety of shapes containing these salient features, may be employed provided the primary components and relationships described herein are maintained.
[0050] The above description is merely illustrative of select embodiments of the present invention and does not, in any way, act to restrict the variations available to accomplish the inventive features therein. The foregoing inventions are solely limited by the appended claims on this patent.
|
A novel foundation system, method of manufacture and method of implementation are disclosed, comprising a simplified cast structure/pile combination advantageously shaped for selective positioning in different soil conditions to become a supporting foundation. In at least one aspect, the shape comprises a cavity or shaped recess that is initially empty, and operable to accept soil displaced by soil heave. The cavity preferably is configured to have a depth estimated to be equal to or greater that an estimated vertical heave displacement of a given site soil, in order to minimize soil heave displacement of the cast structure/pile combination. In at least one other aspect, the shape comprises a portion configured to cleave soil if the soil heaves.
| 4
|
FIELD OF INVENTION
[0001] The present invention relates to organic light emitting devices, and more particularly, to monochromatic organic light emitting devices for improving the lifetime markedly, and further relates to white organic light emitting devices for improving the lifetime markedly.
BACKGROUND OF THE INVENTION
[0002] Organic light emitting devices have attracted a lot of interests because of the advantages such as thin, large-plane, solid-state and flexible, wherein white organic light emitting devices have become focus due to demonstrated applications in the solid-state light source or as backlight for liquid crystal displays.
[0003] Bernanose. A et al. have began the studies on organic light emitting devices (hereinafter, organic light emitting device is often abbreviated as “OLED”) since 1950s, and the initial material was anthracene, because the thickness was so large and resulted in that the drive voltage was too high. Until the year 1987, a low-weight molecule OLED with the structure of ITO/Diamine/Alq 3 /Mg:Ag was reported by C. W. Tang and Vanslyke of Eastman Kodak Co. in USA, and the luminance of the device was up to 1000 cd/m 2 at the drive voltage 10V at that time, and the external quantum efficiency was 1.0%. The studies on the electroluminescent devices have attracted a lot of interests of scientists, which indicated the probabilities of applications in displays. And then the studies and the industrializations of OLEDs as prelude are opened.
[0004] The high efficiency, high luminescent intensity and color stability of OLEDs are particularly significant to their industrializations. Recent years, phosphorescent materials are introduced to OLEDs which result in that the triplet and singlet excitons are fully used, and so that the luminescent intensity and efficiency are improved markedly. However, the lifetime of blue devices and blue emitting layer of devices is the key problem combining the characteristics of OLEDs, and ways of developing long-lifetime blue materials and optimizing the structures of OLEDs are used to improve the lifetime. At the structure optimization aspect, the Chinese patent document 200510007765.9 and 200510007786.0 of sanyo disclosed a device where the lifetime was improved through introducing two kinds of dopants, and the Chinese patent document 01120883.X of Eastman Kodak disclosed a device where the lifetime was as well improved by introducing the first dopant which could accept electron-hole energy from host and the second dopant which could accept energy from hole of host. The doped luminescent layers above are all doped in single luminescent layer, and the disadvantage is the low efficiency.
SUMMARY OF THE INVENTION
[0005] It is an object of the embodiments to provide a monochromatic organic light emitting device with improved lifetime.
[0006] It is a further object of the embodiments to provide a white organic light emitting device with improved lifetime.
[0007] These objects are achieved by the following methods:
[0008] In one aspect, a monochromatic organic light emitting device, comprising:
[0009] a) a substrate;
[0010] b) an anode;
[0011] c) a cathode;
[0012] d) organic electroluminescent medium disposed between the anode and cathode;
[0013] wherein the organic electroluminescent medium comprises a compound monochromatic luminescent layer including host A doped with monochromatic dopant and host B doped with monochromatic dopant,
[0014] wherein the host A includes two kinds of materials with different transporting characteristics, one is hole-transporting material, and the other is electron-transporting material.
[0015] Wherein the compound monochromatic luminescent layer includes either of blue emitting layer, green emitting layer, red emitting layer, or yellow emitting layer.
[0016] Wherein the hole-transporting material includes triarylamine, carbazole derivatives and pyrazolin derivatives.
[0017] Wherein the chemical structure of the hole-transporting material is represented by the following formula {circle around (1)}-{circle around (3)}:
[0000]
[0018] Wherein the electron-transporting material includes anthracene, oxadiazole derivative, metal chelates and conjugated polycyclic aromatic compounds.
[0019] Wherein the chemical structure of the electron-transporting material is represented by the following formula {circle around (4)}-{circle around (7)}:
[0000]
[0020] Wherein one of the host A and the dopant thereof are the same as the host B and the dopant thereof.
[0021] Wherein the host A can be a single material with both the hole-transporting characteristic and the electron-transporting characteristic, such as CBP, and the chemical structure of CBP as follows:
[0000]
[0022] Wherein the host A doped with monochromatic dopant could be adulterated with auxiliary materials, and the auxiliary material could be another monochromatic dopant.
[0023] Wherein the monochromatic luminescent layer is blue emitting layer, and the chemical structure of the blue dopant is represented by the following formula {circle around (8)}-(13):
[0000]
[0024] Wherein the organic electroluminescent medium includes one or more of hole-injection layer, hole-transporting layer, electron-injection layer and electron-transporting layer.
[0025] In another aspect, a white organic light emitting device, comprising:
[0026] a) a substrate;
[0027] b) an anode;
[0028] c) a cathode;
[0029] d) organic electroluminescent medium disposed between the anode and cathode;
[0030] wherein the organic electroluminescent medium at least comprises one compound monochromatic light emitting layer including host A doped with monochromatic dopant and host B doped with monochromatic dopant.
[0031] wherein the host A includes two kinds of materials with different transporting characteristics, one is hole-transporting material, and the other is electron-transporting material.
[0032] Wherein the compound monochromatic luminescent layer includes either of the blue emitting layer, green emitting layer, red emitting layer, or yellow emitting layer.
[0033] Wherein the hole-transporting material includes triarylamine, carbazole derivatives and pyrazolin derivatives.
[0034] Wherein the chemical structure of the hole-transporting material is represented by the following formula {circle around (1)}-{circle around (3)}:
[0000]
[0035] Wherein the electron-transporting material includes anthracene, oxadiazole derivative, metal chelates and conjugated polycyclic aromatic compounds.
[0036] Wherein the chemical structure of the electron-transporting material is represented by the following formula {circle around (4)}-{circle around (7)}:
[0000]
[0037] Wherein one of the host A and the dopant thereof are the same as the host B and the dopant thereof.
[0038] Wherein the host A can be a single material with both the hole-transporting characteristic and the electron-transporting characteristic, such as CBP, the chemical structure of CBP in (14).
[0039] Wherein the organic electroluminescent medium includes compound blue emitting layer, green emitting layer and red emitting layer.
[0040] Wherein the organic electroluminescent medium includes compound blue emitting layer and yellow emitting layer.
[0041] Wherein the organic electroluminescent medium includes compound green emitting layer, blue emitting layer and red emitting layer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] FIG. 1 shows a cross-sectional representation of one embodiment of the structure of the blue organic light emitting device, comprising:
[0043] 01 substrate, 02 anode, 03 cathode, 04 hole-injection layer, 05 hole-transporting layer, 06 blue emitting layer 1 (with host A), 07 blue emitting layer 2 (with host B), 08 electron-transporting layer, 09 luminescent layer
[0044] FIG. 2 is a cross-sectional representation of one embodiment of the structure of the green organic light emitting device, comprising:
[0045] 01 substrate, 02 anode, 03 cathode, 04 hole-injection layer, 05 hole-transporting layer, 06 green emitting layer 1 (with host A), 07 green emitting layer 2 (with host B), 08 electron-transporting layer, 09 luminescent layer
[0046] FIG. 3 is a cross-sectional representation of one embodiment of the structure of the white organic light emitting device with two luminescent centers, comprising:
[0047] 01 substrate, 02 anode, 03 cathode, 04 hole-injection layer, 05 hole-transporting layer, 12 yellow emitting layer, 06 blue emitting layer 1 , 07 blue emitting layer 2 , 08 electron-transporting layer, 09 luminescent layer
[0048] FIG. 4 is a cross-sectional representation of one embodiment of the structure of the white organic light emitting device with three luminescent centers, comprising:
[0049] 01 substrate, 02 anode, 03 cathode, 04 hole-injection layer, 05 hole-transporting layer, 11 green emitting layer, 06 blue emitting layer 1 , 07 blue emitting layer 2 , 13 red emitting layer, 08 electron-transporting layer, 09 luminescent layer
[0050] FIG. 5 is a graph, showing the lifetime comparison of different devices of example 1
[0051] FIG. 6 is a graph, showing the lifetime comparison of different devices of example 3
[0052] FIG. 7 is a graph, showing the lifetime comparison of different devices of example 4
[0053] FIG. 8 is a graph, showing the lifetime comparison of different devices of example 5
[0054] FIG. 9 is a graph, showing the lifetime comparison of different devices of example 7
[0055] FIG. 10 is a graph, showing the lifetime comparison of different devices of example 9
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0056] The structure of the organic light emitting device in the present invention is shown in FIG. 1 , wherein
[0057] 01 is substrate which can be a glass substrate or a flexible substrate made of polyethylene terephthalate or polyimide material.
[0058] 02 is anode which can be inorganic material or organic conducting polymer. The inorganic material is commonly made of metal oxide such as such as indium-tin oxide (ITO), zinc oxide and tin-zinc oxide or some metals with high work function such as aurum(Au), copper and argentums(Ag), and a preferable anode is ITO film. The preferable organic conducting polymer anode is polyethylene dioxythiophene (PEDOTPSS for short ) or PANI films.
[0059] 03 is cathode which can be a metal material with low work function selected from lithium(Li), magnesium (Mg), calcium(Ca), Strontium(Sr), aluminum(Al), indium (In) and their alloy with copper, aurum(Au) or argentums(Ag). The cathode can also be metal and metal fluoride alternately, and a preferable cathode layer is LiF and Al.
[0060] 04 is hole-injection layer(unnecessary). The host material can be CuPc, and the inorganic material can be halide and oxide of bismuth.
[0061] 05 is hole-transporting layer. The host material can be aromatic amine and graft polymer. A preferable material is NPB. The inorganic material can be halide or oxide of bismuth.
[0062] 09 is the luminescent layer selected from low molecular weight compounds generally. The luminescent layer can be fluorescent materials such as Alq 3 , Gaq 3 , Al (Saph-q) or Ga (Saph-q), which is doped with either of fused-ring aromatic compounds (such as rubrene), coumarin (such as DMQA, C545T) or di-pyran (such as DCJTB, DCM), and the concentration is in the range of from 0.01 wt % to 20 wt %. In addition, the luminescent material can also be carbazole derivatives such as CBP, PVK, which is doped with phosphorescent material, such as Ir(ppy) 3 , Ir(ppy) 2 (acac) or PtOEP.
[0063] 08 is electron-transporting layer, commonly selected from low molecular weight electron-transporting materials containing organic metal complex (such as Alq 3 , Gaq 3 , Al(Saph-q), BAlq or Ga(Saph-q)), fused-ring aromatic compounds (such as pentacene, perylene) or o-phenanthroline (such as Bphen, BCP).
[0064] Next described are some examples and figs aimed to explain the technique scheme of the present invention, wherein the examples are only used to understand this invention well, but not limited to this invention.
EXAMPLE 1
[0065] A blue light emitting device is reported in Example 1 and the device structure is shown in FIG. 1 , wherein the luminescent layer 09 is compound blue emitting layer containing two layers 06 and 07 . The blue emitting layer 1 ( 06 ) contains host A doped with blue dopant where the host A is formed by two kinds of materials with different transporting characteristics, one of which is electron-transporting material represented by the following formula 4(BH1 for short):
[0000]
[0066] The other is hole-transporting material represented by the following formula {circle around (1)} (NPB for short):
[0000]
[0067] The formula of the blue dopant is {circle around (8)} (BD1 for short):
[0000]
[0068] The blue emitting layer 2 ( 07 ) is formed by a host B and a blue dopant, where the host B is electron-transporting material and the blue dopant is BD1, and the device has the following device structure:
[0000] ITO/NPB/BH1:NPB:BD1/BH1:BD1/Alq 3 /LiF/Al (1)
[0069] The device of device structure (1) is fabricated by the following procedures successively:
[0070] 1) A transparent glass substrate is cleaned ultrasonically with boiling scour water and deionized(DI) water. Then the substrate is dried under infra-red lamp. An anode material is deposited on the cleaned glass as an anode layer and the thickness of it is 180 nm.
[0071] 2) The cleaned anode film-coated glass substrate is put in the vacuum of about 1×10 −5 Pa, then a NPB film is vapor-deposited as a hole-transporting layer on the anode layer. The deposition rate is about 0.1 nm/s and the resulting NPB layer thickness is about 20 nm.
[0072] 3) The blue emitting layer 1 is vapor-deposited on the hole-transporting layer through the method of evaporating three materials at the same time. The weight ratio of NPB and BD1 to BH1 is respectively 20% and 3% and the thickness of this layer is 10 nm.
[0073] 4 ) The blue emitting layer 2 is subsequently vapor-deposited on the blue emitting layer 1 through the method of evaporating two materials at the same time. The deposition rate of BH1 is 0.2 nm/s and the weight ratio of BD1 to BH1 is 3%, and the thickness of this layer is 20 nm.
[0074] 5) An Alq 3 film is subsequently vapor-deposited on the blue emitting layer 2 as electron-transporting layer. The deposition rate is 0.2 nm/s and the thickness of it is 50 nm.
[0075] 6) Finally, a LiF layer and an Al layer, in sequence, are vapor-deposited as cathode on the above layers. The deposition rate of LiF is 0.01˜0.02 nm/s, and the layer thickness is 0.7 nm. The deposition rate of Al is 2.0 nm/s, and the thickness of it is 150 nm.
COMPARATIVE EXAMPLE 1
[0076] The device has the following device structure:
[0000] ITO/NPB/BH1:BD1/Alq 3 /LiF/Al (2)
[0077] The device of device structure (2) is fabricated by the following procedures successively:
[0078] The device of device structure (2) is fabricated with the same procedures as above described towards the device structure (1), except for cancelling the blue light emitting layer 1 .
COMPARATIVE EXAMPLE 2
[0079] The device has the following device structure:
[0000] ITO/NPB/BH1:NPB:BD1/Alq 3 /LiF/Al ( 3)
[0080] The device of device structure (3) is fabricated by the following procedures successively:
[0081] The device of device structure (3) is fabricated with the same procedures as above described towards the device structure (1), except for cancelling the blue light emitting layer 2 .
[0082] The following Table 1 exhibits the characteristics of these devices of Example 1 and Comparative example 1 and 2, and the corresponding graphs are shown in FIG. 5 .
[0000]
TABLE 1
Lifetime
at
the
same
initial
Device structure of
luminance
Efficiency
Devices
the luminescent layer
(h)
(cd/A)
Example 1
BH1:20%NPB:5%BD1(10 nm)/
428
5.9
BH1:5%BD1(15 nm)
Comparative
BH1:20%NPB:5%BD1(25 nm)
132
4.5
example 1
Comparative
BH1:5%BD1(25 nm)
77
6.1
example 2
[0083] It can be seen from Table 1 and FIG. 5 that the device lifetime of Example 1 is improved markedly compared to that of Comparative example 1 wherein the device has only blue luminescent layer 1 with host A, and Comparative example 2 wherein the device has only blue luminescent layer 2 with host B. Additionally, the efficiency of Example 1 is not decreased so much as higher than the devices with only blue luminescent layer 1 or 2 .
EXAMPLE 2
[0084] The device has the following device structure:
[0000] ITO/NPB/BH1:NPB(X %):BD1(Ynm)/BH1:BD1/Alq 3 /LiF/Al (4)
[0085] The device of device structure (4) is fabricated by the following procedures successively:
[0086] The device of device structure (4) is fabricated with the same procedures as above described towards the device structure (1), except for the weight ratio of NPB and BD1 to BH1 and the total thickness of the blue light emitting layer 1 , wherein the weight ratio of NPB to BH1 is X % and the layer thickness is Ynm.
[0087] The following Table 2 exhibits the characteristics of these devices with different weight ratio and thickness of Example 2.
[0000]
TABLE 2
Lifetime
Efficiency
Device structure of the luminescent layer
Xwt %
Y(nm)
(h)
(cd/A)
BH1:NPB(20%):BD1(3%)(10 nm)/BH1:BD1
20
10
500
6
BH1:NPB(40%):BD1(3%)(10 nm)/BH1:BD1
40
10
200
5.6
BH1:NPB(60%):BD1(3%)(10 nm)/BH1:BD1
60
10
200
4
BH1:NPB(20%):BD1(3%)(20 nm)/BH1:BD1
20
20
250
5
BH1:NPB(40%):BD1(3%)(20 nm)/BH1:BD1
40
20
200
4.5
BH1:NPB(60%):BD1(3%)(20 nm)/BH1:BD1
60
20
150
3.5
[0088] It can be seen from Table 2, the longest lifetime is obtained at the following condition: the weight ratio of NPB and BD1 to BH1 is 20% and 3% respectively, and the layer thickness of the blue light emitting layer 1 is 10 nm.
[0089] The marked lifetime improvement of the device having compound blue luminescent layer according to the above examples and comparative examples, may be attributed to the following reasons:
[0090] The first, effectively widening the blue emission zone can frequently prolong the lifetime of devices. Commonly, there is energy barrier, carriers mainly accumulated at the interface of HTL/BH1:BD(hole-transporting layer represented by HTL, blue host represented by BH1, blue dopant represented by BD), and uncommonly, a compound blue luminescent layer is introduced in the present invention, wherein the blue luminescent layer 1 can transport holes and electrons to the interface of BH 1 :BH 2 :BD/BH 1 :BD, due to the host A of blue luminescent layer 1 containing not only hole-transporting material but also electron-transporting material (hole-transporting layer represented by HTL, blue host with electron-transporting characteristics represented by BH1, blue host with hole-transporting characteristics represented by BH2, and blue dopant represented by BD), so the recombination zone was extended to two interfaces of HTL/BH 1 :BH 2 :BD and BH 1 :BH 2 :BD/BH 1 :BD, and the broadening of the emission zone resulted in the device having the longest lifetime. Meanwhile, the concentration of the dopant of blue light emitting layer 1 is high enough for forming continuous energy level, which effectively increase the carriers transporting, and thus, improving the device lifetime and efficiency.
[0091] Secondly, if the unrecombined holes enter the electron transporting layer Alq 3 , they will form the unstable Alq 3 cationic species that will decrease the stability of the device. But in the present invention, the blue luminescent layer 2 is inserted between the Alq 3 layer and the blue luminescent layer 1 and the holes could be blocked and consumed by recombination in the blue light emitting layer 2 . There are fewer holes to inject into Alq 3 , which prevents the formation of Alq3 + , so the stability and efficiency was enhanced.
[0092] Thirdly, comparing to comparative example 1 or 2 only with either blue light emitting layer 1 or blue light emitting layer 2 , the blue emission of the device of example 1 came from the compound blue emitting structure which consisted of the blue luminescent layer 1 and 2 , thus both of that were complementary to each other during the course of device decay which prolonged the device lifetime.
[0093] Finally, the introducing of the host A caused the enhancement of vitrification temperature. Such as NPB, its vitrification temperature is low generally, however, that was enhanced because of the doping with other materials in the blue luminescent layer 1 , which improved the heat stability of the whole device.
EXAMPLE 3
[0094] Another blue light emitting device using different blue material is reported in Example 3, and the device structure, same as Example 1, is showed in FIG. 1 . The devices also employ compound luminescent layer, wherein the electron-transporting material of blue luminescent layer 1 makes use of BAlq, and the hole-transporting material makes use of NPB, while blue dopant is TBPe. The BAlq and TBPe are also used in blue luminescent layer 2 as host and dopant respectively. The device has the following device structure:
[0000] ITO/NPB/BAlq:NPB:TBPe/BAlq:TBPe/Alq 3 /LiF/Al (5)
[0095] The device of device structure (5) is fabricated by the procedure similar to Example 1
COMPARATIVE EXAMPLE 3
[0096] The device has the following device structure:
[0000] ITO/NPB/BAlq:TBPe/Alq 3 /LiF/Al (6)
[0097] The device of device structure (6) is fabricated by the following procedures successively:
[0098] The device of device structure (6) is fabricated with the same procedures as above described towards the device structure (5), except for cancelling the blue light emitting layer 1 .
COMPARATIVE EXAMPLE 4
[0099] The device has the following device structure:
[0000] ITO/NPB/BAlq:NPB:TBPe/Alq 3 /LiF/Al (7)
[0100] The device of device structure (7) is fabricated by the following procedures successively:
[0101] The device of device structure (7) is fabricated with the same procedures as above described towards the device structure (5), except for cancelling the blue light emitting layer 2 .
[0102] The following Table 3 exhibits the characteristics of these devices of Example 3 and Comparative example 3 and 4, and the corresponding graphs are shown in FIG. 6 .
[0000]
TABLE 3
Lifetime
at the
same
initial
Device structure of
luminance
Efficiency
Devices
the luminescent layer
(h)
(cd/A)
Example 3
BAlq:20%NPB:3%TBPe(10 nm)/
125
4.3
BAlq:3%TBPe(15 nm)
Comparative
BAlq:3%TBPe(25 nm)
16.3
4.4
example 3
Comparative
BAlq:20%NPB:3%TBPe(25 nm)
35
2.3
example 4
[0103] It can be seen from Table 3 and FIG. 6 that the device lifetime of example 3 is improved markedly compared to that of Comparative example 3 and 4. Additionally, the efficiency of Example 3 is not decreased.
EXAMPLE 4
[0104] A green light emitting device is reported in Example 4 and the device structure is shown in FIG. 2 , wherein the luminescent layer 09 is compound green emitting layer containing two layers:layer 10 and layer 11 . The green emitting layer 1 ( 10 ) contains host A doped with green dopant where the host A is formed by two kinds of materials with different transporting characteristics, one of which is electron-transporting material BAlq, the other is hole-transporting material NPB, and the green dopant is C545T. The green emitting layer 2 ( 11 ) is formed by a host B and a green dopant, where the host B is electron-transporting material BAlq and the green dopant is C545T, and the device has the following device structure:
[0000] ITO/NPB/BAlq:NPB:C545T/BAlq:C545T/Alq 3 /LiF/Al (8)
[0105] The device of device structure (8) is fabricated by the procedure similar to Example 1.
COMPARATIVE EXAMPLE 5
[0106] The device has the following device structure:
[0000] ITO/NPB/ BAlq:C545T/Alq 3 /LiF/Al (9)
[0107] The device of device structure (9) is fabricated by the following procedures successively:
[0108] The device of device structure (9) is fabricated with the same procedures as above described towards the device structure (8), except for cancelling the green emitting layer 1 .
COMPARATIVE EXAMPLE 6
[0109] The device has the following device structure:
[0000] ITO/NPB/BAlq:NPB:C545T/Alq 3 /LiF/Al (10)
[0110] The device of device structure (10) is fabricated by the following procedures successively:
[0111] The device of device structure (10) is fabricated with the same procedures as above described towards the device structure (8), except for cancelling the green emitting layer 2 .
[0112] The following Table 4 exhibits the characteristics of these devices of Example 4 and Comparative example 5 and 6, and the corresponding graphs are shown in FIG. 7 .
[0000]
TABLE 4
Lifetime at
the same
initial
Device structure of
luminance
Efficiency
Device
the luminescent layer
(h)
(cd/A)
Example 4
BAlq:20%NPB:2%
895
10.1
C545T(10 nm)/
BAlq:2%C545T (15 nm)
Comparative
BAlq:2%C545T(25 nm)
118
10.5
example 5
Comparative
BAlq:20%NPB:2%
252
8.1
example 6
C545T(25 nm)
[0113] It can be seen from Table 4 and FIG. 7 that the device lifetime of Example 4 is improved markedly compared to that of Comparative example 5 and 6. Additionally, the efficiency of Example 4 is not decreased.
EXAMPLE 5
[0114] A white organic light emitting device with two luminescent centers is reported in Example 5 and the device structure is shown in FIG. 3 , wherein the luminescent layer 09 includes yellow emitting layer 12 and compound blue emitting layer containing two layers:blue emitting layer 1 ( 06 ) and blue emitting layer 2 ( 07 ). The yellow emitting layer 12 is formed by hole-transporting material NPB and yellow dopant (such as rubrene). The blue emitting layer 2 ( 07 ) includes electron-transporting material BH1 and blue dopant BD1, and the blue emitting layer 1 ( 06 ) includes host A doped with green dopant where the host A is formed by two kinds of materials with different transporting characteristics, one of which is electron-transporting material BH1, the other is hole-transporting material NPB. The preferable device has the following device structure:
[0000] ITO/NPB/NPB:rubrene/BH1:NPB:BD1/BH1:BD1/Alq 3 /LiF/Al (11)
[0115] The white organic light emitting device of device structure (11) is fabricated by the following procedures successively:
[0116] 1) A transparent glass substrate is cleaned ultrasonically with boiling scour water and deionized(DI) water. Then the substrate is dried under infra-red lamp. An anode material is deposited on the cleaned glass as an anode layer and the thickness of it is 180 nm.
[0117] 2) The cleaned anode film-coated glass substrate is put in the vacuum of about 1×10 −5 Pa, then a NPB film is vapor-deposited as a hole-transporting layer on the anode layer. The deposition rate is about 0.1 nm/s and the resulting NPB layer thickness is about 20 nm. And then a yellow emitting film is vapor-deposited on the hole-transporting layer through the method of evaporating two materials at the same time. The deposition rate of NPB is 0.2 nm/s and the weight ratio of rubrene to NPB is 2 wt %, and the thickness of this layer is 15 nm.
[0118] 3) The blue emitting layer 1 is vapor-deposited on the yellow emitting layer through the method of evaporating three materials at the same time. The weight ratio of NPB and BD1 to BH1 is respectively 20% and 3% and the thickness of this layer is 10 nm.
[0119] 4 ) The blue emitting layer 2 is subsequently vapor-deposited on the blue emitting layer 1 through the method of evaporating two materials at the same time. The deposition rate of BH1 is 0.2 nm/s and the weight ratio of BD1 to BH1 is 3%, and the thickness of this layer is 20 nm.
[0120] 5) An Alq 3 film is subsequently vapor-deposited on the second blue emitting layer as electron-transporting layer. The deposition rate is 0.2 nm/s and the thickness of it is 50 nm.
[0121] 6) Finally, a LiF layer and an Al layer, in sequence, are vapor-deposited as cathode on the above layers. The deposition rate of LiF is 0.01˜0.02 nm/s, and the layer thickness is 0.7 nm. The deposition rate of Al is 2.0 nm/s, and the thickness of it is 150 nm.
COMPARATIVE EXAMPLE 7
[0122] The device has the following device structure:
[0000] ITO/NPB/NPB:rubrene/BH1:BD1/Alq 3 /LiF/Al (12)
[0123] The white organic light emitting device of device structure (12) is fabricated by the following procedures successively:
[0124] The device of device structure (12) is fabricated with the same procedures as above described towards the device structure (11), except for cancelling the green emitting layer 1 .
COMPARATIVE EXAMPLE 8
[0125] The device has the following device structure:
[0000] ITO/NPB/NPB:rubrene/BH1:NPB:BD1/Alq 3 /LiF/Al (13)
[0126] The white organic light emitting device of device structure (13) is fabricated by the following procedures successively:
[0127] The device of device structure (13) is fabricated with the same procedures as above described towards the device structure (11), except for cancelling the green emitting layer 2 .
[0128] The following Table 5 exhibits the characteristics of these devices of Example 5 and Comparative example 7 and 8, and the corresponding graphs are shown in FIG. 8 .
[0000]
TABLE 5
Lifetime
Efficiency
Device
Device structure of the luminescent layer
(h)
(cd/A)
Color
Example 5
NPB:rubrene/BH1:20%NPB:3%BD1(10 nm)/
312
10
White
BH1:3%BD1(20 nm)
Comparative
NPB:rubrene/BH1:3%BD1(20 nm)
66
10.3
White
example 7
on the
yellow
side
Comparative
NPB:rubrene/BH1:20%NPB:3%BD1(20 nm)
142
8.3
White
example 8
EXAMPLE 6
[0129] The device has the following device structure:
[0000] ITO/NPB/NPB:DCM/BAlq:NPB(X %):TBPe(Ynm)/BAlq:TBPe/Alq 3 /LiF/Al (14)
[0130] The white organic light emitting device of device structure (14) is fabricated by the following procedures successively:
[0131] The device of device structure (14) is fabricated with the same procedures as above described towards Example 5, except for different materials' weight ratio and total thickness, wherein the weight ratio of NPB and TBPe to BAlq is X % and 3% respectively, and the layer thickness is Ynm.
[0132] The following Table 6 exhibits the characteristics of these devices with different weight ratio and thickness of Example 6.
[0000]
TABLE 6
Device structure of the compound blue
Lifetime
Efficiency
emitting layer
Xwt %
Y(nm)
(h)
(cd/A)
Color
BAlq:NPB(20%):TBPe(3%)(10 nm)/BAlq:TBPe
20
10
803
8
White
BAlq:NPB(40%):TBPe(3%)(10 nm)/BAlq:TBPe
40
10
507
7.5
White
BAlq:NPB(60%):TBPe(3%)(10 nm)/BAlq:TBPe
60
10
411
6
White
on the
blue
side
BAlq:NPB(20%):TBPe(3%)(20 nm)/BAlq:TBPe
20
20
453
7
White
BAlq:NPB(40%):TBPe(3%)(20 nm)/BAlq:TBPe
40
20
387
6.5
White
BAlq:NPB(60%):TBPe(3%)(20 nm)/BAlq:TBPe
60
20
344
5.5
White
on the
blue
side
[0133] It can be seen from Table 6 that the longest lifetime is obtained at the following condition: the weight ratio of NPB and TPBe to BAlq is 20% and 3% respectively, and the layer thickness of the blue light emitting layer 1 is 10 nm.
EXAMPLE 7
[0134] Another white organic light emitting device with three luminescent centers is reported in Example 7 and the device structure is shown in FIG. 4 , wherein the luminescent layer 09 includes green emitting layer 11 , compound blue luminescent layer containing the blue emitting layer 1 ( 06 ) and the blue emitting layer 2 ( 07 ), and the red emitting layer 13 , wherein the green emitting layer 11 includes NPB as host and Ir(ppy) 3 as green dopant; the blue emitting layer 2 ( 07 ) includes electron-transporting material BAlq as host and TBPe as blue dopant; the emitting layer 1 ( 06 ) includes host A doped with blue dopant and the host A is formed by two kinds of materials with different transporting characteristics; the red emitting layer includes Alq 3 as host and DCJTB or Ir(piq) 2 (acac) as red dopant. The preferable device has the following device structure:
[0000] ITO/NPB/NPB:C545T/BAlq:NPB:TBPe/BAlq:TBPe/Alq 3 :Ir(piq) 2 (acac)/Alq 3 /LiF/Al (15)
[0135] The white organic light emitting device of device structure (15) is fabricated by the following procedures successively:
[0136] 1) A transparent glass substrate is cleaned ultrasonically with boiling scour water and deionized(DI) water. Then the substrate is dried under infra-red lamp. An anode material is deposited on the cleaned glass as an anode layer and the thickness of it is 180 nm.
[0137] 2) The cleaned anode film-coated glass substrate is put in the vacuum of about 1×10 −5 Pa, then a NPB film is vapor-deposited as a hole-transporting layer on the anode layer. The deposition rate is about 0.1 nm/s and the resulting NPB layer thickness is about 20 nm. And then a green emitting film is vapor-deposited on the hole-transporting layer through the method of evaporating two materials at the same time. The deposition rate of NPB is 0.2 nm/s and the weight ratio of C545T to NPB is 2 wt %, and the thickness of this layer is 15 nm.
[0138] 3) The blue emitting layer 1 is vapor-deposited on the green emitting layer through the method of evaporating three materials at the same time. The weight ratio of NPB and TBPe to BAlq is respectively 20% and 3% and the thickness of this layer is 20 nm.
[0139] 4 ) The blue emitting layer 2 is subsequently vapor-deposited on the blue emitting layer 2 through the method of evaporating two materials at the same time. The weight ratio of TBPe to BAlq is 3%, and the thickness of this layer is 20 nm.
[0140] 5) A red emitting film is vapor-deposited on the blue emitting layer 2 through the method of evaporating two materials at the same time. The weight ratio of Ir(piq) 2 (acac) to Alq 3 is 5%, and the thickness of this layer is 10 nm.
[0141] 6) An Alq 3 film is subsequently vapor-deposited on the red emitting layer as electron-transporting layer. The deposition rate is 0.2 nm/s and the thickness of it is 50 nm.
[0142] 7) Finally, a LiF layer and an Al layer, in sequence, are vapor-deposited as cathode on the above layers. The deposition rate of LiF is 0.01˜0.02 nm/s, and the layer thickness is 0.7 nm. The deposition rate of Al is 2.0 nm/s, and the thickness of it is 150 nm.
COMPARATIVE EXAMPLE9
[0143] The device has the following device structure:
[0000] ITO/NPB/NPB:C545T/BAlq:TBPe/Alq 3 :Ir(piq) 2 (acac)/Alq 3 /LiF/Al (16)
[0144] The white organic light emitting device of device structure (16) is fabricated by the following procedures successively:
[0145] The device of device structure (16) is fabricated with the same procedures as above described towards device (15), except for cancelling the blue emitting layer 1 .
COMPARATIVE EXAMPLE 10
[0146] The device has the following device structure:
[0000] ITO/NPB/NPB:C545T/BAlq:NPB:TBPe/Alq 3 :Ir(piq) 2 (acac)/Alq 3 /LiF/Al (17)
[0147] The device of device structure (17) is fabricated with the same procedures as above described towards device (15), except for cancelling the blue emitting layer 2 .
[0148] The following Table 7 exhibits the characteristics of these devices of Example 7 and Comparative example 9 and 10, and the corresponding graphs are shown in FIG. 9 .
[0000]
TABLE 7
Lifetime
Efficiency
Device
Device structure of the luminescent layer
(h)
(cd/A)
Color
Example 7
NPB:C545T/BAlq:20%NPB:3%TBPe(20 nm)/
248
14.8
White
BAlq:3%TBPe(20 nm)/Alq 3 :Ir(piq) 2
(acac)
Comparative
NPB:C545T/BAlq:3%TBPe(20 nm)/Alq 3 :
72
15
White
example 9
Ir(piq) 2 (acac)
Comparative
NPB:C545T/BAlq:20%NPB:3%TBPe(20 nm)/
128
11
White
example 10
Alq 3 :Ir(piq) 2 (acac)
on the
red side
[0149] It can be seen from Table 7 and FIG. 9 that the device lifetime of Example 7 is improved markedly compared to that of Comparative example 9 and 10. Additionally, the device efficiency of Example 7 is not decreased.
EXAMPLE 8
[0150] A white organic light emitting device with two luminescent centers is reported in Example 8, wherein the luminescent layer includes yellow emitting layer, the blue emitting layer 1 and the blue emitting layer 2 , wherein the blue emitting layer 1 contains a host B with both the hole-transporting characteristic and the electron-transporting characteristic.
[0151] The preferable device has the following device structure:
[0000] ITO/NPB/NPB:rubrene/CBP:TBPe/BAlq:TBPe/Alq 3 /LiF/Al (18)
[0152] The device of device structure (18) is fabricated with the same procedures as above described towards Example 5, except for changing the blue emitting layer 1 which contains a host B CBP. The deposition rate of CBP is 0.1 nm/s and the weight ratio of TBPe is 3%. The thickness of the blue emitting layer 1 and the blue emitting layer 2 is 10 nm and 20 nm respectively.
[0153] Meanwhile, the following comparative devices are fabricated with the same procedures:
[0000] ITO/NPB/NPB:rubrene/BAlq:TBPe/Alq 3 /LiF/Al (19)
[0000] ITO/NPB/NPB:rubrene/CBP:TBPe/Alq 3 /LiF/Al (20)
[0154] The following Table 8 exhibits the characteristics of these devices.
[0000]
TABLE 8
Device structure of
Lifetime
Efficiency
the luminescent layer
(h)
(cd/A)
color
NPB:rubrene/CBP:3%TBPe(10 nm)/
775
9
White
BAlq:3%TBPe(20 nm)
NPB:rubrene/CBP:3%TBPe(20 nm)/
601
7.9
White
BAlq:3%TBPe(20 nm)
NPB:rubrene/BAlq:3%TBPe(20 nm)
497
9
White
NPB:rubrene/CBP:3%TBPe(10 nm)
452
7.5
White
on the
yellow
side
[0155] It can be seen from Table 8 that the lifetime of the device using a host B with both the hole-transporting characteristic and the electron-transporting characteristic in the blue emitting layer 1 and blue emitting layer 2 is improved markedly compared to that of comparative devices, meanwhile, the device efficiency of Example 8 is not decreased. The longest lifetime is obtained at the following condition: the weight ratio of TBPe is 3%, and the layer thickness of the blue light emitting layer 1 is 10 nm.
[0156] Additionally, the dopant of the blue emitting layer can also be either BCzVBi, BCzVB, DPAVBi, DPAVB, BDAVBi or N-BDAVBi.
EXAMPLE 9
[0157] A white organic light emitting device including a compound blue emitting layer is reported in Example 9, wherein the blue emitting layer 1 and blue emitting layer 2 both contain a yellow dye. The blue emitting layer 1 contains host A and a blue dopant, and the host A includes an electron-transporting material and a hole-transporting material. The blue emitting layer 2 contains an electron-transporting material and a blue dopant.
[0158] The preferable device has the following device structure:
[0000] ITO/NPB/BH1:NPB:BD1:rubrene/BH1:BD1:rubrene/Alq 3 /LiF/Al (21)
[0159] The white organic light emitting device of device structure (21) is fabricated by the following procedures successively:
[0160] The device above is fabricated with the same procedures as above described towards Examples, and the differences are the blue emitting layer 1 through the method of evaporating four materials at the same time and the thickness of it is 10 nm. The blue emitting layer 2 through the method of evaporating three materials at the same time and the thickness of it is 15 nm.
[0161] Meanwhile, the following comparative devices are fabricated with the same procedures:
[0000] ITO/NPB/BH1:BD1:rubrene/Alq 3 /LiF/Al (22)
[0000] ITO/NPB/BH1:NPB:BD1:rubrene/Alq 3 /LiF/Al (23)
[0162] The following Table 9 exhibits the characteristics of these devices of Example 9 and Comparative examples, and the corresponding graphs are shown in FIG. 10 .
[0000]
TABLE 9
Lifetime
at the
same
initial
luminance
Efficiency
Device
Device structure of the luminescent layer
(h)
(cd/A)
Color
Example 9
BH1:20%NPB:5%BD1:0.5%rubrene(10 nm)/
1400
11.3
White
BH1:5%BD1:0.5%rubrene (15 nm)
Comparative
BH1:5%BD1:1%rubrene(25 nm)
663
11.8
White
example
11
Comparative
BH1:20%NPB:5%BD1:1%rubrene(25 nm)
834
9.6
White
example
12
|
The present invention relates to monochromatic organic light emitting devices. The organic light emitting device includes a substrate, an anode, a cathode and an organic electroluminescent medium disposed between the anode and the cathode, wherein the organic electroluminescent medium includes compound monochromatic luminescent layer; and the compound monochromatic luminescent layer includes host A doped with monochromatic dopant and host B doped with monochromatic dopant, wherein the host A is consisted of two kinds of materials with different transporting characteristics, one is hole-transporting material, and the other is electron-transporting material. In addition, the present invention further relates to white organic light emitting devices, wherein the organic electroluminescent medium is consisted of at least one compound monochromatic luminescent layer, which includes host A doped with monochromatic dopant and host B doped with monochromatic dopant. The present invention provides a design to improve the lifetime of the organic light emitting device markedly.
| 8
|
BACKGROUND OF THE INVENTION
This invention relates to a visual camera surveillance system that rides along track cables. The operation of the camera system is controlled from a remote location. Such movable unmanned cameras would find particular application in remote outdoor locations where having a camera operator on site would be expensive and not practical due to weather or other conditions. Examples of outdoor locations that would employ such movable camera systems include highways, fences, railroads, rivers, border crossings, beaches, etc.
Visual surveillance systems using video camera are known. Some such systems use an on site video camera whose data is continuously recorded and then preserved or erased to make room for other subsequent data depending on whether or not an awaited event occurred during the recording on that recording period.
In another vision processing system traffic flow is detected and monitored by generating successive images of sections of the roadway, transducing the images into arrays of pixels where each pixel has a luminance value and then summing the values for all pixels. These summed values are then compared to a reference value to generate data when the difference is great enough.
Another road section monitoring system recognizes obstacles in the road such as wave flooding, land slip, etc. Data based on the detected obstacles, measured are taken and drivers informed of the results.
Another traffic surveillance process and device is used to measure the speed of a vehicle within a traffic scene, optically record the traffic scene, and reproduce the traffic scene on a display in synchronism with the display of the measured speed.
DESCRIPTION OF THE PRIOR ART
Devices that record and transmit visual images from remote locations are known. For example, in the U.S. Pat. No. 4,977,451 to Besnard an on site video camera is used to continuously recorded and then conserved or erased data sections to make room for other subsequent data depending on whether or not the awaited event occurred during the recording on in a section.
U.S. Pat. No. 5,296,852 to Rathi discloses a vision processing system wherein traffic flow is detected and monitored by generating successive images of sections of the roadway, transducing the images into arrays of pixels with each pixel having a luminance value and then summing the values for all pixels. These summed values are then compared to a reference value to generate data when the difference is great enough.
U.S. Pat. No. 5,486,819 to Horie discloses a road obstacle monitoring device which recognizes obstacles in the road such as wave flooding, land slip, etc. Data based on the detected obstacles are measured and drivers are informed of the results.
U.S. Pat. No. 5,767,794 to Borsch et al. discloses a traffic surveillance process and device used to measure the speed of a vehicle within a traffic scene, optically record the traffic scene, and reproduce the traffic scene on a display in synchronism with the display of the measured speed.
In contrast to such visual processing systems, the present invention utilizes a movable carriage for a video camera which rides along a track system. The carriage's operation and the transported camera are both controlled from a remote location all as detailed hereafter.
SUMMARY OF THE INVENTION
This invention relates to a remotely controlled camera and a carriage mount for the camera which move along a track system that supplies electrical power to operate the carriage and the camera.
It is the primary object of the present invention to provide for an improved visual surveillance system for remote locations.
Another object is to provide for such a system wherein a remotely controlled camera is transported by a movable carriage that rides along a track system which provides guidance and support for the carriage.
These and other objects and advantages of the present invention will become apparent to readers from a consideration of the ensuing description and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of the surveillance camera vehicle and part of the track system of the present invention.
FIG. 2 is a side view of the surveillance camera vehicle of FIG. 1 along with the carried camera.
FIG. 3 is a end view of the surveillance camera vehicle of FIG. 1 along with the carried camera.
FIG. 4 is an enlarged view of the rollers as they engage the cable shown in FIG. 3 .
FIG. 5 is a schematic representation of how electric power can be supplied to the tracks.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a top view of the surveillance camera vehicle and part of the track system of the present invention. The surveillance camera vehicle 1 acts as the carriage to transport the video camera (not shown in this view) which rides underneath the carriage. Shown supported and fixed to the top of the carriage's flat platform 3 are two facing spaced electric motors 5 and 7 each of which is used to operate two facing propellers 9 and 11 , respectively. Supporting the carriage 1 are two spaced parallel track cables 13 . These cables are in turn supported above the ground by a superstructure 15 which extends between the cables and is mounted by a bracket 17 to the upright vertical member 19 , shown in cross section. Member 19 can be an existing upright member, such as a wooden utility pole, or may be a member specifically placed into the ground to extend upwardly therefrom to provide vertical support for superstructure is and the tracks system 13 .
Conventional electrical conduits within the internal structure of the tracks 13 are used to supply electrical power to run the propeller operating electrical motors 5 and 7 . By operating one of these motors at a time, the propeller for that motor propels the carriage 1 in one direction along the tracks 13 . In a complete track system there would be many spaced vertical members 19 located along the path of desired travel each having a cantilevered bracket 17 and superstructure 15 to suspend the attached tracks 13 above the ground. Between the tracks 13 and the bottom of platform 3 is a track spanning rubber bar member 20 carried with and attached to the platform. A conventional electrically operated solenoid 22 fixed to the bar member 20 and the platform 3 causes the bar to reciprocate vertically when actuated to contact the tracks 13 and act as a brake to stop the movement of the carriage. Normally, the solenoid 22 and its carried bar 20 are spaced above the lower tracks 13 as the carriage moves along the tracks and then lower when stopping of the carriage is desired.
FIG. 2 is a side view of the surveillance camera vehicle 1 of FIG. 1 along with its carried lower conventional video camera 21 having power zoom and focusing capabilities. The vertical support structure 23 extending from the platform 3 for the depending camera 21 can be moved upward and downwardly like a telescope or rotated by an internal conventional electrically powered motor (not shown) when in use to allow for a completely unobstructed view by the camera. The same support structure also allows the camera to be independently rotated around a center axis 360 degrees when in its surveillance mode. To prevent damage to the camera while traveling along the supporting tracks 13 , the camera is normally retained in an elevated position, as shown, with respect to the ground such that the carriage sides 25 and 27 provide some lateral protection. When in a lowered position, shown by the dotted lines, the camera 21 is in its observation mode and has an unobstructed view in all directions.
The rigid depending carriage sides 25 and 27 function to support the platform 3 above the tracks 13 . Two sets of identical rollers whose axles are mounted to the sides 25 and 27 engage the circular in cross section tracks 13 on each track side. The upper track engaging rollers 29 (shown in dotted line format) are large diameter short rollers while the lower track engaging rollers 31 are two long rollers of smaller diameter (also, shown in dotted line format). The end of rubber carriage stopping bar 20 is shown in its lowered track engaging position with the attached solenoid 22 above the bar. The parallel spaced rear track 13 immediately behind the front track 13 in FIG. 2 is not shown but would have the same identical depending carriage sides and two sets of rollers to support the rear side of carriage 1 . This set up allows the supported carriage 1 to moved along the support guide way formed by the tracks 13 in an almost frictionless fashion when one of the propellers is operated to cut through the air to drive the carriage along the tracks. To stop the moving carriage, the solenoid is actuated to lower its carried stopping bar 20 into engagement with the tracks, as shown. When movement of the carriage is desired again, the bar is raised by deactivating the solenoid.
FIG. 3 is a end view of the surveillance camera vehicle or carriage 1 of FIG. 1 along with the carried camera 21 . The two identical inwardly and downwardly slanting sides 27 for the carriage 1 have cut out internal portions that are shaped to receive the axles for the three rollers 29 and 31 . The axle for each of the two shown larger diameter rollers 29 extends through the roller at its center and is journal led at its ends into the cut out portion of the side 27 . Below each of these large diameter rollers are two smaller diameter rollers 31 that are elongated in appearance as shown. Each of the three rollers for each carriage side bear against the track 13 whose circular cross section is shown. Thus there are twelve rollers in all, six on each side of the two carriage sides, as shown in FIG. 3, that engage the two spaced tracks at four different locations along the carriage's undersurface. The upper extending free ends 33 for each of the two bracket extensions 35 and 37 are fixed to the rounded cables 13 to vertically support them. By making the lower gap between adjoining two inwardly facing sides of the cut out portions (just below the extension ends 33 ) for each carriage side 27 smaller than the diameter of the enclosed cable 13 the carriage cannot be dislodged from the supporting lower cable but may ride along its length. The carried solenoid actuated braking system (solenoid 22 and rubber bar 20 ) located between the roller 29 and the vertical support structure 23 over the tracks has been omitted from this view to simply the figure.
FIG. 4 is an enlarged view of the three rollers as they engage the cable 13 shown in FIG. 3 . Looking in the direction of the arrows A—A in FIG. 3 upwardly along the length of bracket extensions 35 and 37 , the circular cross section cable 13 , a section of which is shown, would have its upper surface in engagement with the roller 29 . A center axle 34 extends through roller 29 and is journal led at its two opposite ends into the upper cut out portion of side 27 . Closer to the observer on both sides of the cable 13 are the two identical rollers 31 . Axles 35 extends through the length of each roller 31 and have their opposite ends journal led into upper and lower cut out sides. The side rollers 31 are slightly spaced from the cable 13 and may engage the cable if the carriage 1 tilts slightly when moving along the cable 13 .
FIG. 5 is a schematic representation of how electric power can be supplied to the tracks to provide for the operation of the carriage and the transported camera. The carriage 1 and its attached camera are not shown in this figure but receive electrical power through conventional internal wiring connections in the carriage. Each of the two extension brackets 35 and 37 have their upper terminal free ends 33 fixed to the carriage 1 supporting track cable 13 . Each of the extension brackets have lower base portions 39 and 41 , respectively, that are bolted or otherwise fixed mounted on support member 15 . Both the extensions 35 and 37 and their connected bases are made of electrically conductive material such as steel, cooper, aluminum, etc. The base supporting and connecting lower member 15 - 17 and the upright member 19 are all made of an electrically insulating material such as fiberglass, wood, plastic, etc. Power lines 43 and 45 are connected to the bolts 42 which are used to fix the two bases to lower members 15 - 17 . Each power line is connected to a separate holder having different electrical polarities. Thus, line 45 has a negative polarity while line 43 is given a positive polarity. Both lines are also connected to the remote operator's control center 53 . Separately connected to each of the power lines 43 and 45 are two other power lines 47 and 49 . These latter lines 47 and 49 are internally wired to a conventional intermediate electronic unit 51 which functions as a nearby controller to regulate the signals sent to and from the camera and to control the power being supplied from hot lines 43 and 45 to the carriage and its transported camera 21 . Many of the individual subcomponents used to control the movement and stopping of the carriage 1 and the movement of the camera are conventional. For example, the mechanisms to control the movement of the carriage 1 along the tracks and the stopping solenoid 22 and its attached rubber bar 20 which frictionally engages the tracks 13 are all off-the-shelf items. Also, conventional are the specific electrically operated mechanisms used to lower, raise and rotate the camera 21 . When spaced long distances apart, like miles, each spaced superstructure could have essentially the same set up to receive and control the movement of the carriage and its associated camera and to receive and record signals at the remote location 53 of visual images detected along the way of the track system.
Although the preferred embodiment of the present invention and the method of using the same has been described in the foregoing specification with considerable details, it is to be understood that modifications may be made to the invention which do not exceed the scope of the appended claims and modified forms of the present invention done by others skilled in the art to which the invention pertains will be considered infringements of this invention when those modified forms fall within the claimed scope of this invention.
|
An unmanned visual monitoring system used outdoors to patrol large expanses of space such as along highways, fences, railroad lines, rivers, borders, beaches, etc. Guidance and support for the unmanned surveillance camera carriage vehicle, as well as the electrical power for its operation, are provided to the carriage and camera by conductive track cables. Spaced superstructures having upright poles and a cantilever extension placed along the track system length act to vertically support the system above the ground. At a remote control center location from the carriage, an operator can control the movement of the vehicle and the operation of the video camera. Operational electrical power for moving the carriage and controlling the camera's movement are supplied via power lines connected at different polarities to the track cables of the track system.
| 5
|
This is a continuation-in-part of co-pending application Ser. No. 865,591 filed on May 16, 1986, now abandoned.
BACKGROUND OF THE INVENTION
Applicant is owner of co-pending U.S. patent application Ser. No. 724,097, filed April 17, 1985, and entitled IMPROVEMENTS TO CORRUGATING MACHINES, now abandoned.
The present invention relates generally to corrugating machines, and more specifically to improvements to units that adhesively laminate either mediums or liners prior to their connection together, apply coatings to either of these, and/or impregnate either or both with performance enhancing chemicals. This invention significantly improves the performance to cost of corrugated paper packaging, and has dramatic applications in packaging heavy items and fresh food products.
The unit referred herein includes means to meter the adhesives or coatings onto an intaglio roll surface which is then used to transfer or "print" such adhesive material onto a web surface, and includes mechanisms to maintain predetermined contact between such web surfaces and the surface of the intaglio roll. The invention can be used to laminate two or more mediums to be corrugated to produce what is commonly referred to as dual or multi-arch corrugated member, yet can also be used to laminate liners to each other for either strength enhancing or graphic results, or simply to apply surface coatings or impregnations for such purposes as moisture barriers, scuff resistance or web coloring, the use of which was either very difficult or impractical under prior art methods.
DESCRIPTION OF THE RELATED ART
There exists an increasing need for a corrugating machine capable of producing combined board having increased strength properties, as well as variable coating and/or impregnation capacities. These properties need to be applied to either the fluted medium, the flat liners, or both, and need to be capable of being applied when the individual rolls of materials are combined into the corrugated product. These needs must be fulfilled in a device that is consistent with the application rate, simplicity of operation, economy in production, as well as flexible for various applications of materials and flow rates. The subject improvements should also be compatible for incorporating into existing corrugating machines with minimal change and expense.
The typical corrugating process involves the fluting or corrugating of a web called a "medium", and attaching this fluted medium to a facer member or liner by a machine known as a single-facer. Such combined fluted and flat members can then be attached to another facer liner on the opposite side of the fluted peaks by a machine known as a double-facer. The in-line collection of such machines performs the entire process and is called a "corrugator". The majority of the vertical strength in the final product is the result of the fluted web. To increase strength it has heretofore been the practice to increase the basic weight, and therefore the thickness of the web material that is fluted. However, as the thickness increases, it becomes more difficult to accurately form the fluted curvatures because the medium tends to fracture on the outer radii at the flute bends and in direct proportion to the thickness of the medium. The more costly but heretofore most practical alternative to thicker mediums has been to increase the liner basic weight and/or to add additional fluted plys into what is known as "doublewall" or "triplewall" board. It has also been apparent in the industry that the ability to apply other chemicals at the corrugator which would enhance the original liner and medium properties would be beneficial, if a device could be developed that would have both practical operating capabilities as well as economic results.
Most existing coating devices use either a three-roll metering/applicator/hold down system in contact with the web medium, or a "squeegee" blade backing a fluid puddle onto the surface of the advancing web. Devices capable of producing a dual or double thickness medium have generally used either a very crude gravity flow of the adhesive stream or streams onto the lower of two advancing webs to be laminated or they have used a squeegee blade and puddle, or some other complex system such as those disclosed in U.S. Pat. Nos. 4,495,011 and 4,498,943. Prior to this invention it has not been practical to flute more than two plys of medium, hence the industry's terminology has been restricted to "dual" arch. As used herein, "dual arch" and any number of multiple plys are considered to be synonymous, and not restricted to simply two plys. Nor should any statements herein be considered as restricting the application of this invention to reverse the corrugation process, paper webs, or both.
All of the known previous devices have inherent difficulties in establishing and maintaining consistent and precise material application rates both across the web width and throughout the various machine speeds typical in the corrugating process. Additional operating difficulties occur with prior art means whenever a web splice, tear, or complete breakout happens, when webs of different absorbancy rates are used, or when the desired end product requires that materials be applied which have a relatively high viscosity (over 500 centipoises). Because of the physical damage to the web from mechanical stress created by applicator units such as those described by U.S. Pat. Nos. 4,495,011 and 4,498,943, dual or multiple arch production on single facers using either vacuum or air pressure means to retain the fluted medium against the lower corrugating roller has been impractical due to the tendency of the low viscosity adhesives used in the other systems to penetrate the web and contaminate the single-facer itself.
Finally, the existing adhesive applicator devices are not compatible with the operating needs for adhesively combining more than a single narrow web across a longitudinally wider base web, either as a dual arch medium or as a laminated liner. Such capacity is advantageous when the added strength is required on only a portion of the full web width, and when multiple units of this product are to be produced simultaneously across the width of the corrugator.
SUMMARY OF THE INVENTION
The present improvements to corrugating machines overcome many of the shortcomings and disadvantages associated with known laminators and/or coaters, and teach the construction and operation of relatively simple, effective and economical laminators and coaters. For example, the present device has means to wrap the liner and/or medium web against and over the respective applicator rollers thus allowing the applicator roller time to transfer the precise volumes of adhesive material, which were metered by the doctor blade precisely filling the depressions in the roller's surface, directly onto the respective liner or medium web. This process permits the use of relatively high solids/high viscosity adhesive materials that enhance the final corrugated product with superior bonding and coating properties. The volumes of adhesive materials to be transferred is controlled by the intaglio roll cell configuration including the arrangement and depth of the roll depressions. If these volumes are desired to be applied at different application rates for different end products, the device is constructed so that the intaglio roller can be easily and quickly exchanged.
It is preferable that the web receiving the adhesive impregnating or coating material be held against the intaglio applicator roller by tension within the web itself as it is pulled forward by the inherent resistance of the corrugating machine, and not by the incorporation of any pressure point or hold down roller and associated nip. Certain webs used in the corrugating process may have a tendency to curl away from the applicator roller at the edges. If this occurs, and a bowed wrap bar similar to that included at the entry portion of most single-facers is chosen not to be used, it has been found that this edge tension can be controlled by the strategic placement of low angle sleeves positioned on the wrap rollers. Such sleeves minutely increase the roller's diameter by a desired amount at the precise location of the edge curl and thereby eliminate any tendency for loose edges.
It is normally preferred that the applicator roller be driven at the same speed as the advancing web. However, under some uses it has been found to be advantageous to either "smear" the applied material onto the web by operating the applicator roller at a speed that is slightly slower than the advancing web, or "scrub" the applied material by driving the applicator roller somewhat faster than the advancing web. Adhesives and/or coatings can be applied to either the top surface or to the bottom surface of an advancing web. The location of the device herein described and the threading paths for the web will determine the surface on which the material is to be applied.
A principal object of the present invention is to provide means to produce improved coated or impregnated laminated liners and/or laminated corrugated board media.
Another object is to teach the construction and operation of machinery to produce corrugated board having greater strength, improved barriers to migratory elements such as moisture, grease and oils and improved stacking characteristics as compared to prior constructions.
Another object is to produce corrugated board having improved surface coating characteristics and therefore improved graphic appearance and physical characteristics.
Another object is to produce improved dual or multi-arch combined board by using two or more laminated mediums bonded together with adhesives having higher viscosity than has been practical with prior constructions.
Another object is to teach the construction and operation of machinery to produce corrugated board having more consistency in its coatings and in its laminations.
Another object is to teach the construction and operation of machinery to accomplish the above items, which machinery has improved economic and operating capabilities.
Another object is to teach improvements to corrugating machines that can be incorporated for use in existing machines or built into original equipment.
These and other objects and advantages of the present invention will become apparent after considering the following detailed description of a preferred embodiment in conjunction with the accompanying drawings, wherein:
DESCRIPTION OF THE DRAWINGS
FIG. 1A is a side elevation of a single-facer unit of a corrugating machine embodying the teachings of the present improvements;
FIG. 1B is a side elevational view of a double-facer unit of a corrugating machine embodying other teachings of the present improvements;
FIG. 2 is a fragmentary perspective view of an applicator roller and associated means employed in the present improved construction;
FIG. 3 is an enlarged fragmentary view showing a portion of the surface of the applicator roller of FIG. 2;
FIG. 4 is a fragmentary cross-sectional view taken along line 4--4 of FIG. 3;
FIG. 5 is a fragmentary cross-sectional view showing a modified form of a web wrap roller;
FIG. 6 is a fragmentary perspective view showing one possible material flow construction; and,
FIG. 7 is a fragmentary perspective view showing an alternative embodiment of material flow for use in the present construction.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings more particularly by reference numbers wherein like numbers refer to like parts, number 10 refers to the entire assembly shown in FIGS. 1A and 1B which together constitute a machine for producing corrugated board. The corrugating machine 10 comprises at least one single-facer unit 12 (shown in FIG. 1A) and at least one double-facer unit 14 (shown in FIG. 1B). The single-facer unit 12 is connected by one or more bridges or single-facer accumulation means such as bridge 16 which receives the output of the single-facer unit 12 and accumulates it for feeding to the double-facer unit 14.
The single-facer unit as shown in FIG. 1A, includes two laminating units 18 and 20 as depicted, and either or both of such units may be employed, the precise locations of which may be varied within limits which is an advantage in that it substantially contributes to the flexibility and versatility of the machine. In the single-facer unit 12 two separate mediums 22 and 24 are fed from respective supply rolls 26 and 28 and are laminated together to form a double thickness medium 30 by passing the top web 22 circumferentially around a portion of an adhesive covered intaglio roller 32 shown in more detail in FIG. 2, and bringing the adhesively coated medium web 22 into contact with the second medium web 24 at a point such as that produced by roller 34. Thereafter the double thickness laminated medium 30 passes around attaching member or roller 36 and then is directed through and between cooperatively engaged first and second corrugating rollers 38 and 40. An adhesive applicator roller 42 is employed in the unit 12 to apply adhesive to the advancing flute tips 44 of the now laminated corrugating medium 46.
A liner is simultaneously formed by two liner web members 48 and 50 fed from separate source rolls 52 and 54. The webs 48 and 50 are laminated together by having one of the webs (web 48) exposed to an intaglio applicator roller 56 and thereafter coming into contact with the other web 50 as the two webs pass around portions of other rolls 58 and 60 positioned as shown. This brings the adhesively coated side of the web 48 into contact with the second liner web 50 and bonds them together as they are fed around the rolls 58 and 60 to form laminated liner member 66. The member 66 is then fed to and around a pressure roller 62 and through a nip 64 formed by and between the pressure roller 62 and the second corrugating roller 40. The two laminated web members 46 and 66 are brought into contact with each other as they move around and through the nip 64. In so doing, the laminated liner 66 will contact the flute tips of the corrugated web 46 and be adhesively bonded thereto to form single-face web 68. The single-face web 68 may be guided by means constructed as shown onto an accumulation device or platform such as the bridge 16 where it accumulates in an accordian-like manner and is drawn off therefrom adjacent to the opposite end of the bridge 16 to be fed over a series of other spaced rollers to be described later for feeding into the double-facer unit 14 shown in FIG. 1B.
In FIG.. 1B a laminating unit 70 is depicted and may be employed in tandem with units 18 and/or 20 in FIG. 1A or separately. The unit 70 may likewise be positioned in a variety of places as desired which adds to the versatility of the machine and makes it possible to install the subject improvements on existing corrugating machines as well as in new machines. The double facer machine 14 receives an input from the single-facer machine 12 by way of the accumulation on the bridge 16. A controlled drag producing means such as suction means 72 is provided adjacent to the bridge 16 as shown and engages the smooth or liner side of the single-face member 68 and operates to maintain controlled suction tension thereon as the web 68 is fed to the double-facer unit 14. In the double-facer unit 14, adhesive is applied to the flute peaks on the under side of the single-face web 68 which is the opposite side from the side that is attached to the liner 66. This occurs while the single-face web 68 is passing through an adhesive applicator unit 74. Also in the double-facer unit 14, second liner members 76 and 78 from respective source rolls 80 and 82 are brought together for laminating into a laminated web 84 by passing the upper web 76 around idler rollers 86 and 88 and then circumferentially around a portion of an adhesive coated intaglio applicator roller 90 included in the unit 70. The adhesively coated liner web 76 is then brought into contact with the second liner web 78 after the web 78 has moved around guide rollers 92 and 94 by passing the two engaged webs 76 and 78 around a portion of another roller 96. The two webs 76 and 78, which are now laminated into the web 84 and are thereafter brought into contact with and bonded to the flute tips of the single-face web 68 to complete the construction of the double-face corrugated web 98. The completed web 98 thereafter passes between means such as endless belt 100 and support member 102 which members cooperate to hold the parts of the double-face web 98 together for a sufficient period for the adhesives to bond. The various supply rolls used to supply the individual web members that form the liners and parts of the corrugated medium need to be resupplied from time-to-time as materials run out. This procedure is routine in all corrugating machines.
Additional similarly constructed single-facer units such as the unit 12 shown in FIG. 1A may optionally be provided and utilized within the same overall machine 10 to separately or simultaneously produce additional single-face webs for use in producing multiple layered corrugated structures in a double-facer similar to that shown in FIG. 1B for assembling single-face webs. Such a second single-face web 104 is shown in dotted outline in FIG. 1B and is accumulated on another bridge structure similar to the bridge 16. The second single-face web 104 is fed through another adhesive applicator unit 106 wherein the corrugation peaks of the web 104 have adhesive applied to them in the same manner as in the case of the web 68. Thereafter the web 104 is bonded to the liner side of the web 68 to produce a double-fluted corrugated panel. Additional single-facer units can also be included in the overall machine 10 depending on the desired construction of the output corrugated panel.
The adhesive units 18, 20, and 70 may be employed using either identical web widths that are the same across the width of the machine, or they can accommodate one or more webs that are less than the full width of the members being constructed and strategically placed as desired. The adhesive units 18, 20, and 70 are depicted as applying adhesive material to the lower surfaces of the upper web members that pass therethrough. However, the adhesive units may be installed with wrap rollers strategically positioned so as to bring the top surfaces of the lower webs into contact with the respective applicator rollers and thus apply adhesive material to the top surfaces of the lower webs instead of to the bottom surfaces of the upper webs. The adhesive units may also be constructed to impregnate or saturate the respective webs, as well as to apply surface coatings.
It is important that the present improvements can be built into new equipment as well as adapted to be installed in existing state of the art corrugating machines including those that employ either mechanical guide fingers to hold the medium against the lower corrugating rollers, as well as those that employ either vacuum or air pressure to hold the web in place against the lower corrugating rollers. The fact that the subject improvements can also be applied with minimal machine modifications to existing corrugators is an important advantage because it means that the subject improvements will be able to have broad acceptance in the corrugating industry with minimal labor and expense.
The applicator roller 32 (or 56) shown in FIG. 2 is positioned adjacent to a doctor blade/adhesive reservoir assembly 108 containing adhesive 110. In this way some of the adhesive 110, or other application material, is continuously being picked up by the intaglio surface 112 of the applicator roller 32 as the roller 32 rotates. The roller 32 is shown in FIG. 2 rotating in a counterclockwise direction, and the adhesive material 110 being picked up is preferably selected from among adhesives such as a vinyl-acetate ethlene, polyvinyl acetate, polyvinyl alcohol or other synthetic co-polymers, compounds or resins, although other types of materials may also be used. Coatings and impregnations when used may be selected from among the waxes, sealants, varnishes, colored tintings, urethanes, and any other materials that can be formulated so that sufficient viscosity and cohesive properties exist. The application devices are preferably located a sufficient distance away from the other portions of the corrugating machines so as to permit ease of operating as well as to insulate or substantially insulate the applicators from the relatively high temperatures normally used by many known corrugators.
A wiper or doctor blade 114, which may form one side of the reservoir assembly 108, is located to be in contact with the intaglio surface 112 of the applicator roller 32. The blade 114 is preferably biased into engagement with the roller surface 112 and the scraping edge of which is directed opposite to the direction of rotation of the applicator roller 32. The wiper or scraper blade 114 is included to provide means to remove by a positive scraping action excess adhesive or coating from the surface 112 of the applicator roller 32 as the roller turns, but without removing the adhesive material that has accumulated in the plurality of small surface depressions 116 which form the intaglio roller surface 112 (FIGS. 3 and 4). The form or shape, depth, and locations of the depressions 116 are important and will be more fully understood by reference FIGS. 3 and 4. The shape of the depressions 116 should preferably also be such that they do not have straight side edges parallel to the axis of the roller 32. This improves the metering and releasing action of the doctor blade 114 as it moves over the surface 112. The small amounts of adhesive material that remain in each of the depressions 116 after the surface has been scraped by the blade 114 is thereafter transferred as in a printing action from the roller surface 112 onto the surface of the medium or liner during the time that such members or portions thereof are held and maintained in contact with the surface 112. The maintaining of the liner or medium in contact with the roller 32 can be accomplished in various ways, including providing means such as tension producing wrap rollers 118 and 120 positioned as shown in FIG. 2. Also, in the embodiment shown in FIG. 2, contact occurs between the web 22 and the roller 32 over an arc of the roller 32 which is preferably from between about 40° to about 120°, although the exact amount of engagement is not critical and depends to some extent on certain parameters such as, on the roll speed, the properties of the adhesive material being applied, and the related dyne factors of the components. By incorporating wrap adjustment mechanisms such as provided by the rollers 118 and/or 120, a relatively wide arc of contact between the web member to which adhesive is to be applied and the applicator roll 32 can be achieved. The important thing is that the contact be of long enough duration for the adhesive to transfer from the depressions 116 to the web member, as a continuous pattern of dots. After leaving contact with applicator roller 32, the web is drawn forward until it contacts the web member to which it is to be attached and an adhesive bond is produced between them. If the subject machine is being used as a coater or impregnator, a second or unimpregnated web is not normally incorporated and the coated web is drawn into the corrugator in the normal manner.
In some applications it may be desired to install a "hold down" roller 122 (shown in dotted outline in FIG. 2) so that a nip 124 is formed between the applicator roller 32 and the hold down roller. This feature may also help to eliminate some web flutter. However, use of such a hold down roller generally has resulted in accumulation of small portions of the coating material on the hold down roller which is undesirable, and this feature also does not usually allow for very close tolerances between the hold down roller 122 and the applicator roller 32 to be maintained.
If web flutter especially adjacent to the edges of the web is a problem, it has been found that the use of strategically placed low angle sleeves such as the sleeve 126 shown in FIG. 5 can be installed on one or both opposite ends of the wrap rollers 118 or 120 to eliminate the flutter. Such sleeves 126, when used, usually are of minimal size and angle, and it is contemplated to form the wrap rollers themselves with enlarged end portions to accomplish the same result. The principal web tension producing means and the controls therefor may be of various known designs. The important thing is to bring one of the webs to be laminated into contact with the applicator roller surface such, as with the surface 112 in FIG. 2, and to the extent possible to prohibit web wrinkle as the web enters the corrugating machine proper.
Referring to FIG. 4, the cross-sectional shape of the several of the depressions 116 is shown. The depressions or indentations 116 can be formed by having the roller surface indented, etched, engraved or otherwise treated and the treatment should be uniform and should extend over as much of the surface 112 as possible. The shape and depth of the depressions 116 are designed for each different adhesive material to be applied, and is based on the idea that one volume or "dot" of adhesive material 110 is transferred to the web by contact of the webs for each distinct depression 116. The spacing and geometry of the depressions 116 is selected so that the resultant transfer of material onto the web is correct for the product to be manufactured. Also, the ability to be able to quickly and easily exchange applicator rollers, or build applicator devices with multiple applicator rollers is contemplated to accommodate different flow or transfer rates as needed.
In forming the multi-ply medium 46, a certain amount of machine-direction slippage will take place between the webs which form the medium as they pass into the flute formation means including the corrugating rolls 38 and 40. This machine direction slippage is usually an advantage as it serves to further spread the adhesive as well as to lubricate the webs which permits them to individually better conform to the flute peaks and valleys in the labyrinth of rollers 38 and 40.
Speed synchronization including electronically controlled variable speed drive motors and tracking sensors (not shown) may be used to control the surface speeds of the applicator rollers such as of the roller 32 to precisely match the speed of the web advancing into the corrugator machine. It has been found that most applied adhesive materials and webs will perform best when these speeds are identical. It is contemplated, however, that for certain applications the applicator rollers will be driven at speeds somewhat different than the speed of the advancing web in which case some slippage may be desired.
The webs constructed and combined into corrugated sheet or board using the improvements discussed herein have strength properties, barriers and/or graphic qualities that are far superior to those produced by the methods and machinery currently known and available.
FIG. 6 shows another possible construction for an adhesive container and reservoir assembly 130. The assembly 130 includes a wiper blade 132 as a portion thereof, the edge of wiper blade 132 being inclined in a direction opposite to the direction of rotation of associated applicator roller 32 to positively engage and scrape the roller surface. The assembly 130 is located adjacent to one side, as distinguished from at the bottom of an applicator roller such as the roller 32, and the adhesive material 134 contained therein is fed to the container through an inlet conduit 136 such as depicted. A predetermined depth of adhesive is maintained in the assembly by means such as spaced end dams 138, the upper edges 140 of which control the depth of the adhesive.
FIG. 7 shows another embodiment of a device 142 for applying adhesive to the applicator rollers such as to the roller 32. In this case the roller 32 is partially submerged in a bath of adhesive 144 in container 146. The roller 32 is shown rotating in a clockwise direction, and a doctor blade 148 is resiliently and positively engaged with the roller surface to remove by scraping adhesive material in excess of that which is contained in the depressions 116. The doctor blade 148 may be formed as part of the side wall of the container 146. All of the adhesive material 144 so removed drains back into the container 146 where it can be re-used.
Thus there has been shown and described novel, non-obvious, improvements to corrugating machines used for producing single-face, double-face, and multiple ply corrugated panels or boards that have laminated members in them, including improvements at the single-facer and at the double-facer units which fulfill all of the objects and advantages sought therefor. It will be apparent to those skilled in the art, however, after a review of this description that many changes, modifications, variations and other uses and applications for the subject constructions, in addition to those which have been disclosed, are possible and contemplated, and all such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention which is limited only by the claims which follow.
|
An apparatus for making laminated dual and multiple arch corrugated structures including a first unit for making single-face corrugated members formed of a corrugated member and an attached liner and a second unit for combining one or more single-face corrugated structures into a double-face structure. The subject invention includes a novel mechanism for laminating one or more portions of the single-face or double-face corrugated structures and/or for impregnating one or more of the members of the such structures with an impregnating substance. The subject improvements also reside in a novel hold down roll construction to prevent wrinkling of the edge portions of web members used in the construction of corrugated panels.
| 1
|
BACKGROUND OF THE INVENTION
This application claims priority based on German application 199 43 183.3, filed Sep. 9, 1999 and the contents thereof are incorporated herein by reference.
1. Field of the Invention
The present invention relates to methods for adjusting color in an image, more particularly, to adjusting color in an X-ray image.
2. Background Art
In the radioscopy of objects, sub-objects are represented by varying brightness levels in accordance with their X-ray absorption (grayscale image). In films, high-absorbing objects/sub-objects are represented as light images, while low-absorbing objects/sub-objects produce significant darkening and are therefore represented as darker images. In electronic image processing, using reverse imaging is also customary, i.e. light grayscale values are used for objects/sub-objects having weak X-ray absorption.
The objects/sub-objects may be X-rayed using varied energy levels to provide improved identification of the material(s) that the objects/sub-objects are made from. The type materials of the X-rayed objects or sub-objects may be determined from absorption values determinable at the different energy levels.
For visual determination of the objects'/sub-objects' materials, the materials of the objects/sub-objects may be represented by different colors. For example, a color is assigned to an average atomic number that defines a specific material type. This produces a so-called false-color-image for the human eye, made up of two specific types of information: absorption and material.
Accordingly, if two materials having identical absorption (brightness), but are made from different materials (color), are compared to this false-color-image, the two material appear to have different brightness levels to the human eye, since the human eye has different sensitivity to different colors. Therefore, a green object is perceived to be much brighter than a blue object. This results in the conclusion that the blue object is subject to a higher absorption than the green one, because the human eye is especially sensitive to green, and on the contrary, is insensitive to blue. This leads to unpleasant visual strain for a person viewing the image and to poor discernability of objects represented by darker colors. The latter is particularly important when analyzing an X-ray image, because here indeed is where superimposed sub-objects in the image must be discernable as shadings lying one behind another.
European patent documents EP 0 523 898 B1, EP 0 584 690 B1, and EP 0 758 514 B disclose devices and processes that improve color images in the television and video sector, taking into account the three primary colors—red, green, and blue—according to the NTSC (National Television System Committee) standard.
SUMMARY OF THE INVENTION
It is an object of the invention to regenerate and optimize a color image viewed by the human eye, specifically an X-ray image, so that the observer is subjected to less visual strain and the discernability of sub-objects is improved.
This and other objects of the present invention are achieved by providing a method for adjusting colors of an image, in particular of an X-ray image, in which an object having sub-objects shown in different colors is depicted. The steps of the method include determining an absorption attribute of a plurality of the sub-objects, assigning a specific color to each of the plurality of sub-objects having a same absorption attribute, each specific colors being different from each other, adjusting a brightness level of one of the specific colors by adjusting each pixel thereof with a determined color proportion of at least one of red, green or blue, whereby the adjustment of the brightness level takes into consideration the sensitivity of the human eye, and displaying at least the plurality of sub-objects having the same absorption attributes on a monitor, whereby adjustment of the brightness level of one of the specific colors causes the human eye to view at least the plurality of sub-objects as having equal brightness levels.
The present invention is based on the idea of adapting the representation of different colors to the viewing behavior of the human eye, so that the different colors at the same X-ray absorption are represented with the same degree of brightness to the human eye. The same degree of brightness thus means that after adapting the colors to the spectral sensitivity curve of the eye, the observer has the impression that the colors are equally bright.
In addition, it is also advantageous that smaller areas having a lower degree of brightness are also quickly discerned by the viewer, since they are more quickly perceived by the human eye after the brightness is adjusted.
Red, Green and Blue (RGB) values calculated for the adaptation are stored in support tables of a computer or processor, which is accessed for representation of colors on a display device or monitor. Therefore, a brightness specification and a present color value are input into the computer, as a result of which the RGB values previously calculated and stored for the input brightness and special color value are taken from the support tables.
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention are given by way of illustration only, since various changes and modifications within the sprit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not imitative of the present invention, and wherein:
FIG. 1 is a block diagram illustrating various elemental features according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a block diagram illustrating various elemental features according to an embodiment of the present invention. Although elements according to the drawing will be discussed in detail they are not to be construed as limiting of the claimed invention, as it is understood by those skilled in the art that various modifications and/or additions may be made to the illustrated elements and such are embraced by the scope of the hereinafter set forth claims.
Referring to FIG. 1 , as illustrated an object 1 , containing several sub-objects 2 , 3 , 4 , is moved through a plurality of X-ray beams FX (may also be just one X-ray beam) via a conveyor (not shown in detail) or the like. The X-ray beams FX are generated by an X-ray beam source 5 .
The sub-object 2 , for example, is made of an organic material (clothing or the like) having an average thickness. The sub-object 3 , for example, is made of iron having a thickness of 3 mm. The sub-object 4 is (pure) aluminum having a thickness of 20 mm. The sub-objects 2 , 3 and 4 absorb the X-ray beams FX in different ways, whereby the sub-objects 3 and 4 generate identical absorption values despite their differing thickness in the example.
The absorption of the X-ray beams FX is measured via detectors 6 and input into a computer or processor 7 for evaluation and processing. In the computer 7 , the absorption values are converted for grayscale imaging in a known manner. With the aid of the grayscale image, the absorption behavior, particularly of the sub-objects 2 , 3 , and 4 , is depicted on a monitor 8 . In this grayscale image on the monitor 8 , brightness levels that differ among the sub-objects 2 and 3 , or 2 and 4 , and that are identical between sub-objects 3 and 4 , are discerned by the human eye of a viewer (not shown in further detail).
In order to provide a visual representation of the materials of the sub-objects 2 , 3 and 4 themselves, a signal for absorption in the high-energy range of the X-ray spectrum and a separate signal for absorption in the low-energy range are measured from the detectors 6 in a known manner using the two-energy process (not shown in further detail here for the sake of clarity). From these two signals, the average atomic number of the sub-objects 2 , 3 and 4 is determined in the computer 7 . Using the average atomic number of each sub-object 2 , 3 and 4 a display color is assigned to each of the sub-objects. For example, the color orange is assigned to organic materials having a low average atomic number, the color green is assigned to aluminum that has a higher average atomic number, and the color blue is assigned to iron and steel, which have even higher average atomic numbers. These shades are depicted dark or bright depending on material thickness or material density. This means that the density or the thickness of the sub-objects 2 , 3 and 4 determine the apparent brightness of the respective color or respective shade thereof.
The sub-object 2 is thus depicted in a color image (false-color-image), for example, as bright orange. In a color image of this type, the sub-object 3 would then be depicted as a dark blue and the sub-object 4 would be depicted as a strong green (if the sub-object 4 were thinner, it would be depicted as a light green).
Accordingly, especially in the representation of the materials of the sub-object 3 and the sub-object 4 , different perceived color intensities with regard to the brightness of the color or the shade appear. While the sub-object 3 and the sub-object 4 appeared equally bright in known grayscale imaging because the two have the same absorption, the impression is now different in the color image because the sub-object 3 is depicted in the color blue and the sub-object 4 is depicted in green, whereby the color green is perceived to be much brighter by the human eye than the color blue.
To avoid this, a color adjustment for the human eye of the entire color image and of parts of the color image is now performed based on the three-color theory.
For the sake of clarity, the sub-object 2 is not taken into consideration in the following description.
In the color image representation, the sub-objects 3 and 4 , which appear equally bright due to their having identical absorption properties, are preferably adjusted to the same or approximately the same brightness. This is done in accordance with the known formula (according to Grassmann):
Y =0.299 *R +0.587 *G +0.114 *B
where Y is the brightness, R is the primary color red, G is the primary color green, and B is the primary color blue, which are thus the RGB values of a color pixel. The quantities R, G, B and Y may range in value from 0.000 to 1.000.
To obtain an approximately equal brightness Y for all color pixels, in particular, those with the same absorption values, the color proportion R, G, B for each pixel is calculated, which must be adjusted or added for increasing the intensity, as is described hereinbelow.
The two sub-objects 3 and 4 have an identical absorption of 60%, for example, but each have a different thickness. A brightness of Y=4.0 results in a known manner from the absorption of 60%.
Due to the average atomic number, the sub-object 4 is depicted in a green shade. Assuming the material is pure aluminum, this yields the following RGB-values: 0.000/0.681/0.000, since no red and no blue are present in the pure green shade (0.587*0.681=0.4).
The sub-object 3 is represented in blue due to its average atomic number. Following the discussion hereinabove, the RGB values are: 0.000/0.000/3.509, thereby resulting in a blue shade (0.114*3.509=0.4).
Therefore, according to the above calculations, the brightness Y G for green is approximately equal to the brightness Y B for blue, i.e. Y G =0.4=Y B .
RGB values over 1.000 are not possible.
Therefore, with the addition of red and/or green and taking the color theory into consideration, the brightness of the sub-object 3 is adjusted in a manner visually perceptible to the eye, in this case a brightening of the shade of blue, since blue is darker than green. This brightening is done preferably so that red and green values share in equal proportion in the RGB value of the blue color.
Accordingly the necessary RGB value is calculated as follows:
Y =0.4=0.299*0.323+0.587*0.323+0.114*1.000, i.e. RGB =0.323/0.323/1.000.
With this process, to the human eye, the sub-object 3 is depicted as a blue equal in brightness to the green of the sub-object 4 . This process can also be applied in an analogous manner to secondary colors.
The intensity of the green color can also be reduced, if this helps provide uniform observation for the viewer. In this process, it is not the brightness of the green color that is decisive, but rather the brightness of another reference color.
In practice, tables for brightness adjustment are stored in the computer 7 . For a brightness adjustment to be performed for each color, these tables contain the corresponding color values or RGB values to be re-regulated, which are pre-calculated as described and then accessed during the color image display on the monitor 8 . Accordingly, the brightness specification and the present color value are input into the tables of the computer 7 . The color control of the monitor 8 is then handled via three outputs for color image representation, now consisting of the newly calculated RGB values.
It is understood that this process is not limited to representation of X-ray images. Thus, brightness adjustment for the human eye can also be used in the video and television sector.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
|
In the representation of X-ray images, an atomic number characteristic for an X-rayed sub-object ( 2, 3, 4 ) is determined from X-ray beams having different energies and the absorption values determined in that process, to which specific colors and shades are assigned. The representation of the color intensity is influenced so that, when representing objects ( 3, 4 ) having the same X-ray absorption on a monitor ( 8 ), the colors appear equally bright to the viewer. To that end, while the pre-set color for the objects ( 3, 4 ) is maintained, the brightness of the different colors is adjusted to an equal or approximately equal brightness, taking into account the spectral sensitivity of the human eye.
| 7
|
This application claims the benefit of U.S. Provisional Application No. 60/227,146 filed Aug. 22, 2000.
FIELD OF THE INVENTION
The present invention is directed to protocol stacks used to transfer data between a plurality of host computing devices connected to one or more networks and more specifically to a method and protocol stack for transferring Fibre Channel frames over a Gigabit Ethernet.
BACKGROUND OF THE INVENTION
A Storage Area Network (SAN) is a sub-network of shared storage devices such as disk and tape. SANs provide high-speed, fault-tolerant access to data for client, server and host computing devices (“host computers”). Traditionally, computers were directly connected to storage devices, such that only the computer that was physically connected to those storage devices could retrieve data stored therein. A SAN allows any computer connected to the SAN to access any storage device included within the SAN. As more storage devices are added to a SAN, they become accessible to any computer connected to the SAN. The explosion of the Internet, the consolidation of servers and the growing complexity of applications, with more graphics, video and sound data to be stored, are resulting in a burgeoning demand for improved storage interconnect solutions for enterprise wide systems and for networks of such systems.
Typically one or more SANs can be liked to one or more Local Area Networks (LANs), Metropolitan Area Networks (MANs), or Wide Area Networks (WANs) to provide for the data storage needs of these networks. However some problems arise when a host computing device connected to a LAN, MAN or WAN wants to retrieve information from a SAN because protocol used to transfer data from SANs differs from protocol used to transfer data across the above-referenced network types.
Specifically, a Fibre Channel Protocol (FCP) standard is widely used in SANs to provide a reliable, guaranteed, low latency data transfer mechanism. FCP does not provide for “stack-like functions” but is an effective serial replacement for a parallel small computer systems interface (“SCSI”), which is the interface between a storage device that is physically connected to a computer. According to this protocol, data is organized into Fibre Channel (FC) Frames of up to 2148 bytes in length. FIG. 1B illustrates the typical structure of a FC Frame. It includes a four byte Start of Frame field, a twenty-four byte Frame Header field, an Optional Header field of sixty-four bytes, a Payload field of from zero to 2048 bytes, a four byte Cyclic Redundancy Check field (“CRC”), and a four byte End of Frame field.
By contrast, LANs, MANs, and WANs typically use a Transmission Control Protocol/Internet Protocol (“TCP/IP”) standard to transfer data from one computer to another. TCP/IP is a layered group (“stack”) of protocols used to efficiently transfer data across such networks by addressing problems such as data loss and out of order delivery of data blocks. TCP/IP has five layers each having a different function during data transfer. From the lowest hierarchy level to the highest hierarchy level, the five layers include a Physical Layer, a Media Access Control (“MAC”) Layer, a Network Layer, a Transport Layer and a Session Layer. The functions of these five layers are based upon the functions performed by a seven-layered international protocol standard called Open Systems Interconnection (OSI) Model.
The Physical Layer is concerned with transmitting raw data bits over a communication channel. This layer makes sure that when a transmitting side sends a ‘1’ it is received by a recipient correctly. The MAC Layer corresponds to a Data Link Layer of the OSI Model. The main task of this layer is to transmit frames sequentially. The Network Layer implements Internet Protocol (“IP”) for controlling the operation of the network. A packet is the basic unit of data defined at this layer. The Network Layer determines how packets are routed from a source to a desired destination. Routes are based on static or dynamic tables available to persons of ordinary skill in the art. The Transport Layer splits the data from the Session Layer into smaller units called segments, if need be, and pass these segments to the Network Layer. It also ensures that the segments arrive correctly at the other end. Transmission Control Protocol (“TCP”) is implemented by the Transport Layer. TCP generates a sequence number for each data packet. To reassemble data into the original frames, the sequence numbers must be matched up. Finally, the Session Layer defines guidelines for application user interface and communications between host computers.
Gigabit Ethernet is widely used as the physical medium in LAN, WAN and MAN environments. FIG. 1A illustrates the typical structure of an Ethernet Frame as defined by IEEE 802.3. The maximum packet size in the Ethernet domain is 1500 bytes. The Ethernet Frame includes a MAC Layer for enabling the Ethernet Frame to be transmitted sequentially. The MAC Layer includes a Start of Frame byte, a six byte destination address (“DA”) field, a six byte source address (“SA”) field, and a four byte virtual LAN (“VLAN”) field. The remainder of the Ethernet Frame is a Payload field, and a four byte Frame Checksum (“FCS”) field, which is an error checking code for the Frame.
When transferring FC frames over the Gigabit Ethernet, a given FC Frame may require being transferred as two Ethernet Frames because the maximum packet size of an FC Frame (2148 bytes) is larger than the maximum packet size of an Ethernet Frame (1500 bytes). The problem with prior art data transfers of FC Frames over the Ethernet is the inability of the TCP/IP stack to accurately transfer FC Frames of varying sizes over the Ethernet Frames, especially those FC Frames that are larger that the maximum size of a Gigabit Ethernet Frame, because prior art TCP/IP stacks are not equipped to adequately and reliably handle additional functions associated with such a transfer.
What is needed is a method and an improved TCP/IP protocol stack for: mapping any sized FC frame onto one or two Gigabit Ethernet Frames; reliably transferring the corresponding Ethernet Frame(s) over the Ethernet; and reconstructing the original FC frame at its destination, if necessary.
SUMMARY OF THE INVENTION
The present invention is directed at addressing the above-mentioned shortcomings, disadvantages, and problems of the prior art.
Broadly stated, the present invention comprises a method for generating one or more Ethernet frames having a maximum length and a maximum payload from a Fibre Channel (“FC”) frame having a frame length and for transmitting said FC frame over a Gigabit Ethernet to an intended destination, said method comprising the steps of: (a) determining whether said FC frame length is smaller than said Ethernet frame maximum payload and if so generating an Ethernet frame wherein its payload comprises said FC frame and transmitting said FC frame to said intended destination, and if not then performing steps (b) through (f); (b) dividing said FC Frame into a first and second FC fragment, wherein each said FC fragment is smaller than said Ethernet frame maximum payload; (c) generating a storage transport layer field comprising said frame length; (d) generating a first Ethernet Frame comprising said storage transport layer field and said first FC fragment; (e) generating a second Ethernet Frame comprising said second FC fragment; and (f) transmitting said first and second Ethernet Frames including said FC fragments over the Ethernet to enable said FC frame to be reassembled at said intended destination.
The present invention also provides for a Transmission Control Protocol/Internet Protocol (“TCP/IP”) protocol stack having a transport layer for transferring over a Gigabit Ethernet one or more FC frames having a frame size for each said FC frame, the improvement comprising said transport layer comprising a storage transport layer, wherein said storage transport layer enables said transport layer to be operative for: determining based upon said frame size of a given FC frame whether to generate one or two Ethernet frames, said one or two Ethernet frames comprising a payload that includes said given FC frame; transmitting said one or two Ethernet Frames including said given FC frame over said Ethernet to an intended destination; and enabling, if necessary, said FC frame to be reassembled from said two Ethernet frames at said intended destination.
The object and advantage of the present invention is that it provides for a method and protocol for the efficient, high bandwidth, low-latency and reliable transfer of variable length FC Frames over the Ethernet.
BRIEF DESCRIPTION OF THE DRAWINGS
The forgoing aspects and the attendant advantages of this invention will become more readily apparent by reference to the following detailed description when taken in conjunction with the accompanying drawings wherein:
FIG. 1A is a diagram illustrating the format of an Ethernet Frame;
FIG. 1B is a diagram illustrating the format of an FC Frame;
FIG. 2 illustrates a protocol stack for transferring FC Frames over the Ethernet according to a preferred embodiment of the present invention;
FIG. 3 illustrates the storage transport layer of the protocol stack of FIG. 2 ;
FIG. 4 illustrates a method for segmenting an FC Frame into two Ethernet Frames according to a preferred embodiment of the present invention; and
FIG. 5 illustrates a method for encapsulating an FC Frame into a single Ethernet Frame according to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 2 illustrates a protocol stack for transferring FC Frames over Gigabit Ethernet according to a preferred embodiment of the present invention. The protocol stack of FIG. 2 can be used to link one or more SANs to one or more existing LANs, MANs or WANs. As seen in FIG. 2 , the protocol stack comprises the five layers of a typical TCP/IP stack as described above and known and understood by one of ordinary skill in the art. Those five layers are a Physical Layer, a Media Access Control (“MAC”) Layer, a Network Layer, a Transport Layer, and a Session Layer.
The Gigabit Ethernet is the physical medium for transferring information within the one or more linked networks. Internet Protocol as described above and known and understood by one of ordinary skill in the art is implemented at the Network Layer. Transmission Control Protocol as described above and known and understood by one of ordinary skill in the art is implemented at the Transport Layer. An FC frame is the unit of transfer at the Session Layer for the one or more SANs.
As illustrated in FIG. 2 , the protocol stack according to the preferred embodiment further includes a Storage Transport Layer (STL). The STL is a sublayer to the Transport Layer, wherein the STL in conjunction with implementation of TCP comprises the complete Transport Layer for transferring FC Frames over the Ethernet. The STL provides data regarding the size of the FC Frames being transferred, and TCP provides a reliable delivery of the FC frames.
FIG. 3 illustrates the storage transport layer of the protocol stack of FIG. 2 . The STL comprises two fields, a 16 bit Checksum field and a sixteen bit Frame Length field. The Frame Length identifies the size of the FC Frame being transferred. TCP uses this information to map a given FC Frame onto one or two Ethernet Frames to transfer the FC Frame over the Ethernet. TCP would then reliably deliver the resulting one or more Ethernet Frames and reassemble the FC Frame, if necessary, at an intended destination. The Checksum bits help in error checking of the Storage Transport Layer. Preferably the Checksum is an inverted Frame Length.
Thus, the inventive Transport Layer, which includes the STL, functions in a conventional way to handle sequencing and reliable delivery of data packets using TCP. The addition of the STL enables TCP to also handle segmenting and sequencing of FC Frames into one or more Ethernet Frames and enables the reliable delivery of FC Frames over the Ethernet. One of ordinary skill in the art could revise TCP software code or hardware code as appropriate to include these additional elements and functions of the Storage Transport Layer. Moreover, the STL could be expanded to include additional fields.
FIG. 4 illustrates a method for segmenting an FC Frame into two Ethernet Frames according to a preferred embodiment of the present invention. In FIG. 4 , a 2148 byte FC Frame is segmented into a first and second Ethernet Frame, each capable of having a maximum size of 1500 bytes and a maximum payload size of 1454 bytes. The FC Frame includes a four byte Start of Frame field, a 24 byte Frame Header field, a 64 byte Optional Header field, a 2048 byte Payload field, a four byte Cyclic Redundancy Check (“CRC”) field, which includes the length of the FC Frame (“Frame Length”), and a four byte End of Frame field.
The steps of the method illustrated in FIG. 4 are as follows. First, TCP determines based upon the size of the FC Frame that the FC Frame should be encapsulated into two Ethernet Frames. Then TCP divides the FC Frame into two fragments, FC Fragment 1 and FC Fragment 2 . FC Fragment 1 includes the four byte Start of Frame, the 24 byte Frame Header, the 64 byte Optional Header, and a first portion of the 2048 byte Payload, wherein FC Fragment 1 does not exceed the maximum payload size of the first Ethernet Frame, and the first Ethernet Frame does not exceed its maximum size. FC Fragment 2 includes a remaining portion of the 2048 byte Payload, the four byte CRC and the four byte End of Frame. After TCP divides the FC frame, TCP then creates a four byte STL field that includes the FC Frame Length. TCP then generates the first and second Ethernet Frames. The First Ethernet frame includes a MAC Header, an IP Header, a TCP Header, the STL field and FC Fragment 1 . The second Ethernet frame includes a MAC Header, an IP Header, a TCP Header and FC Fragment 2 . Finally, TCP ensures the reliable transmission of the first and second Ethernet Frames including the FC Fragments over the Ethernet to enable TCP to reassemble the FC Frame at an intended destination.
FIG. 5 illustrates a method for encapsulating an FC Frame into a single Ethernet Frame according to another embodiment of the present invention. In FIG. 5 , a 1148 byte FC Frame is encapsulated into a single Ethernet Frame. The FC Frame includes a four byte Start of Frame field, a 24 byte Frame Header field, a 64 byte Optional Header field, a 1048 byte Payload field, a four byte CRC field, which includes the length of the FC Frame (“Frame Length”), and a four byte End of Frame field.
The steps of the method illustrated in FIG. 5 are as follows. First, TCP determines based upon the size of the FC Frame that the FC Frame should be encapsulated into one Ethernet Frame. Then generates an FC Fragment 1 that includes the four byte Start of Frame, the 24 byte Frame Header, the 64 byte Optional Header, the 1048 byte Payload, the four byte CRC and the four byte End of Frame. TCP then creates a four byte STL field that includes the FC Frame Length. TCP then generates the Ethernet Frame, which includes a MAC Header, an IP Header, a TCP Header, the STL field and FC Fragment 1 . Finally, TCP ensures the reliable transmission of the Ethernet Frame including the FC Frame over the Ethernet to an intended destination.
The embodiments of the present invention described above are illustrative of the present invention and are not intended to limit the invention to the particular embodiments described. Accordingly, while the preferred embodiment of the invention has been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.
|
The present invention provides for a method and protocol for high bandwidth, low-latency and reliable transfer of variable length FC Frames over the Gigabit Ethernet.
| 7
|
FIELD OF THE INVENTION
[0001] The present invention relates to a system and method of enhancing attention and more particularly to a technique correlating virtual reality with biofeedback for enhancing attention.
BACKGROUND OF THE INVENTION
[0002] Recent progress in politics, economics, and social environment has resulted in a variety of psychoses. The deficiency of attention can be thought of as a critical loss not only to the personal point of view but also to the society.
[0003] The attention is a fundamental recognizing capability, and the attention deficit disorder (ADD) results in difficulties in mental absorption, listening, and memorizing activities.
[0004] In other words, the psychiatric patients suffering from the attention deficit disorder (ADD) tend to become in attentive, impulsive, emotionally unstable, and sometimes excessively active.
[0005] The above-mentioned symptoms give rise to problems in studying, working, completing the responsibilities, and keeping company. The attention enhancement system is a therapy suffering from ADD (attention deficit disorder).
[0006] A conventional therapy for ADD is a drug-based treatment such as retalin. Another method for curing the ADD is a bio-graph employing a biofeedback.
[0007] The conventional treatments, however, have shortcomings in that the patient should visit a hospital or a therapy house in order to have a diagnosis and/or a treatment.
[0008] The virtual reality (VR) is a novel technology that enables the user to enter the computer-generated world and interact with computer through vision, auditory sense, and the sense of touch.
[0009] The virtual reality differs from the traditional displaying technique in a sense that it provides the user with the feeling of existence or the feeling of absorption as well as a variety of the computer graphic interface.
[0010] The virtual reality provides a paradigm where human being interacts with the computer, and consequently the user is no longer an observer that simply appreciates the computer image on the screen.
[0011] The user in virtual reality is absorbed in the activity in the three-dimensional virtual world that is generated by the computer.
[0012] The virtual environment is sometimes called in different terms such as virtual reality, remote reality, artificial world, cyber space, and multi-sense I/O (input and output).
[0013] The above-mention virtual reality can be employed for the treatment of ADD.
[0014] The children suffering from attention deficit disorder (ADD) have a tendency to respond very sensitively to the static and prompt compensation rather than the physical punishment.
[0015] The virtual reality enables the patient to feel the compensation from the computer-generated environment that is quite similar to reality. Due to absorbing property of the virtual reality, the virtual reality can enhance the chance of social adaptability of the patient.
BRIEF SUMMARY OF THE INVENTION
[0016] The patient suffering from attention deficit disorder can be effectively treated through a virtual reality wherein the patient is not only provided with familiarity in practice and exercise in a computer-generated cyber classroom, which can be generalized in reality, but directly compensated by a cyber teacher via biofeedback.
[0017] Therefore, there is a need in the art for a therapy system and method for enhancing attention through virtual reality and biofeedback.
[0018] Accordingly it is an object of the present invention to provide a therapy system and method for enhancing attention as well as diagnosis of the attention level.
[0019] Yet it is another object of the present invention to provide a therapy system and method for enhancing attention that is adaptively applicable in accordance with the level of the patient's attention level.
[0020] It is also another object of the present invention to provide a therapy system and method for enhancing attention that correlates the treatment contents with the biofeedback.
[0021] A more detailed explanation of the invention is provided in the following description and appended claim taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] [0022]FIG. 1 is a schematic diagram illustrating the configuration of a first embodiment of a system for enhancing attention in accordance with the present invention.
[0023] [0023]FIG. 2 is a schematic diagram illustrating the interaction between the biofeedback module and the virtual reality in accordance with the present invention.
[0024] [0024]FIG. 3 is a schematic diagram illustrating the configuration of a second embodiment of a system for enhancing attention in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Preferred embodiments in accordance with the present invention will be explained in detail with reference to the accompanying drawings.
[0026] [0026]FIG. 1 is a schematic diagram illustrating a first preferred embodiment of a system for enhancing attention in accordance with the present invention. Referring to FIG. 1, the present invention includes a biofeedback device 120 and a virtual reality device 140 .
[0027] The trainee or the patient is absorbed in a virtual reality computer 140 and the biofeedback device 120 detects the time-development of the trainee's brain wave. The data regarding the detected spectrum of the trainee's brain waves is then sent to a VR computer so that the VR computer 140 responds to the status of the trainee's attention status that is reflected on the biofeedback parameter.
[0028] In other words, the time-development of the brain wave, which correlates with the level of attention, is reflected on the new VR environment for the next-step exercise.
[0029] As a consequence, it becomes possible to evaluate the level of the trainee's attention and to provide the trainee with compensation for the response of the VR environment to the time change of the brain waves. The VR device 140 in accordance with the present invention comprises software 150 and hardware 160 .
[0030] The hardware 160 comprising the VR device 140 includes an HMD (head mounted display) 161 , a three-dimensional sound system 162 , a data glove 163 , and a head tracker 164 .
[0031] The attention-enhancing system in accordance with the present invention comprises a variety of VR contents 150 for the diagnosis of the attention level as well as for the treatment.
[0032] As a preferred embodiment in accordance with the present invention, the VR contents comprise a visual comparison module, an auditory comparison module, a memory comparison module, and attention-shifting module.
[0033] The present invention has a feature that the system displays not only the level of attention but also the degree of improvement of the trainee's attention level. The VR contents in the present invention can comprise contents of attention shift, selective attention, attention concentration, and sustained attention.
[0034] The biofeedback device 120 in accordance with the present invention measures a spectrum of brain waves of the trainee 100 through a brain-wave sensor 130 .
[0035] As a preferred embodiment of the brain wave sensor 130 , either a sensor installed at the center of the head or the reference sensor installed at the edge of the ear can be employed.
[0036] The SMR-wave (12˜16 Hz), beta-wave (16˜20 Hz), and the theta-wave (4˜8 Hz) are extracted 131 from the data of the brain-wave sensor 130 , and then sent to the VR device 140 after normalization 132 .
[0037] As a preferred embodiment in accordance with the invention, the relative ratio of the strength of each brain-wave signal can be employed for the definition of the attention level.
[0038] More preferably, the brain-wave sensor 130 extracts a first beta-wave (13˜20 Hz), theta-wave (4˜8 Hz), alpha-wave (8˜13 Hz), and a second beta-wave (20˜40 Hz).
[0039] Preferably, the level of attention can be evaluated by calculating the ratio of the sum of a first beta-wave and a second beta-wave to the sum of theta-wave and alpha-wave.
[0040] In this case, a variety of VR contents can be classified in such a way that they match each level of attention. As another preferred embodiment of the present invention, the duration of performance of each VR content can be controlled in accordance with the trainee's attention level.
[0041] In addition, the attention level of the trainee is initially determined and then the appropriate level of VR contents can be chosen for the trainee's exercise.
[0042] [0042]FIG. 2 is a schematic diagram illustrating the interaction between the biofeedback module and the virtual reality in accordance with the present invention.
[0043] Referring to FIG. 2, the brain wave is detected through the brain-wave detector 130 of the trainee 100 and then normalized at EEG amplifier 132 .
[0044] The relative ratio of the strength of each brain wave is thereafter calculated at a biofeedback module 133 to evaluate the level of the trainee's attention.
[0045] Now, the VR contents for attention enhancement are selected in accordance with the current level of the trainee's attention. As an exemplary preferred embodiment, the VR environment can be assumed to be a classroom for students.
[0046] At the front of the classroom is located a large screen. A teacher is now explaining the subjects while there is a large desk in front of the trainee. The trainee takes a lot of subjects and gives answers for attention enhancement on the desk.
[0047] Preferably, the subjects for attention enhancement include visual comparison module, auditory comparison module, memory comparison module, and attention shifting module.
[0048] As a preferred embodiment of visual comparison module in accordance with the present invention, a couple of objects out of a circular cylinder, a circular cone, a sphere, a quadrilateral cone, a triangular cone, a regular hexahedron, a hexahedron can be chosen to show up on the desk.
[0049] After comparing the two objects that are shown in front of him, the trainee clicks the mouse if he thinks the two objects are identical. Furthermore, the next question asking if he thinks that the currently displayed objects of the two are identical can be presented after some interval.
[0050] Preferably, the level of difficulty can be adjusted by employing objects with wide range of complexity. The biofeedback VR system in accordance with the present invention presents VR contents comprising a couple of geometric objects to the trainee.
[0051] The trainee is then requested to answer to the questions related to the objects. Now, the VR contents are updated with different visual element for presentation in response to the trainee's answer.
[0052] As a preferred embodiment of auditory comparison module in accordance with the invention, a vocabulary can listed in a moving fashion on the monitor while a teacher is explaining about a subject that is correlated with the current vocabulary.
[0053] In this case, the trainee is supposed to click the mouse once he thinks the listed vocabulary coincides with the teacher's explanation or the implication of the environment.
[0054] Now, the response time of the trainee's recognition to the abrupt appearance of a vocabulary on the monitor can be evaluated and then the level of attention is calculated with the evaluated response speed.
[0055] In response to the trainee's attention level, a subsequent set of problems asking the trainee if the associated word is supposed to have something to do with what he listens.
[0056] Then the VR computer can either change the displayed moving speed of the associated word or alter the auditory elements of the VR contents. As a consequence, the attention level of the trainee can be forced to enhancement.
[0057] As a preferred embodiment of memory comparison module in accordance with the present invention, the trainee can be asked to detect the change in the classroom environment where a new item is stealthily introduced in the VR environment under fade-in and fade-out mode.
[0058] The above-mentioned embodiment can be employed for enhancing the environment memorizing capability of the trainee. In other words, a first VR content that has been chosen in response to the attention level of the trainee is made gradually disappear and replaced by a second VR content. In this case, there is a minor change between the first and second VR contents for testing the trainee's recognition capability.
[0059] Then the trainee has to detect an object in the current VR content from the previous VR content.
[0060] Now, the VR computer updates the level of the contents for the trainee' exercise in response to the trainee's answer to the inquiry of telling the difference between a couple of successive VR contents.
[0061] Additionally, as a preferred embodiment of attention shifting module in accordance with the present invention, the VR computer can present several models like a star, a ball, or a bell together with a reference model.
[0062] In this case, the trainee is requested to choose one model that he believes to be the most similar to the reference model in terms of shape, coloring, or other features.
[0063] Preferably, the VR computer can respond to the trainee's answer by generating a specific sound for correct answer.
[0064] More preferably, the trainee can be asked to choose a second most similar object by having him reconsider other features of the reference model if he has selected a wrong answer.
[0065] In other words, the present invention presents a multiple of object models with the reference model for comparison. Then the trainee is requested to choose the most appropriate one out of a multiple of object models that he thinks to be the most similar to the reference model.
[0066] If the trainee's answer is correct, the VR computer upgrades the level of attention-shift capability in order to induce the enhancement of the trainee's attention.
[0067] [0067]FIG. 3 is a schematic diagram illustrating a second embodiment of a VR system in accordance with the present invention. Referring to FIG. 3, the VR system for enhancing attention comprises a virtual reality environment 160 , an attention enhancement software module 150 , a biofeedback device 120 , and a doctor or a trainer 200 .
[0068] The biofeedback device 120 in accordance with the invention senses brain waves of specific spectral ranges including a first beta-wave (13˜20 Hz), a second beta-wave (20˜40 Hz), an alpha-wave (8˜13 Hz), and a theta-wave (4˜8 Hz).
[0069] Now, the attention level of the trainee can be evaluated by estimating the strength ratio of the sum of the first and second beta-waves and the sum of the alpha-wave and the theta-wave.
[0070] Preferably, the level of the VR contents can be downgraded if the attention level of the trainee goes up. In the meanwhile, the level of the VR contents can be upgraded if the attention level of the trainee goes downward.
[0071] More preferably, if the trainee's attention level goes downward, the speed of the moving object in the VR contents should be raised.
[0072] In addition, if the trainee's attention level goes upward, the VR contents wherein the velocity of the moving object is reduced are preferably provided to the trainee in order to enhance the trainee's attention level.
[0073] More preferably, if the trainee's attention level goes downward, the VR contents with relative difficulty can be presented for the enhancement of the trainee's attention.
[0074] In the meanwhile, the updated VR contents should include relatively less difficult exercises if the trainee's attention level goes up.
[0075] As a preferred embodiment in accordance with the present invention, the trainee 100 is absorbed in the VR while the trainee's attention level is estimated from the information of the detected brain waves through the biofeedback sensor.
[0076] Thereafter, the VR contents are updated in response to the estimated level of the trainee's attention. Now, the doctor 200 can make diagnosis of the trainee 100 both in reality and in virtual reality.
[0077] Although the invention has been illustrated and described with respect to exemplary embodiments thereof, it should be understood by those skilled in the art that various other changes, omissions and additions may be made therein and thereto, without departing from the spirit and scope of the present invention.
[0078] Therefore, the present invention should not be understood as limited to the specific embodiment set forth above but to include all possible embodiments which can be embodies within a scope encompassed and equivalents thereof with respect to the feature set forth in the appended claims.
|
The present invention discloses a system and method for the enhancement of attention and further the treatment of attention deficit disorder. The present invention also presents a virtual reality environment for enhancing attention shift, selective attention, and sustained attention by correlating a biofeedback device that estimates the current attention level of the patient.
| 0
|
BACKGROUND
1. Field of Invention
The present invention relates the field of magnetocardiogram (MCG) imaging. More specifically, it relates to the generation of high-resolution MCG images from sparse data input from an electromagnetic sensor unit.
2. Description of Related Art
Cardiac electric currents are generated by electrophysiological processes in the heart. Localizing abnormal electric currents is very important for diagnosing ischemic diseases such as myocardial infarction, angina cordis, etc. It also benefits patients in the catheter lab for both treatment and follow-up, as is explained in “Forty Years of Magnetocardiology”, by F. Stroink, in Int. Conf. on Biomagnetism Advances in Biomagnetism, 28:1-8, 2010.
Traditionally, cardiac electric activities such as arrhythmia are diagnosed by means of an electrocardiogram (ECG). However, since an ECG only provides temporal information, it cannot localize abnormal currents in the heart directly, even if the ischemic disease has been detected. However, by using a large number of electrodes (leads), Body Surface Potential Mapping (BSPM) is able to reconstruct a body surface potential map, as is explained in “Noninvasive volumetric imaging of cardiac electrophysiology”, by Wang et al., in CVPR , pages 2176-2183, 2009. Nonetheless, the accuracy of electric current localization is still limited because the signals are often distorted due to the poor conductivity of body tissue.
The advent of the magnetocardiogram, or magnetocardiography, (MCG) provides more accurate measurements of cardiac electric currents, both spatially and temporally. With reference to FIG. 1A , an MCG system consists of a sensor unit 11 consisting of a small number of electromagnetic sensors 13 (typically arranged as a planar array of sixty-four or fewer sensors). Electrical impulses within the body create a magnetic field 15 . In the present case, the human heart 19 functions as the observed current source 17 .
Each sensor 13 is a capture point, and hereinafter may be referenced as a capture 13 . Each capture 13 measures a one-dimensional (i.e. 1D) magnetic waveform in a direction perpendicular to the sensor planar array (i.e. the z-direction) emanating from the patient's chest 21 (i.e. human torso). The MCG sensor unit 11 is usually placed five to ten centimeters above the patient's chest 21 , and measures the patient's heart magnetic field in a non-invasive way. At each capture 13 a low resolution (hereinafter, low-res), two-dimensional (2D) MCG map of electromagnetic activity is measured.
Compared to ECG, MCG has a few advantages. First, the magnetic field generated by the heart's electrical impulses (i.e. currents) is not distorted in the direction perpendicular to the body surface (i.e., z direction), due to the magnetic property of body tissue. Thus MCG is more accurate and sensitive to weak electrical activities in the early stage of heart disorders. Second, the MCG sensor array can localize the position of electrical currents in the heart. Finally, MCG measurements are non-invasive. After forty years of research in MCG, cardiac electric current localization and high resolution visualization for MCG measurements are attracting more and more interest from both research and clinical areas.
However, there are a number of difficulties associated with MCG, which so far has prevented MCG from becoming a mainstream medical diagnostic tool in cardiology. One difficulty is that the low-res 2D MCG maps are not sufficient for localizing electric currents in the heart. For example, a 64 channel Hitachi™ MCG system with a 25 mm sensor interval (as described in “Newly Developed Magnetocardiographic System for Diagnosing Heart Disease”, by Tsukada et al., in Hitachi Review, 50(1):13-17, 2001) only measures an 8×8 MCG map (i.e. an 8×8 array of 64 measurement points).
The resolution of an MCG map is limited due to the size of the sensors 13 , which limit the number of sensors 13 that an MCG sensor unit 11 may have.
Thus, a necessary step in MCG, is creating a high resolution (hereinafter High-res) MCG image, or map, from a low-res 2D MCG map. Two image examples 23 and 25 of such high-res images are shown in FIG. 1B . Image 23 shows the tangential image of a restored high-res MCG image of a healthy heart. The maximal point 25 (i.e. strongest point) within image 23 indicates the location (or source) of electric current in the heart. Thus, high-res MCG images permits doctors to directly “see” the electrical activity in the heart. Image 25 shows the tangential image of a restored high-res MCG image of an unhealthy heart. It differs significantly from image 23 of a healthy heart, and thus provides important cues for diagnosis. Compared to low-res MCG maps, high-res MCG images provide more diagnostic significance, and serve as the basis for an accurate electric current localization.
Most current MCG systems use curve fitting interpolation methods to reconstruct high-res MCG images from low-res 2D MCG maps, as is shown in “Magnetocardiographic Localization of Arrhythmia Substrates: A Methodology Study With Accessory Path-Way Ablation as Reference”, by B. A. S. et al., in Ann Noninvasive Electrocardiol, 10(2):152-160, 2005, and shown in “Evaluation of an Infarction Vector by Magnetocardiogram: Detection of Electromotive Forces that Cannot be Deduced from an Electrocardiogram”, by Nomura et al, in Int. Congress Series, 1300:512-515, 2007. Unfortunately, the accuracy of curve fitting methods is usually limited.
Another method for improving the accuracy of high-res MCG images first reconstructs a three-dimensional (3D) position, magnitude and orientation of electric currents, given the low-res MCG measurements. This method is generally called the inverse problem, and is more fully explained in “Magnetocardiographic Localization of Arrhythmia Substrates: A Methodology Study with Accessory Pathway Ablation as Reference”, by R. J. et al., in Europace, 11(2):169-177, 2009, and explained in “Conversion of Magnetocardiographic Recordings Between Two Different Multichannel Squid Devices”, by M. B. et al., in IEEE Trans. on Biomedical Engineering, 47(7):869-875, 2000. This method generally computes a high-res MCG image based on current reconstructed by the Biot-Savart law.
As it is known in the art, however, according to the Helmboltz reciprocity principal, the inverse problem for MCG is an ill posed problem unless the number of electric currents is known. But even when the current number is known, it requires solving a large scale nonlinear optimization problem which is often computationally expensive and may lead to undesired local minimum.
R. J. et al. therefore propose a simplified solution by assuming a single electric current located at the world origin and far from the sensor array. As it is known in the art, linear solutions may be presented for special cases where the current positions are fixed at uniform grids in the heart. The presented linear solutions can be over-constrained or under-constrained. These methods, however, make another assumption that the sensor array and heart are perfectly aligned. In practice, these assumptions often can be difficult to satisfy.
Therefore, high-res MCG image restoration based on these types of methods can often be unreliable.
Recently machine learning techniques have been applied to high-res MCG image restoration. An example of this approach applies learned nonlinear interpolation functions using neural networks.
SUMMARY OF INVENTION
An object of the present invention is a method of creating more accurate high-res MCG images.
Another object of the present invention is to provide a less computing-intensive approached toward generating accurate high-res MCG images form low-res 2D maps.
A further object of the present invention is to eliminate the need for assumption regarding the alignment of an MCG system and a patient's torso.
These objects are achieved by considering the high-res MCG image restoration as an example based super-resolution problem. Typically, one would require a library of true examples from which to learn characteristic of such true examples. However, since it is infeasible to measure dense magnetic fields, and thus not feasible to obtain such true example from direct measures, the presently preferred embodiment uses a model learning algorithm based on synthetic high-res MCG images. The sample images are randomly generated based on the Biot-Savart Law. From these samples the algorithm constructs a linear model by principal component analysis (PCA). By projecting the sparse measurements into the subspace of the linear model, the model coefficients are estimated and the high-res MCG image can be restored as a model instance.
As is explained above, an MCG image typically provides low-res, 2D MCG maps, and the inverse problem (i.e. reconstruction of the position and moment of the electric current) would typically be applied to the low-res, 2D MCG maps. It is presently preferred, however, that the inverse problem be applied to the restored high-res MCG image.
Given the high-res MCG image, the 2D position of the electric current can be localized as the maximal point of the tangential components of the high-res MCG image. To improve the 2D localization accuracy, a nonlinear optimization algorithm is developed to solve the inverse problem. At the same time, the depth, magnitude and orientation of the electric current are also recovered. More specifically, the preferred algorithm alternates two steps iteratively. The first step estimates the 3D current position, and the second step reconstructs its magnitude and orientation. The 2D current location estimated from the model based restoration is used as the initialization. The present method is efficient, accurate and reliable without the need of special assumptions.
The above objects are met in a magnetocardiogram (MCG) system comprising: a sensor unit including M×M electromagnetic sensors producing a sparse measurement output of M×M data units, said sparse measurement output constituting a first MCG image; a linear model defining a second MCG image of substantially higher resolution than said first MCG image, said second MCG image having a P×P resolution where P>M, said linear model establishing interpolation patterns between characteristics of the linear model and any data point of said M×M measurement output; and a high resolution MCG image synthesizer for producing a third MCG image by projecting said first MCG image onto the subspace of the linear model, and establishing coefficients for said third MCG image in accordance with the linear model and said M×M data units.
In this MCG system, the third MCG image has a P×P resolution.
Preferably, the MCG system further has an electric current localizer for determining a position and momentum of an electric current in accord with said third MCG image, said electric current localizer evaluating the electromagnetic output data from each electromagnetic sensor in an x-y orientation (Bxy) assuming single dipole, computing dense Bxy from dense Bz, finding the image maximum in said third MCG image, and using this determined position information as a starting point in an iterative process for identifying a three-dimensional position vector {right arrow over (p)} and momentum vector {right arrow over (J)} for said electric current.
In this approach, the identifying a three-dimensional position vector {right arrow over (p)} and momentum vector i for said electric current further includes: Given said third MCG image B z (i,j)(i=1, 2, . . . , N; j=1, 2, . . . , N), the maximal point of the tangential components B′ xy (i,j) of B z (i,j) refers to the 2D position (x p , y p ) of the electric current, and the tangential components of B z (i,j) is computed as B xy (i,j)=√{square root over ((∂B z (i,j)/∂x) 2 +(∂B z (i,j)/∂y) 2 )}{square root over ((∂B z (i,j)/∂x) 2 +(∂B z (i,j)/∂y) 2 )}; and said iterative process for identifying position vector {right arrow over (p)} and momentum vector {right arrow over (J)} for said electric current includes: (a) defining the Biot-Sarvart Law as {right arrow over (B)} m ={right arrow over (J)}×{right arrow over (R)} m =−{right arrow over (R)} m ×{right arrow over (J)}, where {right arrow over (B)} m ={right arrow over (B)}({right arrow over (r)} m ), {right arrow over (J)}={right arrow over (J)}({right arrow over (p)}) and
R → m = μ 0 4 π ( r → m - p → ) r → m - p → 3 ;
(b) expanding this definition of the Biot-Sarvart Law to a matrix form by using a skew-symmetric matrix:
B
→
m
=
-
[
R
→
m
]
×
J
→
=
-
[
0
-
R
m
3
R
m
2
R
m
3
0
-
R
m
1
-
R
m
2
R
m
1
0
]
·
[
J
1
J
2
J
3
]
where the z component of the magnetic field is computed as:
B z m =[R m 2 ,−R m 1 ]·[J 1 ,J 2 ]′
where R m 1 ,R m 2 are x,y components of {right arrow over (R)} m , and for said M×M electromagnetic sensors one has a linear system:
[
B
z
1
B
z
2
⋮
B
z
M
]
︸
B
=
[
R
1
2
-
R
1
1
R
2
2
-
R
2
1
⋮
⋮
R
M
2
-
R
M
1
]
︸
R
·
[
J
1
J
2
]
︸
J
where B is a measured M×1 vector, R is a M×2 position matrix that is computed from given {right arrow over (p)} and {right arrow over (δ)} m , and a lease square solution for J provides an estimation of J defined as J=(R T R) −1 R T B; (c) defining the Biot-Sarvart Law
B
→
m
=
μ
o
4
π
J
→
×
(
(
r
→
o
+
δ
→
m
)
-
p
→
)
(
r
→
o
+
δ
→
m
)
-
p
→
3
=
μ
o
4
π
J
→
×
(
ɛ
→
o
+
δ
→
m
)
ɛ
→
o
+
δ
→
m
3
,
letting α=4π/μ 0 and {right arrow over (ε)} 0 ={right arrow over (r)} 0 −{right arrow over (p)}, identifying {right arrow over (δ)} m as known for each sensor to redefining the Biot-Sarvart Law as
α
B
→
m
=
J
→
×
ɛ
→
o
+
J
→
×
δ
→
m
ɛ
→
o
+
δ
→
m
3
letting {right arrow over (τ)} m ={right arrow over (J)}×{right arrow over (δ)} m and {right arrow over (ε)}=(x ε ,y ε ,z ε ) T and computing {right arrow over (τ)} m from {right arrow over (J)}, for each sensor m=1:M, defining a nonlinear equation in terms of (x ε ,y ε ,z ε ) as
α
B
z
m
+
-
J
x
ɛ
2
+
J
y
ɛ
1
+
τ
m
3
(
(
x
ɛ
+
δ
m
1
)
2
+
(
y
ɛ
+
δ
m
2
)
2
+
(
z
ɛ
+
δ
m
3
)
2
)
3
/
2
=
f
m
(
x
ɛ
,
y
ɛ
,
z
ɛ
)
=
0
letting F=(f 1 ; f 2 ; . . . ; f M )=0, and solving a least square solution of the nonlinear system F for {right arrow over (ε)} 0 ; (d) using {right arrow over (ε)} 0 from step (c) to update the position matrix R and recompute J as in step (b), and iteratively repeat steps steps (b) and (c) until converges is achieved; and (e) defining the {right arrow over (p)}={right arrow over (r)} 0 −{right arrow over (ε)} 0 , and defining the initial depth z and magnitude ∥{right arrow over (J)}∥ of the electric current as
z
=
d
/
2
.3
cm
,
J
→
=
4
π
d
2
B
z
max
0.385
μ
0
where d is the distance between two magnetic poles in the third MCG image.
Further preferably, in the present MCG system, the linear model is defined as creating a plurality of synthesized magnetocardiogram images having the same resolution as said second MCG image, said synthesized magnetocardiogram images being based on simulated electrical impulses within a three-dimensional spatial heart volume, as it would be perceived in an expected magnetocardiogram system.
In this case, the plurality of synthesized magnetocardiogram images includes at least one thousand synthesized images simulating perceived electrical impulses per predefined depth level within said heart volume.
Additionally, the synthesized MCG images are synthesized using the Biot-Savart Law.
Also, the synthesized MCG images are based on randomly generated currents within said heart volume.
Furthermore, the linear model is created using by principal component analysis (PCA).
In the presently preferred MCG system, the interpolation patterns are established by the following steps: (A) defining the following notation: N×N dense Bz magnetic field map to form a vector; M×M sparse measurement to form a vector; K randomly generated single current dipoles Q; (B) for each randomly generated current Q, compute N×N magnetic field map using Biot-Savart equation and stack the image to a vector f 1 ; (C) repeating step (B) to obtain K samples and get a data matrix A=└f 1 , f 2 , . . . f K ┘; and (D) training a PCA model given input data A, to obtain the eigenmatrix Σ f .
In an embodiment of the present invention, the third MCG image is created by: given a new dipole and M×M sparse measurements g j finding the corresponding rows in the eigenmatrix, and denoting a resultant submatrix as Σ g ; projecting the sparse measurement to the PCA subspace and computing the coefficients as c g =Σ g + (g j −g mean ), where Σ g + is an estimation of the inverse of Σ g ; and using the computed coefficients and original PCA space to reconstruct the dense magnetic field map Bz, as f j =Σ f c g +f mean .
Also in an embodiment of the present invention, the producing of said third MCG image includes: defining the sparse measurement output as a vector g; defining the linear model as Σ; extracting from Σ the row corresponding to sparse measurement output to form a sub-eigenmatrix Σ g ; projecting g onto Σ g ; defining the establishment of coefficients as c g =Σ g + (g i =μ g ), where Σ g + is the pseudo inverse of Σ g , μ g are extracted coefficients from a mean vector μ of linear model Σ; and defining the high resolution MCG image vector h as h=Σ·c g +μ
The above objects also are met in a method of creating a magnetocardiogram (MCG) image from a sparse measurement output provided by a sensor unit including a plurality of electromagnetic sensors, each electromagnetic sensor contributing its output data to said sparse measurement output, said method comprising; defining high resolution to mean a resolution substantially higher than the resolution provided by said sparse measurement output; creating a plurality of synthesized high resolution magnetocardiogram images based on simulated electrical impulses within a three-dimensional spatial heart volume, as it would be perceived in an expected magnetocardiogram system; creating a linear model of the synthesized high resolution magnetocardiogram images to establish interpolation patterns between characteristics of the linear model and any sparse measurement output; and creating a representative high resolution MCG image by projecting said sparse measurement output onto the subspace of the linear model, and establishing coefficients.
Preferably in this method, the plurality of synthesized high resolution magnetocardiogram images includes more than one thousands images simulating perceived electrical impulses at different depths within said heart volume.
Further preferably, the synthesized high resolution MCG images are synthesized using the Biot-Savart Law.
If desired, the synthesized high resolution MCG images may be randomly generated.
In a preferred embodiment, the linear model is created using by principal component analysis (PCA).
Also in a preferred embodiment, the interpolation patterns are established by the following steps: (A) defining the following notation: N×N dense Bz magnetic field map to form a vector; M×M sparse measurement to form a vector; K randomly generated single current dipoles Q; (B) for each randomly generated current Q, compute N×N magnetic field map using Biot-Savart equation and stack the image to a vector f 1 ; (C) repeating step (B) to obtain K samples and get a data matrix A=└f 1 , f 2 , . . . f K ┘; and (D) train a PCA model given input data A, to obtain the eigenmatrix Σ f .
In this approach, the representative high resolution MCG image is created by: given a new dipole and M×M sparse measurements g j , finding the corresponding rows in the eigenmatrix, and denoting a resultant submatrix as Σ g ; projecting the sparse measurement to the PCA subspace and computing the coefficients as c g =Σ g + (g j −g mean ), where Σ g + is an estimation of the inverse of Σ g ; and using the computed coefficients and original PCA space to reconstruct the dense magnetic field map Bz, as f j =Σ f c g +f mean .
More specifically, the step of creating a representative high resolution MCG image includes: defining the sparse measurement output as a vector g; defining the linear model as Σ; extracting from Σ the row corresponding to sparse measurement output to form a sub-eigenmatrix Σ g ; projecting g onto Σ g ; defining the establishment of coefficients as c g =Σ g + (g i −μ g ), where E g + is the pseudo inverse of Σ g , μ g are extracted coefficients from a mean vector μ of linear model Σ; and defining the high resolution MCG image vector h as h=Σ·c g +μ.
Other objects and attainments together with a fuller understanding of the invention will become apparent and appreciated by referring to the following description and claims taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings wherein like reference symbols refer to like parts.
FIG. 1 a illustrates an MCG measurement system in accord with the present invention.
FIG. 1 b compares the tangential image of a restored high-res MCG image of a healthy heart with that of an unhealthy heart;
FIG. 2 illustrates a 2D sensor array in spatial relation with a heart volume in a simulation setup in accord with the present invention.
FIG. 3 shows various examples of training images in accord with the present invention.
FIG. 4 a illustrates the random generation of electric currents at different depth layers;
FIG. 4 b plots the results of 64 trials at different depths, z.
FIG. 5 compares high-res MCG images created using the present invention with a prior art method and with a ground truth example.
FIG. 6 illustrates the spatial configuration of sensors and electric current in accord with the present invention.
FIG. 7 compares high-res MCG images created using the present invention with a prior art method and with a ground truth example.
FIG. 8 illustrates 2D voxel current localization errors with respect to different sizes of voxel current.
FIG. 9 shows a real phantom experimental setup in accord with the present invention.
FIG. 10 illustrates the absolute and relative errors between the real measurement and the ground truth which is computed based on the Biot-Savart Law.
FIG. 11 shows 2D Localization results shown in B′ xy (i,j) for three measurements while changing the distance between the sensor and the coil to: 5 cm, 10 cm and 15 cm.
FIGS. 12 a to 12 c show various equations useful in explanation of the present invention.
FIGS. 13 a to 13 d show various tables showing test results.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The presently preferred embodiment considers the high-res MCG image restoration as an example based super-resolution problem. Typically, one would require a library of true examples from which to learn characteristics of such true examples. However, since it is impractical to measure dense magnetic fields, and thus not feasible to obtain such true examples from direct measures, the presently preferred embodiment uses a model learning algorithm based on synthetic high-res MCG images.
The sample images are preferably randomly generated based on the Biot-Savart Law. From these sample images, a linear model is constructed a by use of principal component analysis (PCA). Sparse measurements from an MCG sensor unit are then projected into the subspace of the linear model to estimate model coefficients and restore a high-res MCG image as a model instance.
With a high-res MCG image thus reconstructed, it can then be analyzed to identify the location, depth, magnitude and orientation of an electric current.
As is explained above, an MCG image typically provides low-res, 2D MCG maps that do not provide enough information for directly recovering specific information of electrical currents. However, once the high-res MCG image is reconstructed, the 2D position of the electric current can be localized as the maximal point of the tangential components of the high-res MCG image. To improve the 2D localization accuracy, a nonlinear optimization algorithm is developed to solve the inverse problem. At the same time, the depth, magnitude and orientation of the electric current are also recovered. More specifically, the preferred algorithm alternates two steps iteratively. The first step estimates the 3D current position, and the second step reconstructs its magnitude and orientation. The 2D current location estimated from the model based restoration is used as the initialization. The present method is efficient, accurate and reliable without the need of special assumptions. For the sake of simplicity, the presently preferred system/method is illustrated as applied to a single electric current case only. It is to be understood, however, that extension of the present system/method to multiple currents is straightforward.
The present embodiment utilizes various computing devices (or data processing devices) to learn (i.e. create) a linear model from a set of high-res MCG images generated by random electric currents. Sparse data (i.e. a low resolution image) received from an MCG sensor unit is then projected onto the linear model, and a high resolution image representation of the low resolution image is created there from. An example of this approach is illustrated in FIG. 2 .
With reference to FIG. 2 , the left-hand image (a) illustrates a top-view of a 2D sensor array (or sensor plane) in relationship with a side-view, 3D spatial heart volume 33 (right-hand image (b)) in a simulation setup. Left-hand image (a) is a top view of an MCG system, such as that shown in FIG. 1( a ). In the present example, the top view (a) of FIG. 2 shows an MCG sensor unit 11 with 64 physical sensors 13 arranged in an 8×8 sensor array. In the present embodiment, however, four virtual sensors 31 are inserted between adjacent real, physical sensors 13 , and the area within the square defined by physical sensors 13 and virtual sensors 31 is filled with a 4×4 array of additional virtual sensors 31 . Thus, the present embodiment adds 1232 virtual sensors 31 to the 64 physical sensors 13 for a total of 1296 sensors. This is equivalent to a 36×36 sensor array, and constitutes the basis for the present high-res image. Assigning one image pixel per sensor, the present embodiment provides for a P×P (P >8) pixels in a high-res MCG image. Preferably, the sensor plane is 5 to 10 cm above the heart volume bounding box 33 , which in the present case is 10×10×10 cm 3 . The electric current is represented by a vector located at a 3D point.
It is to be understood that the number of virtual sensors, and thus the value of P is design choice. A later experiment described below, for example, incorporates a higher number of virtual sensors to produce an even higher resolution MCG image.
FIGS. 12A to 12C show various equations (Eq. 1 to Eq. 12) to facilitate discussion of the present invention.
Given a single electric current, a magnetic field at each sensor 13 can be computed based on the Biot-Sarvart Law, equation Eq. 1, where {right arrow over (J)}({right arrow over (p)}) is the moment of the current including its magnitude and orientation. In this case, {right arrow over (p)} is the 3-dimensional (i.e. 3D) position vector of the current. Note that this representation of electric current is an approximation by assuming the size (or magnitude) of the current is zero. One can consider that the volume (size, or density) information is included in the moment vector {right arrow over (J)}. {right arrow over (B)}({right arrow over (r)} m ) is the magnetic vector measured by the m th sensor at position {right arrow over (r)} m ={right arrow over (r)} o +{right arrow over (δ)} m , where r o is the reference point of the sensor plane and δm indicates the offset of the m th sensor with respect to r o . As it is known in the art, μ o is the magnetic constant.
In typical MCG systems, only the z component of {right arrow over (B)} is measured.
From Eq. 1 one may compute B z (the z component of {right arrow over (B)}) by means of equation Eq. 2, where J 1 ,J 2 ,J 3 represent the three components of the current moment vector {right arrow over (J)}; x p ,y p ,z p represent the three components of the current position vector {right arrow over (p)}; and r m 1 ,r m 2 ,r m 3 represent the three components of the sensor position vector {right arrow over (r)} m .
In a training step, a set of high-res P×P MCG images (where P>>M) are generated. To generate each P×P MCG image, a single electric current with both random moment and 3D position is created. The high-res P×P MCG image is computed based on Eq. 2.
Some examples of training images are shown in FIG. 3 . Each high-res MCG image is generated by a single electric current with both random moment and 3D position. Since the magnetic field generated by the heart is very weak (10 −12 to 10 −10 Tesla), the high-res MCG image is normalized to 0˜255 and displayed using a JET color map. The images from different rows are generated from different depths (the distance of the electric current in z direction). In this manner, K high-res MCG training images are generated. All the image vectors (the mean vector is denoted by μ) are centralized, and they are stacked into a matrix A. Matrix A thus consists of K columns of P×P vectors. PCA is applied to extract the eigenvectors of matrix A.
A received sparse M×M measurement from an MCG sensor unit defines a vector g. To restore (i.e. create) a high-res MCG image given a sparse M×M measurement (vector g), one first extracts the corresponding rows from the eigenmatrix Σ to form a sub-eigenmatrix Σg. Similarly, vector g's corresponding elements from mean vector μ form a sub-mean vector μ g . Vector g is then projected to sub-eigenmatrix Σg, and model coefficients c g are calculated as c g =Σ g + (g j −ρ g ), where Σ g + is the pseudo inverse of Σg. Finally the original eigenmatrix Σ along with estimated coefficients c g are used to reconstruct the high-res MCG image vector h, as h=Σ·c g +μ, where h is a P×P vector.
FIG. 3 illustrates four rows of different MCG images. The four rows of MCG images are generated at four respective depths, or layers, (i.e. different distances to electric current locations, or sources, in the z direction). A big variance can be seen between the MCG images when changing depths.
An illustration of these depth layers 41 is shown in FIG. 4A . In the presently preferred embodiment, electric currents are randomly generated at different depth layers 41 . It would be too exhaustive to sample every depth to select a set of depth layers. This approach assumes that B z can be approximated as a linear function of the current depth, as is explained more fully below.
In the present approach, the sensor positions {right arrow over (r)} m , the 2D position (x p , y p ), and the moment J of the electric current are fixed. B z is only affected by the depth z of the current. Thus, Eq. 2 can be simplified to Eq. 3, where a m and b m are constants but unknowns, c=20 cm is the depth of the sensor, and z is the depth of the current, which varies between 0 to 10 cm within the heart volume bounding box. Preferably, a m lies in a range from −7.5 to 7.5 cm, and b m lies in a range from 0 to 112.5 cm.
By applying Taylor expansion to Eq. 3, one obtains Eq. 4. By ignoring O(Δz 3 ), one only needs to prove that
d 2 2 d z B z m ( z )
is close to zero for any possible z and any sensor.
A graph of
d 2 2 d z B z m ( z )
versus depth, z, is shown in FIG. 4 b . More specifically, the graph shows
d 2 2 d z B z m ( z )
in 64 trials with random a m and b m in each trial. As shown,
d 2 2 d z B z m ( z )
demonstrates a very small value (close to zero) when z varies from 0 to 10 cm. Therefore, a set of depth layers was sampled within this depth range, as is illustrated in FIG. 4 a.
In the present experiments, 1000 samples were generated in each of 10 evenly distributed depth layers. The presently preferred method of creating a restored high-res MCG image was then compared with the bicubic interpolation method, as well as with the actual, ground truth images.
With reference to FIG. 5 , a restored high-res MCG image generated by the bicubic interpolation is shown adjacent a corresponding high-res MCG image generated according to the present method. For evaluation purposes, a high-res MCG image reconstructed from the ground truth current based on the Biot-Sarvart Law is shown on the right. To better simulate physical conditions, 5% uniformly distributed random noise is added to each sensor. As is visually evident from the side-by-side comparison of the three images, the high-res MCG image constructed by the present method more closely matches the ground truth MCG image. Thus the present method achieves a higher level of accuracy in constructing high-res MCG images.
As is mentioned above, a 2D estimate of the electric current location can be obtained by analyzing the high-res MCG image. A presently preferred method for improving the localization accuracy is to solve a nonlinear optimization that reconstructs both 3D position and moment of the electric current, i.e. the inverse problem. An accurate high-res MCG image restored by the linear model provides a good initialization for the inverse problem and helps it converge on the global optimum more quickly. The preferred method for generating a 2D estimate from a high-res MCG image is as follows.
Given a high-res MCG image B z (i,j)(i=1, 2, . . . , N; j=1, 2, . . . , N), the maximal point of the tangential components B′ xy (i,j) of B z (i,j) refers to the 2D position (x p ,y p ) of the electric current. This may be seen in the second row images of FIG. 5 . The tangential components of B z (i,j) may be computed using equation Eq. 5. One now is left with solving the inverse problem.
The inverse problem is to solve both 3D position {right arrow over (p)} and moment {right arrow over (j)} of the electric current. This approach may be better understood with reference to FIG. 6 , where {right arrow over (r)} o is set as the world origin. If {right arrow over (p)} is given, the inverse problem becomes a linear one. First, Eq. 1 may be rewritten as Eq. 6, where {right arrow over (B)} m ={right arrow over (B)}({right arrow over (r)} m ), {right arrow over (J)}={right arrow over (J)}({right arrow over (p)}), and
R
→
m
=
μ
o
4
π
(
r
→
m
-
p
→
)
r
→
m
-
p
→
3
.
Eq. 6 is then expanded to a matrix form by using a skew symmetric matrix, which results in Eq. 7. In this case, the z component of the magnetic field can be computed as shown in Eq. 8, where R m 1 ,R m 2 are x,y components of {right arrow over (R)}. Given M sensors, a linear system is defined as illustrated in equation Eq. 9, where B is a measured M×1 vector, R is a M×2 position matrix that is computed from given {right arrow over (p)} and {right arrow over (δ)} m . In the present case, J is a 2×1 unknown vector. When rank(R)≧2 (this holds for the single electric current case with 64 sensors), one can solve a least square solution for J, as illustrated in equation Eq. 10.
Note that by only measuring B Z it is impossible to recover J 3 . In fact, the magnetic field generated by the z component of the current only propagates along the horizontal direction and never reaches outside of the body. For the following computation, one sets J 3 =0. Given an estimated current moment {right arrow over (J)}=[J,0], one can update the current position {right arrow over (p)}.
Eq. 1 is rewritten as equation Eq. 11. One may then let α=4π/μ 0 and {right arrow over (ε)} 0 ={right arrow over (r)} 0 −{right arrow over (p)}. {right arrow over (δ)} m is known for each sensor. One may then apply equation Eq. 12 to obtain α{right arrow over (B)} m . In Eq. 12, let {right arrow over (τ)} m ={right arrow over (J)}×{right arrow over (δ)} m and {right arrow over (ε)} 0 =(x ε ,y ε ,z ε ) T . It is noted that {right arrow over (τ)} m can be computed given {right arrow over (J)}. Again, the cross product is removed from Eq. 12 by using a skew-symmetric matrix. Therefore for each sensor m=1:M, one obtains a nonlinear equation in terms of (x ε ,y ε ,z ε ), as illustrated in Eq. 13. Letting F=(f 1 ; f 2 ; . . . ; f m )=0, one then solves a least square solution of the nonlinear system F for {right arrow over (ε)} 0 .
Once the offset {right arrow over (ε)} 0 is obtained, the position matrix R can be updated and J can be recomputed. These iterations are repeated until the algorithm converges. The inverse problem step converges in real time (0.5 seconds on average). Finally {right arrow over (p)}={right arrow over (r)} 0 −{right arrow over (ε)} 0 . Since the high-res MCG image only provides an estimate for 2D current position (x p ,y p ), the initial depth z and magnitude ∥{right arrow over (J)}∥ of the electric current are given by equation Eq. 14, where d is the distance between two magnetic poles in the high-res MCG image.
The present high-res MCG image restoration method and electric current localization algorithm was evaluated using both simulations and physical phantom setups. In both scenarios the ground truth of the 3D position {right arrow over (p)} g and moment {right arrow over (J)} g of the electric current are known.
The present simulation setup is similar to the setup showed in FIG. 1 . There are 8×8 physical sensors 13 with a 2.5 cm sensor interval. The entire measuring area is 17.5×17.5 cm 2 . The heart volume 19 is 10×10×10 cm 3 . The distance from the sensor array (or sensor unit) 11 to the top of the heart volume 19 is 5 cm. In each trial, a random electric current within the heart volume is generated. B z is computed at the 64 sensors 13 , and 5%, 10% or 15% random noise is added to each sensor. This added noise has a uniform or Gaussian distribution. The 64 sparse measurements with noise are used to restore a high-res MCG image having an N×N resolution. To achieve this, 50 pixels are inserted between two adjacent real sensors, which means that the interval between adjacent pixels in the high-res MCG image is 0.5 mm. In this case N=50×7+1=351.
Tables 1 to 4 in FIGS. 13 a to 13 d , respectively, illustrate some simulation results. Table 1 in FIG. 13 a shows the 2D electric current localization error with respect to different noise types and ratios over 200 trials (depth is not considered in this case). There are a number of previous works that report accuracy about the 2D electric current localization. For example, “Biomagnetic Noninvasive Localization of Accessory Pathways in Wolff-Parkinson-White Syndrome”, in Pacing and Clinical Electrophysiology , by Weismuller et al., 14(111):1961-1965, 1991, and in “Magnetocardiographic Non-invasive Localization of Accessory Pathways in the Wolff-Parkinson-White Syndrome by a Multichannel System”, in European Heart J ., by P. Weismuller and et al, 13(5):616-622, 1992, the 2D localization accuracy for Wolff-Parkinson-White (WPW) syndrome is between 0 cm to 5 cm, and average 1.8 cm. Also, “Magnetocardiographic Localization of Arrhythmia Substrates: a Methodology Study with Accessory Pathway Ablation as Reference”, in IEEE Trans. on Medical Imaging , by P. L. Agren and et al., 17(3):479-485, 1998, reports the 2D localization accuracy for arrhythmia substrate as being 2.1 cm and 9.6 cm. Lastly, “Noninvasive Diagnosis of Arrhythmic Foci by Using Magnetocardiograms,—Method and Accuracy of Magneto-Anatomical Mapping System”, in J. of Arrhythmia , by S. Yamada and et al., 16:580-586, 2000, and “Magnetocardiograms in clinical medicine: unique information on cardiac ischemia”, by S. Yamada et al., in Arrhythmias and Fetal Diagnosis, 2005, show a similar setup consisting of 8×8 sensors, a 2.5 cm sensor interval, and a 5% random noise, but neither the sensor depth nor the noise type is reported. They report the 2D localization accuracy as being 1.4 mm+/−0.7 mm for simulation, 8 mm for WPW and 7 mm PCV. Compared to previous work, the method shows better accuracy than the current state of art.
Moreover, since the present method solves the inverse problem, the present method permits the reconstruction of the 3D position of the electric current and its moment. Applicants believe that the the present ability to reconstruct a 3D current is new to the present field.
Table 2 in FIG. 13 b shows the 3D current localization error. When the noise level is increased, the depth reconstruction becomes less accurate, which can be caused by an inaccurate initialization. Table 4 in FIG. 13 d shows the orientation difference between the reconstructed current moment {right arrow over (J)} rec and the ground truth current moment {right arrow over (J)} g . As can be seen, the orientation of the electric current is very robust to not only the measurement noise, but also the depth error.
Table 3 in FIG. 13 c shows the current magnitude reconstruction error. Since the current magnitude is very weak, the relative error is computed. All the results are averaged from 200 trials. FIG. 7 shows an example of a high-res MCG image restored by the linear model (left), a high-res MCG image computed given the reconstructed current ({right arrow over (J)} rec ,{right arrow over (p)} rec ) (middle), and a high-res MCG image computed given the ground truth current ({right arrow over (J)} g ,{right arrow over (p)} g ) (right), and 5% uniformly distributed random noise is added to each sensor.
In reality, an electric current is more like a voxel rather than a point. Different sizes of voxel currents were simulated by generating a set of point currents within a small cube by a 0.5 mm interval. FIG. 8 shows the 2D localization error for voxel currents. The geometric center of the voxel current is used as the ground truth. The results demonstrate that the present localization algorithm is robust to the size of the electric current, and comparable to the state of art (which only considers the point current).
A real phantom experiment is shown in FIG. 9 . In this setup, a 4-turn vertical circular coil 51 is used as the ground truth current. It is built in a “Signal Coil” component. Above the coil there is a table 53 with a fixed (x,y) position but a varying z position with respect to the coil 51 . On the table is printed an 8×8 grid 55 marked in 2 cm intervals, spanning from −4 to 3 in each direction. The coil 51 is right below the (0,0) coordinate. A fluxgate sensor 57 (Mag639™) is used to measure the z component of the magnetic field at each grid point. A spectrum analyzer 59 is used to read the signal from the fluxgate sensor.
In this real phantom experiment, the electric current has a physical shape and size. It can be considered as a set of small line segment currents. The present localization algorithm estimates the 2D position of the geometric center of the coil. By synchronizing the fluxgate sensor measurement with the AC generator, one can simulate an 8×8 MCG system. The output of the fluxgate sensor 57 is imported to the spectrum analyzer 59 and converted to measurements in Tesla.
The real phantom setup is totally unshielded thus the measurement noise is big, which is shown in FIG. 10 . Three MCG measurements were simulated by changing the distance between the sensor and the coil to: 5 cm, 10 cm and 15 cm, and then estimated the 2D geometric center of the coil. FIG. 10 compares the absolute and relative errors between the real measurements and the ground truth measurements which are computed based on the Biot-Sarvart Law. When z=5 cm, over a ¼ of sensor measurements have over 70% noise; for other two cases the noise ratio is a little bit smaller but still about half of sensors have over 30% noise. Even in such a noisy setup, the present localization method can still achieve 6:9 mm 2D accuracy, as is shown in FIG. 11 . When the sensor depth increases, high-res MCG images B z (i,j) and corresponding tangential components B′ x,y (i,j) change much. However the global minimal point of B′ xy (i,j) stays close to the ground truth robustly. This is a very encouraging result compared to the state of art using shield MCG systems. It is noted that the best accuracy is achieved when z=5 cm although the measurement error is the biggest. One reason is that the local measurements closer to the coil are more accurate than the other two cases.
A couple of parameters can affect the accuracy of the high-res MCG image restoration and current localization. Presently, the resolution is decreased by changing N from 351 to 141, i.e. 20 instead of 50 pixels are inserted between adjacent real (or physical) sensors, and the localization error is increased by 150%. On the other hand, when one inserts more than 50 pixels, the accuracy does not change much. The sensor number also affects the accuracy. With the same covering area (17.5×17.5 cm 2 ), the more sensors that are used in the MCG system, the better the accuracy of the present algorithm that one can achieve. For example, with the 5% white Gaussian random noise, the localization error is 0.878 mm for 8×8 sensors; 0.850 mm for 10×10 sensors; 0.837 mm for 12×12 sensors; 0.768 mm for 18×18 sensors; and 0.660 mm for 36×36 sensors. These two parameters are therefore very important for MCG system design.
Hereinabove, only the single electric current localization problem is considered, and a good initialization can be computed from the dense MCG image. In reality there can be more than one electric voxel current. Signal decomposition might be needed for initialization of the multiple current localization. In summary the present method is capable of restoring/creating accurate high-res MCG images. The high-res MCG images are created in an efficient, accurate and reliable manner for single current 2D localization. In addition the present algorithm can reconstruct the depth and moment of the current. It can also be easily extended to solve for multiple current sources.
While the invention has been described in conjunction with several specific embodiments, it is evident to those skilled in the art that many further alternatives, modifications and variations will be apparent in light of the foregoing description. Thus, the invention described herein is intended to embrace all such alternatives, modifications, applications and variations as may fall within the spirit and scope of the appended claims.
|
Magnetocardiogram (MCG) provides temporal and spatial measurements of cardiac electric activities, which permits current localization. An MCG device usually consists of a small number of magnetic sensors in a planar array. Each sensor provides a highly low-resolution 2D MCG map. Such a low-res map is insufficient for cardiac electric current localization. To create a high resolution MCG image from the sparse measurements, an algorithm based on model learning is used. The model is constructed using a large number of randomly generated high resolution MCG images based on the Biot-Savart Law. By fitting the model with the sparse measurements, high resolution MCG image are created. Next, the 2D position of the electric current is localized by finding the peak in the tangential components of the high resolution MCG images. Finally, the 2D current localization is refined by a non-linear optimization algorithm, which simultaneously recovers the depth of the electric current from the sensor and its magnitude and orientation.
| 0
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 13/566,896, filed Aug. 3, 2012 and now pending, which claims the benefit of U.S. Provisional Patent Application No. 61/522,058, filed Aug. 10, 2011, both of which are incorporated herein by reference.
BACKGROUND
The present embodiments are directed to an ice hockey skate system that is useful in providing optional blade stiffness and ease of swapping out ice hockey skate blades.
For nearly 150 years, hockey has been an important winter pastime for outdoor enthusiasts. In that time, hockey has evolved in rules and equipment. For example, in 1879, teams had nine players on each side, yet today teams have only six players. Also, old fashioned hockey skates were once steel blades tied to the bottom of stiff pair of shoes, but today their construction can include over-molded stainless steel blades attached to high technology skate boots.
Today the sport of ice hockey has spread to street hockey, which does not require any skate whatsoever to rollerblading and roller skating. However, the hockey skate is distinguishable over other forms of roller related skates, such as roller skates or roller blades because of the high rigidity required by the ice hockey skate. Accordingly, the only thing similar between a roller skate or roller blade and a hockey skate is the boot. All other aspects have diverged (though they may look similar) because of the very different requirements between ice hockey skates and roller blades, roller skates, etc.
FIG. 1 is a prior art illustration depicting the present state of the art hockey skate 100 . As depicted, today's hockey skate 100 provides a standard leather or plastic boot 104 with a tendon guard 102 and a high stiffness arrangement comprising a skate blade 108 embedded in a one-piece blade holder 106 that is riveted or screwed onto the boot sole 112 .
It is to innovative improvements related to ice hockey skates systems that the claimed invention is generally directed.
SUMMARY
The present embodiments generally relate to an ice hockey skate system that is useful in providing optional blade stiffness and ease of swapping out ice hockey skate blades. Some embodiments of the present invention contemplate a hockey skate apparatus comprising: a first runner-blade assembly that possesses: a steel ice-hockey skate blade that extends in length between a front end and a back end and has an ice surface and a top surface; a runner that is integrated with the skate blade, the runner essentially covers the top surface and extends part way towards the ice surface; a front cup removably attached to the first runner-blade assembly towards the front end; a back cup removably attached to the first runner-blade assembly towards the back end, the back cup and the front cup are adapted to be independent from one another, the front cup and the back cup are of a different material than the runner; the front cup and the back cup are removably attached to an ice-skate boot sole such that when fully assembled, the cups and the first runner-blade assembly essentially form a rigid structure connected to the ice-skate boot sole; the first runner-blade assembly adapted to be replaced with a second runner-blade assembly that possesses a different stiffness than the first runner-blade assembly.
Other embodiments contemplate the hockey skate wherein the front cup and the back cup have different vibration damping properties than the runner, wherein the front cup is removably attached to the first runner-blade assembly via a front bolt and the back cup is removably attached to the first runner-blade assembly via a back bolt, wherein the first runner-blade assembly is adapted to be replaced with the second runner-blade assembly by removing the front cup and the back cup from the ice-skate boot sole, wherein at least one of the cups is adapted to be removably attached to the ice-skate boot sole in various lateral positions, wherein the runner is composed of a polymer based material, wherein the cups are composed of magnesium, wherein further comprising either a front mounting plate between the front cup and the ice-skate boot sole or a back mounting plate between the back cup and the ice-skate boot sole, the runner essentially covers the top surface of the skate blade means the runner covers at least 90% of the top surface, the first runner-blade assembly is attached to the front cup by way of a bolt that is accommodated by a hole that penetrates both the skate blade and the runner.
Yet other embodiments envision the hockey skate apparatus wherein the runner possesses a slot that accommodates the skate blade, and further, the skate blade is received by a plurality of different runners wherein each of the runners provides different stiffness.
Other embodiments contemplate the hockey skate apparatus further comprising both a front mounting plate between the front cup and the ice-skate boot sole and a back mounting plate between the back cup and the ice-skate boot sole, wherein the mounting plate is metal, wherein the mounting plates are adapted to create a vibration damping interface, wherein the mounting plates further include at least one layer of dissimilar material adapted to create a vibration damping interface, wherein the at least one layer of dissimilar material is from the group consisting of: a metal plate, a polymer, a compliant metal (lead), compliant glue.
Other embodiments contemplate a hockey skate apparatus comprising: a hockey boot possessing a boot sole that defines a toe end and a heel end; attached to the boot sole near the toe end is a first cup and attached to the boot sole near the heel end is a second cup, wherein the first cup is capable of being swapped out with a like first cup from the boot sole while the second cup remains attached; a first runner-blade assembly attached to the first and the second cups, the runner-blade assembly possessing a steel ice-hockey skate blade that extends in length between a front end and a back end and has an ice surface and a top surface; the runner-blade assembly further possessing a runner that is integrated with the skate blade, the runner covers a significant portion of the length of the top surface and extends part way towards the ice surface on both sides of the skate blade; the cups and the first runner-blade assembly when fully attached to the boot sole are essentially positionally fixed.
Yet other embodiments envision the hockey skate apparatus wherein the first cup is a different material than the second cup, or wherein the cups are attached to the boot sole via at least one intermediary structure, wherein the at least one intermediary structure is an interface plate or wherein the at least one intermediary structure is made of a different material than the cups.
Yet other embodiments contemplate a method comprising: providing a first runner-blade assembly that is fixedly connected to a first front cup and a first back cup wherein the first cups are attached to a hockey skate sole, the first cups are positionally static relative the first runner-blade assembly and the hockey skate sole; detaching the first cups from the hockey skate sole without detaching the first runner-blade assembly; attaching a second front cup and a second rear cup, that are fixedly connected to a second runner-blade assembly, to the hockey skate sole wherein the second runner-blade assembly has a different stiffness than the first runner-blade assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration of a prior art ice hockey skate.
FIGS. 2A and 2B are illustrations of an ice hockey skate constructed in accordance with certain embodiments of the present invention.
FIGS. 3A-3D are illustrations of an ice hockey blade and runner and runner-blade assembly constructed in accordance with certain embodiments of the present invention.
FIGS. 4A-4F are illustrations of ice hockey cups including their construction with an ice hockey blade and runner-blade assembly constructed in accordance with certain embodiments of the present invention.
FIGS. 5A-5C are illustrations of a mounting plate and the mounting plate's relationship with the runner-blade assembly constructed in accordance with certain embodiments of the present invention.
FIG. 6 is a block diagram of a method to swap out runner-blade assemblies in accordance with certain embodiments of the present invention.
DETAILED DESCRIPTION
Before proceeding with the detailed description, it is to be appreciated that the present teaching is by way of example only, not by limitation. The concepts herein are not limited to use or application with a specific ice hockey skate system or method. Thus, although the instrumentalities described herein are for the convenience of explanation shown and described with respect to exemplary embodiments, it will be understood and appreciated that the principles herein may be applied equally in various types of ice hockey skates.
It should further be appreciated that the forgoing description is strictly intended for only ice hockey skates because the demands on the structures that comprise the inventive embodiments provide the essential rigidity absent in non-ice hockey skates, such as roller-blades, for example. Non-ice hockey skates, such as roller-blades require the kind of vibration related structures to compensate for rough asphalt and bumpy surfaces, which do not exist on a sheet of ice.
Referring to the drawings in general, and more specifically to FIG. 2A , shown therein is an illustration of an ice hockey skate arrangement 200 constructed in accordance with various embodiments of the present invention. In what follows, similar or identical structures may be identified using identical callouts.
More specifically, FIG. 2A illustratively shows the hockey skate arrangement 200 possessing a hockey skate boot 218 , which is adapted to accommodate a hockey player's foot (not shown). The hockey skate boot 218 has a toe end (front end) 106 and a heel end (back end) 104 . Fixedly attached to the ice hockey skate boot sole 216 at the toe end 106 is a front mounting plate 208 . Fixedly attached to the ice hockey skate boot sole 216 at the heel end 106 is a rear mounting plate 206 . The front mounting plate 208 removably connects a front cup 202 to the toe end 106 of the boot sole 216 and the back mounting plate 206 removably connects a back cup 204 of the heel end 104 of the boot sole 216 . The term removably attached is used herein to indicate that an object is essentially rigidly attached to another object but removable such as by bolts, screws, etc. Objects which are glued or welded together are considered not removably attached because there is no intention to separate the objects. The front cup 202 and the back cup 204 are removably connected to a runner-blade assembly 220 via a front bolt 212 and a rear bolt 214 respectively. The term cup is used herein to mean any structure or mechanism suitable for directly or indirectly attaching the runner-blade assembly 220 to the skate boot. The runner-blade assembly 220 is comprised of an ice-hockey blade 211 , preferably made from stainless steel, that is integrated with a runner 210 , preferably made from a polymeric material, such as nylon to withstand impacts of a hockey puck, hockey stick, or other hockey skate, for example.
FIG. 2B illustrates a preferred embodiment consistent with embodiments of the present invention wherein the front mounting plate 208 is recessed in the front cup 202 and the rear mounting plate 206 is recessed in the back cup 204 such that the cups 202 and 204 are essentially flush with the bottom/externally exposed part of the boot sole 216 . As shown by the illustrative embodiment, the constructed components essentially comprise the runner-blade assembly 220 , the cups 202 and 204 , the mounting plates 208 and 206 and the boot sole 216 to form, more or less, a rigid structure. That is, the constructed components when attached are immobile and static with the exception of the natural deflection properties associated with the structures that are dictated by modulus of elasticity and moment(s) of inertia. Hence, to a layman, the constructed components essentially feel like a solid rigid structure when attempted to be manipulated by a pair of hands. Certain embodiments contemplate the opening 280 can optionally be small enough to prevent a hockey puck from going through the opening 280 . Optional embodiments contemplate a shield (not shown) that can block a substantial portion, or all of, the opening 280 .
With reference to FIGS. 3A-3D , shown therein is an embodiment of the runner-blade assembly 220 consistent with embodiments of the present invention. As illustratively shown in FIG. 3A , in conjunction with FIG. 3B and FIG. 3C , the runner-blade assembly 220 is generally comprised of runner 210 that is integrated with an ice skate blade 211 . The ice skate blade 211 extends in length between a front end 308 and a back end 306 , whereby the front end 308 corresponds to approximately where the toe end 106 of the hockey skate boot 218 resides and the back end 306 corresponds to approximately where the heel end 104 of the hockey skate boot 218 resides (see FIGS. 2A and 2B ). Certain embodiments of the present invention contemplate the front end 308 of the runner-blade assembly 220 extending beyond the toe end 106 of the hockey skate boot 218 (shown in FIG. 2A ), and, optionally, the back end 306 of the runner-blade assembly 220 extending beyond the heel end 104 of the hockey skate boot 218 (shown in FIG. 2A ). With further reference to the ice skate blade 211 embodiment, shown in FIG. 3B , the ice skate blade 211 is defined by a top surface 312 and an ice surface 310 , whereby the ice surface 310 is adapted to be in contact with a sheet of ice (not shown). The runner 210 is integrated with the ice skate blade 211 such that the runner 210 essentially covers the top surface 312 of the ice skate blade 211 . As shown in the present illustrative embodiment, the front end 318 of the ice skate blade 211 extends beyond the runner 210 , however the back end 320 of the ice skate blade 211 does not extend beyond the runner 210 , hence, the runner 210 essentially covers the top surface 312 of the ice skate blade 211 . In this embodiment, essentially covers is contemplated to mean that at least 90% of the top surface 312 of the ice skate blade 211 is covered by the runner 210 . In optional embodiments, the back end 320 of the ice skate blade 211 extends beyond the runner 210 . As further shown, the ice skate blade 211 includes a front protrusion 316 that accommodates a front hole 304 and a rear protrusion 314 that accommodates a rear hole 304 . The front hole 304 and the rear hole 302 provide a suitable location for the front bolt 212 and the rear bolt 214 to respectively connect the runner-blade assembly 220 to the front cup 202 and the back cup 204 . Optional embodiments contemplate other means for removably connecting the runner-blade assembly 220 to the front cup 202 and the back cup 204 , such as pins, for example.
FIG. 3C provides an axial views of the front 308 of the runner-blade assembly 220 integrated with the runner 210 and the ice skate blade 211 and FIG. 3D provides an axial view of the front 308 of the runner-blade assembly 220 not integrated with the runner 210 and the ice skate blade 211 , consistent with certain embodiments of the present invention. As shown in FIG. 3C , the runner 210 is adapted to accommodates the ice skate blade 211 via a slot 325 . The top of the runner 210 is also illustratively shown possessing a runner-blade tongue 336 that engages a cup 202 , discussed in more detail in conjunction with FIGS. 5A and 5B . FIG. 3D illustratively shows the runner 210 extending over the top surface 312 of the ice skate blade 211 about 50% part way towards the ice surface 310 . In a preferred embodiment, the runner 210 extends between 25%-75% from the top surface 312 of the ice skate blade 211 towards the ice surface 310 of the ice skate blade 211 . Other embodiments contemplate the runner 210 extending from the top surface 312 of the ice skate blade 211 towards the ice surface 310 of the ice skate blade 211 in different percentages. Certain embodiments contemplate the runner 210 being made from a polymeric material such as nylon 6/6 to withstand being struck by a hockey puck. Yet other embodiments contemplate the runner 210 being constructed from a carbon fiber, such as a carbon mesh in a resin that is directionally positioned to provide various engineered stiffness.
In an optional embodiment, the ice skate blade 211 and the runner 210 are irremovably connected. One embodiment contemplates the runner 210 formed over the ice skate blade 211 and a polymeric runner material molded over the ice skate blade 211 and cured with contiguous polymeric material in the holes 302 and 304 , thus locking the ice skate blade 211 to the runner 210 . Other embodiments contemplate a different means for irremovably connecting the runner 210 and the ice skate blade such as rivets, pins that are expanded in the holes 302 and 304 , over-molded bolts and pins, etc.
FIGS. 4A-4E illustratively show an embodiment of cups 202 and 204 in more detail. With reference to FIGS. 4A and 4B , shown therein are perspective views of one half of the front cup 202 and one half of the back cup 204 , respectively. Both the front cup 202 and the back cup 204 show a hollowed out portion 408 and stiffening webs 406 . The hollowed out portion 408 provides weight reduction while the stiffening webs 406 increase the stiffness of the cups 202 and 204 . The front cup 202 illustratively shows a front runner-blade assembly cup space 402 that accommodates the front end 308 of the runner-blade assembly 220 . The front cup 202 further provides a front hole 304 adapted to align with the front hole 304 in the runner-blade assembly 220 to accommodate the front bolt 212 . Likewise, the back cup 204 illustratively shows a back runner-blade assembly cup space 404 that accommodates the back end 306 of the runner-blade assembly 220 . The back cup 204 further provides a back hole 302 adapted to align with the back hole 302 in the runner-blade assembly 220 to accommodate the back bolt 214 . The front runner-blade assembly cup space 402 and rear runner-blade assembly cup space 404 are recessed to accommodate the width of the runner-blade assembly 220 . The front and back cups 202 and 204 also provide top surfaces 410 and 412 and holes 414 , respectively, that can accommodate the mating surfaces of the front mounting plate 208 and the rear mounting plate 206 , which are removably attached via cup-plate bolts 413 .
FIG. 4C illustratively shows an embodiment of a cut-away assembly of one half of the front cup 202 and one half of the back cup 204 with the ice skate blade 211 in a removably attached position. The ice skate blade 211 is shown without the runner 210 to illustrate the position of the ice skate blade 211 relative to the cups 202 and 204 . The front bolt 212 and the back bolt 214 are disposed in the respective holes 304 and 302 to help illustrate the placement of the ice skate blade 211 .
FIG. 4D illustratively shows an embodiment of a cut-away assembly of one half of the front cup 202 and one half of the back cup 204 with the runner-blade assembly 220 in an attached position. The runner-blade assembly 220 is illustratively shown in a mounted position with the front bolt 212 and the back bolt 214 in the respective holes 304 and 302 .
FIG. 4E illustratively shows an embodiment of a full assembly of the front cup 202 and the back cup 204 with the runner-blade assembly 220 removably connected thereto. The runner-blade assembly 220 is in a mounted position with the front bolt 212 and the back bolt 214 disposed in the respective holes 304 and 302 . Hence, the back cup 204 is removably attached to the runner-blade assembly 220 towards the back end 306 and the front cup 202 is removably attached to the runner-blade assembly 220 towards the front end 308 . Because the front cup 202 is separate and independent from the back cup 204 , the front cup 202 can be replaced (swapped out) with a different front cup while the back cup 204 remains attached to the runner-blade assembly 220 , and vice-versa. The runner-blade assembly 220 fits, via a runner-blade tongue 336 (shown in FIG. 3 ), into an accommodating runner-blade assembly slot 430 in the cups 202 and 204 . In the present embodiment, the front cup halves 202 A and 202 B and the back cup halves 204 A and 204 B are fixedly assembled together with epoxy, however other means for fixedly attaching the halves of the cups together contemplate bolts, welds, and other means known to those skilled in the art. In an optional embodiment, the front cup 202 and back cup 204 do not have halves but are rather formed as a single cup 202 and 204 . In another optional embodiment, the front cup halves 202 A and 202 B and the back cup halves 204 A and 204 B are removably assembled together with bolts, however other means for attaching the cup halves such pins, latches or quick releases are contemplated. Certain embodiments contemplate the cups 202 and 204 being made from metal, such as a titanium alloy or an aluminum alloy to withstand the shock impact of a hockey puck or stick, for example. Other embodiments contemplate the cups 202 and 204 being made out of composite carbon such as a woven carbon mesh in a resin. Yet other embodiments envision stiff composite polymer cups 202 and 204 .
FIG. 4F illustratively shows a front view of the runner-blade assembly 220 removably attached to the front cup 202 . The runner-blade tongue 336 fits into the accommodating runner-blade assembly slot 430 , as shown. Certain embodiments contemplate the runner-blade assembly slot 430 comprising an angle that tapers from the opening of the slot 432 to the back of the slot 434 in order to improve the seating of the runner-blade assembly 220 , or more specifically the runner-blade tongue 336 , in the slot to a “snug fit”. Certain embodiments further contemplate the runner-blade tongue 336 possessing a similar angle to the angle of the tapered runner-blade assembly slot 430 in order to optimally mate. In a preferred embodiment, the tapered runner-blade assembly slot 430 is between 1 degree and 8 degrees whereby the opening of the slot 432 is wider than the back of the slot 434 . Other embodiments contemplate a taper as much as 25 degrees or more. Optional embodiments contemplate a compliant surface, such as a rubber coating, on the surface of slot 432 and/or the runner-blade tongue 336 to improve friction between the slot 432 and the runner-blade tongue 336 when assembled together with the bolts 212 and 214 .
FIGS. 5A and 5B illustratively show a mounting plate consistent with certain embodiments of the present invention. In certain embodiments, the front mounting plate 208 and the rear mounting plate 206 are essentially identical, herein generically designated as element 500 . Other embodiments contemplate the front and rear mounting plates 208 and 206 as having different shapes, but fundamentally both function to attach the cups 202 and 204 to the boot sole 216 . With continued reference to the mounting plate 500 , shown therein are three bolts 413 that are used to removably attach the cup 202 or 204 to the mounting plate 500 . Other means for removably attaching the cups 202 and 204 to the mounting plates 500 include quick releases, mating structures that removably interlock, just to name a few examples. Certain embodiments contemplate the mounting plates 500 integrated in (built in) the boot sole 216 . For example, the mounting plates 500 are formed in the rigid boot sole 216 such that the mounting plate top 502 is essentially flush with the top portion of the boot sole 216 that is in contact with a hockey player's foot or a sole insert (not shown) that is used as a cushion between the hard top portion and the hockey player's foot. Certain embodiments contemplate the mounting plate thickness 506 to be essentially the thickness of the boot sole 216 . In one embodiment, the boot sole 216 is constructed out of a hard plastic that is molded around by the boot sole 216 to fixedly retain the mounting plate 500 in the boot sole 216 exposing only the mounting plate top 502 and the mounting plate bottom 504 , wherein the mounting plate bottom 504 provides a surface that is adapted to be in contact with the top 410 or 412 of a cup 202 or 204 , respectively. Another optional embodiment contemplates the boot sole 216 being constructed from carbon fiber that is molded around to fixedly retain the mounting plate 500 exposing only the mounting plate top 502 and the mounting plate bottom 504 . In yet another optional embodiment, the mounting plate top 502 is slightly buried under the inside surface of the boot sole 216 , such that slotted shapes are machined out from the inside surface of the boot sole 216 to expose the slotted openings 510 . One embodiment contemplates the mounting plate 500 being textured to be better secured to the boot sole 216 when molded therein. The mounting plates 500 can be made of metal, such as aluminum, steel, titanium, etc., or can be a composite carbon material or polymer, for example, or ceramic. Yet other embodiments contemplate the mounting plates 500 constructed from a laminate of different materials sandwiched together that run parallel to the surface that mates with the ice hockey skate boot sole 216 .
In an optional embodiment, shown in FIGS. 5 B 1 and 5 B 2 , the mounting plate 500 provides slotted openings 510 that accommodate the bolts 413 and allow for offset adjustment of the cups 202 and 204 and runner-blade assembly 220 . More specifically, as illustratively shown in FIG. 5 B 1 , the bolts 413 fixedly screw into accommodating holes 414 in the back cup 204 essentially retaining the cup 204 in an offset position to the far left to create an offset of the runner-blade assembly 220 . The back cup 204 is used herein to simplify the explanation; however the same optional adjustments can be done with the front cup 202 . FIG. 5 B 2 shows the inverse of FIG. 5 B 1 whereby the bolts 413 are positioned in the far right of the slots 510 , thus creating an offset with the runner-blade assembly 220 in the other direction. Optionally, the bolts 413 are positioned in the slots 510 of the front mounting plate 500 to the far left and the bolts 413 are positioned in the slots 510 of the rear mounting plate 500 to the far left, thus positioning the runner-blade assembly 220 offset to one side of the boot sole 216 , but without an angular offset. Optionally, the bolts 413 are positioned in the center of the slots 510 in the front and back mounting plates 500 for a neutral positioning of the runner-blade assembly 220 . Optionally, the bolts 413 are positioned in the slots 510 such that the positioning of the runner-blade assembly 220 offset has an angular offset (e.g., the bolts 413 are to the left side of the slots 510 in the rear mounting plate 500 and to the right side of the slots 510 in the front mounting plate 500 ). Other embodiments contemplate the tops 410 and 412 of the cups 202 and 204 , respectively, and/or the mounting plates 500 providing detents to position the offset in a standard manner, for example −3 (corresponding to the far left), −2, −1, 0 (corresponding to neutral), +1, +2, +3 (corresponding to the far right). In this way, a hockey player that knows their personal setting is a +1 (a little in offset to the right), for example, can simply move the mounting plate to +1 and tighten the bolts 413 .
Certain embodiments contemplate the front mounting plate 208 and the back mounting plate 206 being joined together to form a one piece unit 520 , as illustratively shown in FIG. 5C . A one piece unit 520 can improve the stiffness of the boot sole 216 and the manufacturability of integrating the mounting plates within or on the sole. Another embodiment contemplates a boot sole and the mounting plates being one and the same unit. For example, the one sole unit being a size-9, yet another being a size-12 unit that is integrated (sown in, glued in) the boot 218 .
The slots 510 can accommodate a method for customizing the position of the runner-blade assembly 220 relative to the boot sole 216 . One embodiment contemplates loosening the bolts 413 , such as with an allen-key if it is an allen-head bolt, in the rear mounting plate 206 and in the front mounting plate 208 . This is accomplished by accessing the inside surface of the boot sole 216 by reaching inside the hockey skate boot 218 ; sliding the front cup 202 to a non-neutral position, such that the bolts 413 slide to one side of the slots 510 in the front mounting plate 208 ; sliding the back cup 204 to a non-neutral position, such that the bolts 413 slide to one side of the slots 510 in the rear mounting plate 206 , wherein the neutral position is when the bolts 413 are in the center of the slots 510 ; tightening the bolts 413 to essentially lock the cups 202 and 204 to the mounting plates 206 and 208 in an immobile arrangement to secure the offset positioning. The offset positioning can be optimized for a specific hockey skater.
Certain embodiments contemplate a compliant gasket between the bottom surface 504 of the mounting plates 208 and 206 and the mating surface 410 and 412 of the cups 202 and 204 , respectively, such as a rubber gasket, a low elastic modulus metal gasket, a fabric gasket, etc. Such a surface adds friction to reduce the chance of any movement between the cups 202 and 204 and the mounting plates 208 and 206 . Yet other embodiments contemplate a compliant overcoat on the surfaces of the mounting plates 206 and 208 that mate with (are in contact with) the ice hockey skate boot sole 216 , such as a thin rubber or polymer paint, for example. Yet other embodiments contemplate an interlocking structure on the bottom surface 504 of the mounting plates 208 and 206 and the mating surface 410 and 412 of the cups 202 and 204 , respectively. Such interlocking structures can be grooves, waffle shapes, pins and accommodating holes, etc.
FIG. 6 illustrates an embodiment of a method for exchanging (swapping out) a first runner-blade assembly that has a first stiffness with a second runner-blade assembly with a second stiffness that is different from the first stiffness. FIG. 6 is described in conjunction with FIGS. 2B and 4F . It should be recognized that the steps presented in the described embodiments of the present invention do not necessarily require any particular sequence unless otherwise stated. When the runner-blade assembly 220 needs to be replaced with a different runner-blade assembly because of damage, wear to the blade surface 310 , or to change the stiffness of the runner-blade assembly the following steps are carried out. With reference to step 602 , the front bolt 212 is loosened and removed from the front cup 202 and the rear bolt 214 is loosened and removed from the back cup 204 . As illustratively shown in step 604 , once the bolts 212 and 214 are removed, the first runner-blade assembly 220 is pulled-out from the corresponding runner-blade assembly slots 430 in the bottom of the cups 202 and 204 . A second runner-blade assembly is then inserted, via the second runner-blade assembly tongues 336 , in the corresponding runner-blade assembly slots 430 in the bottom of the cups 202 and 204 , step 606 . Once the holes 302 and 304 are aligned, the front bolt 212 is inserted and tightened in place and the rear bolt 214 is inserted and tightened in place. Certain embodiments contemplate a mating structure in the tongue 336 and corresponding runner-blade assembly slot 430 to align the holes 304 between the cups 202 and 204 and the runner-blade assembly 220 , such as a key and key-hole, or another tongue and groove system that extends from the opening of the slot 432 to the back of the slot 434 . A stiffer runner-blade assembly may be used for a heavier, more aggressive, or less tired hockey player, for example.
It is to be understood that even though numerous characteristics and advantages of various embodiments of the present invention have been set forth in the foregoing description, together with the details of the structure and function of various embodiments of the invention, this disclosure is illustrative only, and changes may be made in detail, especially in matters of structure and arrangement of parts within the principles of the present invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. For example, the shape of the runner 210 and ice skate blade 211 may differ from the depicted embodiments to alter certain directional stiffness, for example, while still maintaining substantially the same functionality without departing from the scope and spirit of the present invention. Another example can include alternate assemblies to construct the cups 202 and 204 , such as a molded or machined cup without a top 410 or 412 whereby the top 410 or 412 are attached later to form the complete cup 202 and 204 , or optionally no top exists, just receiving holes 414 for the bolts 413 , to name a few examples while still maintaining substantially the same functionality without departing from the scope and spirit of the present invention. Further, for purposes of illustration, a first and second runner-blade assembly is used herein to simplify the description for a plurality of optional runner-blade assemblies. Additionally, as touched upon in conjunction with FIGS. 2A and 2B , multiple styles of hockey skate boots, such as a goalie's boot or a defense player's boot, can operatively be employed while maintaining substantially the same functionality without departing from the scope and spirit of the present invention. Another example can include alternate runner-blade assemblies that are shorter, longer, higher, etc., with the ability to interchangeably couple to the cups 102 and 104 to name a few examples while still maintaining substantially the same functionality without departing from the scope and spirit of the present invention. Finally, although the preferred embodiments described herein are directed to standard ice hockey skate and related technology, it will be appreciated by those skilled in the art that the teachings of the present invention can be applied to alternate types of ice hockey skates, without departing from the spirit and scope of the present invention.
It will be clear that the present invention is well adapted to attain the ends and advantages mentioned as well as those inherent therein. While presently preferred embodiments have been described for purposes of this disclosure, numerous changes may be made which readily suggest themselves to those skilled in the art and which are encompassed in the spirit of the invention disclosed and as ultimately defined in the claims.
|
A customizable hockey skate includes a removable runner-blade assembly such that a runner-blade assembly having a first stiffness may be readily replaced with a runner-blade assembly having a second stiffness. The runner-blade assembly may be removably attached to first and second cups that are optionally removably attached to the sole of a skate boot. The first and second cups optionally are removably attachable at multiple lateral locations on the sole. Mounting plates to which the first and second cups are mounted may be included to provide damping interfaces between the first and second cups and the boot sole. The first and second cups may be separately removable from the sole such that the first cup may be replaced with a third cup (for example, a cup having a different stiffness than the first cup) without removal of the second cup.
| 0
|
FIELD OF THE INVENTION AND RELATED ART
The present invention relates to an image heating apparatus for heating the image on recording medium.
There are various image heating apparatuses. For example, a fixing device for fixing an unfixed image on recording medium to the recording medium, an apparatus for heating a fixed image on recording medium to increase the image in glossiness, and the like can be listed as an image heating apparatus.
There are a variety of image heating apparatuses, which have been known as a fixing device employed by an electrophotographic image forming apparatus to fix an unfixed toner image to recording medium. One of the fixing devices has been known as a fixing device of the heat roller type, the fixing member of which has an elastic roller. A fixing device of the heat roller type has two heating rollers, that is, a fixation roller and a pressure roller, and is structured so that the two heating rollers form a fixation nip by being pressed upon each other. In an operation for fixing an unfixed toner image on recording medium, the two heating rollers are kept at a preset level in temperature, and recording medium on which an unfixed toner image is present is moved through the fixation nip. As the recording medium on which an unfixed toner image is present is moved through the fixation nip of the fixing device, heat and pressure are applied to the unfixed toner image on the recording medium so that the toner image becomes fixed to the recording medium; the unfixed toner image is turned into a permanent image. There have also been known film (belt)-based fixing devices (Japanese Laid-open Patent Application H04-44075). In the case of some film (belt)-based fixing devices, the film (endless belt) is externally heated, whereas in the case of the other, which are referred to as a fixing device of the electromagnetic induction type (Japanese Laid-open Patent Application 2001-42670), the film (endless belt) is internally (electromagnetically) heated. Image fixing devices of the electromagnetic induction type have also been in practical use.
In recent years, the wave of colorization has been spreading in the field of image forming apparatuses, such as printers and copying machines. A color image forming apparatus is used for outputting a photographic image. Therefore, it is required to be capable of outputting a glossy image.
While the wave of colorization has been spreading in the field of image forming apparatuses, the following fixing device, has been disclosed in Japanese Laid-open Patent Application 2004-184518, which is excellent in terms of energy efficiency and can yield a permanent image which is high and uniform in glossiness. More specifically, this fixing device has a fixation film (endless belt) and a pressure roller. More concretely, the fixing device has also a pad on which the fixation film slides. The pad is placed within the loop which the fixation film forms. It is kept pressed against the pressure roller, with the presence of the fixation film between the pad and pressure roller, creating thereby a fixation nip between the fixation film and pressure roller. Further, the pad is provided with a ridge, the position of which relative to the pad is such that as the pad is pressed against the pressure roller (fixation film), it will be on the downstream side of the center of the fixation nip in terms of the direction in which recording medium conveyed through the fixation nip. Thus, the pressure peak of the pressure distribution in the fixation nip is on the downstream side of the center of the fixation nip.
However, the fixing device disclosed in Japanese Laid-open Patent Application 2004-184518 has the following problems when thin paper or film, which is low in rigidity, is used as recording medium. That is, as a sheet of thin paper or film is sent into the fixation nip, it is possible that the sheet is adhered to the fixation film by the thermally melted toner. That is, it is possible that the so-called “wrapping jam” or the phenomenon that a sheet of recording medium wraps around the fixation film will occur.
It seems to be reasonable to think that the primary cause of the above described jam is as follows: That is, as the toner softens between the fixation film and recording medium, it becomes adhesive, being therefore likely to cause the recording medium to adhere to the surface of the fixation film. The secondary cause of the above describe jam seems to be as follows: That is, the ridge of the pad is on the downstream side of the center of the fixation nip in terms of the recording medium conveyance direction, and presses the recording medium downward (toward pressure roller). Thus, as the recording medium comes out of the fixation nip, its leading end portion is made to bend upward (toward fixation film) by the ridge, impeding thereby the recording medium from separating from the fixation film. This is why the fixing device disclosed in the abovementioned patent application is likely to cause a sheet of thin paper or film to adhere to, and wrap around, the fixation film.
SUMMARY OF THE INVENTION
Thus, the primary object of the present invention is to provide an image heating device which is superior to any of image heating devices in accordance with the prior art, not only in terms of recording medium separation, but also, in terms of glossiness level.
According to an aspect of the present invention, there is provided an image heating apparatus comprising a rotatable belt member for heating an image on a recording material; a rotatable member pressing against said belt member; a nip forming member, provided inside said belt member, for cooperating with said rotatable member to form a nip for nipping and feeding the recording material; a projection provided on a side of said nip forming member near the nip and projecting toward the nip; and an executing portion for executing a first image heating mode operation in which an image formed on the recording material having a first thickness with said projection projected into a nip region and a second image heating mode operation in which an image formed on the recording material having a second thickness which is smaller than the first thickness with said projection is outside the nip region.
These and other objects, features, and advantages of the present invention will become more apparent upon consideration of the following description of the preferred embodiments of the present invention, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic sectional view of the image forming apparatus which employs the fixing device in the first preferred embodiment of the present invention, and shows the general structure of the image forming apparatus.
FIG. 2 is a schematic sectional view of the fixing device in the first preferred embodiment of the present invention.
FIG. 3( a ) is a schematic sectional view of an example of the pressure pad in the first preferred embodiment of the present invention, and FIG. 3( b ) is a perspective view of the pressure pad.
FIG. 4 is a block diagram of the operational sequence for controlling the movement of the heating unit.
FIG. 5 is an example of the flowchart of the image outputting (forming) operation of the image forming apparatus in accordance with the present invention.
FIG. 6( a ) is a schematic sectional view of the fixing device in the normal mode, and FIG. 6( b ) is a graph which shows the pressure and temperature distributions of the fixing nip in the normal mode.
FIG. 7( a ) is a schematic sectional view of the fixing device in the thin paper mode, and FIG. 7( b ) is a graph which shows the pressure and temperature distributions of the fixing nip in the thin paper mode.
FIG. 8 is a schematic sectional view of the interface between the fixation roller and pressure roller, and its adjacencies, and shows the state of the leading edge portion of the sheet of recording medium when the sheet has just begun to come out of the fixation nip.
FIG. 9 is a schematic side view of the fixing device, and is for describing the method for moving the heating unit.
FIG. 10 is a schematic top plan view of the fixing device, and is for describing the method for moving the heating unit.
FIG. 11 is an example of the timing chart of the image outputting operation in accordance with the present invention.
FIG. 12 is a schematic sectional view of an example of the pressure pad which is different from the pressure pad shown in FIG. 3 .
FIG. 13 is a schematic sectional view of an example of the pressure pad which is different from the pressure pads shown in FIGS. 3 and 12 .
FIG. 14 is another example of the flowchart of the image outputting operation in accordance with the present invention.
FIG. 15 is another timing of the image outputting operation in accordance with the present invention.
FIG. 16 is a drawing for describing the various parameters which affect the performance of the fixing device in accordance with the present invention, and shows their relationship when the toner alignment on recording medium is idealistic.
FIG. 17 is a schematic sectional view of yet another example of the pressure pad in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, the present invention is described in detail with reference to the image heating device in accordance with the present invention and the appended drawings.
[Embodiment 1]
1. Image Forming Apparatus
FIG. 1 is a schematic sectional view of the image forming apparatus 100 which employs the fixing device in the first preferred embodiment of the present invention. This image forming apparatus 100 is a laser beam printer capable of forming a full-color image with the uses of an electrophotographic image forming method. It is of the intermediary transfer type, and is also of the tandem type.
The image forming apparatus 100 has multiple image forming stations, more specifically, the first, second, third, and fourth image forming stations Sa, Sb, Sc, and Sd, respectively. In this embodiment, the image forming stations Sa, Sb, Sc, and Sd are practically the same in structure and operation, although they are different in the color of the toner they use. Therefore, they are described together. That is, the suffixes of the referential codes given to identify their structural components and the like will not be shown unless necessary to show the difference among the multiple image forming stations.
The image forming station S has a photosensitive drum 101 , which is an electrophotographic photosensitive member (photosensitive member) as an image bearing member. It is in the form of a cylindrical drum. It is rotated in the direction (counterclockwise direction) indicated by an arrow mark R 1 in FIG. 1 . The image forming station S has also the following means, which are in the adjacencies of the peripheral surface of the photosensitive drum 101 . That is, it has: a charge roller 102 , which is a charging member (charging device of contact type) as a charging means; a developing device 104 as a developing means; a first transfer roller 105 as the first transferring member (charging device of contact type) as a first transferring means; and a drum cleaner 106 as a means for cleaning the photosensitive member.
The image forming apparatus 100 has also an exposing device 103 as an exposing means for exposing each of the photosensitive drums 101 a - 101 d . The exposing device 103 is above the photosensitive drums 101 a - 101 d . It has a light source, a polygonal mirror, etc.
The image forming apparatus 100 has also an intermediary transfer belt 107 as an intermediary transfer member. The intermediary transfer belt 107 is an endless belt, and is positioned so that it opposes all of the photosensitive drums 101 a - 101 d of the image forming stations Sa-Sd, respectively. The intermediary transfer belt 107 is suspended and kept stretched by a driver roller 171 , a tension roller 172 , and a second transfer roller 173 . As rotational driving force is transmitted to the driver roller 171 , the intermediary transfer belt 107 is rotated (circularly moved) by the rotation of the driver roller 171 in the direction (clockwise direction) indicated by an arrow mark R 2 . The first transfer rollers 105 a - 105 d are on the inward side of the loop which the intermediary transfer belt 107 forms. They form first transfer stations T 1 a , T 1 b , T 1 c , and T 1 d, where the intermediary transfer belt 107 is placed in contact with the photosensitive drums 101 a - 101 d by being pressed against the photosensitive drums 101 a - 101 d by the first transfer rollers 105 a - 105 d, respectively. The image forming apparatus 100 has also a second transfer roller 108 and a transfer belt backing roller 173 . The second transfer roller 108 is a second transferring member (charging device of contact type) which is a second transferring means. It is on the outward side of the loop which the intermediary transfer belt 107 forms. It is positioned in contact with the outward surface of the intermediary transfer belt 107 in such a manner that it is pressed against the transfer belt backing roller 173 , with the presence of the intermediary transfer belt 107 between the two rollers 108 and 173 , forming thereby the second transfer station T 2 where the intermediary transfer belt 107 is in contact with the second transfer roller 108 .
Next, the image forming operation of this image forming apparatus 100 is described with reference to the formation of a full-color image, for example. First, the photosensitive drums 101 a - 101 d are uniformly charged across their peripheral surface by the charging rollers 102 a - 102 d , in the image forming stations Sa-Sd, respectively. Then, the charge portion of the peripheral surface of the photosensitive drum 101 is exposed by the exposing device 103 . More specifically, the exposing device 103 projects a beam of laser light while modulating the beam of laser light with the image formation signals obtained by separating the optical image of the image to be formed into four monochromatic images of primary colors, one for one. The beam of laser light is reflected by the rotating polygonal mirror of the exposing device 103 , in such a manner that it scans the peripheral surface of the photosensitive drum 101 while being focused on the generatrix of the photosensitive drum 101 by the f-θ lens of the exposing device 103 . As a result, an electrostatic latent image is formed on the peripheral surface of each of the photosensitive drums 101 a - 101 d . Then, the electrostatic latent images on the photosensitive drums 101 a - 101 d are developed by the developing devices 104 a - 104 d into four visible images, that is, four monochromatic images formed of toners which correspond in color to the aforementioned primary colors, one for one.
The developing devices 104 a - 104 d contain yellow, magenta, cyan, and black developers, respectively, which are two-component developers. Basically, each developer is a mixture of nonmagnetic toner particles (toner) and magnetic carrier particles (carrier). The two-component developer is circulated in the developing devices 104 a - 104 d . Incidentally, in order to compensate for the consumption of the toner in the developer by image formation, the developing devices 104 a and 104 d are supplied as necessary with a fresh supply of toner by toner supplying devices 141 a - 141 d, respectively.
As the image outputting operation is started, it is first confirmed whether or not the intermediary transfer belt 107 is in a preset position. As soon as it is confirmed that the intermediary transfer belt 107 is in the preset position, the driver roller 171 is rotated to circularly move the intermediary transfer belt 107 . At the same time as the driver roller 171 begins to be rotated, an image writing start signal is sent in, and then, a monochromatic image begins to be formed on the peripheral surface of the photosensitive drum 101 a , with a timing set with reference to the image writing start signal, in the first image forming station Sa.
The toner image formed on the peripheral surface of the photosensitive drum 101 a in the first image forming station Sa is transferred (first transfer) onto the intermediary transfer belt 107 by providing the first transfer roller 105 a with an electric field or electric charge, in the first transfer station 1 a. This toner image, or the toner image of the first primary color, is conveyed to the first transfer station T 1 b of the second image forming station Sb.
Thereafter, the monochromatic toner images, different in color (primary color), formed in the second to fourth image forming stations Sb-Sd, one for one, as in the same manner as the monochromatic toner image of the first primary color is formed in the first image forming station Sa, are transferred (first transfer) in layers onto the intermediary transfer belt 107 . Then, the portion of the intermediary transfer belt 107 , onto which the four monochromatic toner images, different in color, have just been transferred in layers, is conveyed to the second transfer station T 2 .
Meanwhile, one of the sheets P of recording medium in recording medium cassettes 109 a or 109 b is conveyed from the cassette 109 a or 109 b to the second transfer station T 2 by way of multiple pairs of recording medium conveyance rollers and a pair of registration rollers 110 , and then, is conveyed through the second transfer station T 2 . As the sheet P of recording medium is conveyed through the second transfer station T 2 , the toner images on the intermediary transfer belt 107 are transferred together (second transfer) by the provision of an electric field or an electric charge by the second transfer roller 108 .
As the sheet P of recording medium, on which the unfixed monochromatic toner images are present, comes out of the second transfer station T 2 , it is conveyed to the fixing device 6 as an image heating device. In the fixing device 6 , heat and pressure are applied to the unfixed toner images on the sheet P of recording medium. Thus, the unfixed toner images become fixed to the sheet P of recording medium. The fixing device 6 is described later in detail.
Thereafter, the sheet P of recording medium is discharged from the image forming apparatus 100 . As for the toner particles remaining on the peripheral surface of the photosensitive drum 101 after the first transfer, they are recovered by the drum cleaner 106 . The toner particles remaining on the intermediary transfer belt 107 after the second transfer are recovered by a belt cleaner 174 as an intermediary transfer belt cleaning means.
In this embodiment, the image forming stations Sa-Sd, intermediary transfer belt 107 , second transfer roller 108 , etc., make up the image forming means for forming toner images on the sheet P of recording medium.
Also in this embodiment, the toner is 5.5 μm in average particle diameter, and 1.1 g/cm 2 in specific gravity. Further, the theoretical amount by which toner is to be transferred (adhered) to the sheet P of recording medium to form a solid monochromatic portion of the image to be formed is 0.5 mg/cm 2 , whereas the maximum amount by which toner is transferred (adhered) to the sheet P of recording medium is 1.0 mg/cm 2 . The “theoretical amount by which toner is to be transferred (adhered) to the sheet P of recording medium to form a solid monochromatic portion of the image to be formed” means the amount by which toner is transferred (adhered) to the sheet P of recording medium (peripheral surface of photosensitive drum 101 ) per unit area when an electrostatic latent image, which is highest in terms of density, is developed by monochromatic toner. Further, the “average particle diameter of toner” means the weight average particle diameter measured with the use of the following method. First, 100-150 ml of water solution of electrolyte (roughly 1% water solution of NaCl, for example), which contains several milliliters of surfactant (preferably, alkyl benzene sodium sulfonate) is prepared. Then, 2-20 mg of toner is added to the water solution, and is dispersed several minutes with the use of an ultrasonic dispersing device. Then, the weight average particle diameter of the toner is obtained by measuring this solution with the use of a Coulter counter TA-11 (product of Beckman-Coulter Co., Ltd.).
2. Fixing Device
Next, the fixing device 6 is described. FIG. 2 is a schematic sectional view of the fixing device 6 in this embodiment.
In this embodiment, the fixing device 6 is a fixing apparatus of the so-called film heating type. That is, the fixing device 6 has a fixation film 11 which is an endless belt and is circularly movable (circularly movable heating member). It has also a pressure roller 21 and a pressure pad 13 . The pressure roller 21 is a rotatable member (pressure applying rotatable member) and is kept pressed against the pressure pad 13 to form a nip N (fixation nip) through which the sheet P of recording medium is conveyed while remaining sandwiched by the pressure roller 21 and pressure pad 13 . The pressure pad 13 is one of the nip forming members for forming the fixation nip N, and is on the inward side of the loop which the fixation film 11 forms. Further, the fixing device 6 has an IH coil 31 , a side core 32 , a center core 33 , a pressure pad supporting member 12 , etc. The fixation film 11 , pressure pad supporting member 12 , pressure pad 13 , etc., make up the heating unit 10 . The pressure roller 21 makes up a pressure unit 20 . The means for heating the fixation film 11 is made up of the IH coil 31 , side core 32 , center core 33 , etc.
The fixation film 11 has three layers, which are a substrate layer, an elastic layer, and a parting layer, listing from the inward side of the fixation film 11 . In this embodiment, the fixation film 11 is 30 mm in diameter. The substrate layer is a heat generating metallic layer, in which eddy current is generated by the alternating magnetic field generated by the IH coil 31 . It is formed of iron, stainless steel, nickel, or the like substance. It is desired to be no less than 10 μm and no more than 100 μm in thickness. If the substrate layer of the fixation film 11 is no more than 10 μm in thickness, the fixation film 11 is inferior in durability, and also, it can hardly absorb the electromagnetic energy, rendering therefore the fixation film 11 inferior in efficiency. On the other hand, if it is no less than 100 μm in thickness, it makes the fixation film 11 excessively rigid, that is, unlikely to easily bend. Thus, using a fixation film ( 11 ), the substrate layer of which is no less than 100 μm, is unrealistic, since the fixation film 11 has to be circularly moved. The elastic layer is formed of a substance which is heat resistant, excellent in thermal conductivity, and elastic. The elastic layer is desired to be no less than 10 μm and no more than 500 μm in thickness. As the material for the parting layer, a substance, such as fluorinated resin (PTFE, PFA, FEP, etc.) silicone resin, fluorinated rubber, silicone rubber, which is superior in parting properties and heat resistance, is desired. The thickness of the parting layer is desired to be no less than 1 μm and no more than 100 μm. If the parting layer is no less than 1 μm in thickness, it is likely to allow toner to offset from the sheet P of recording medium onto the fixation film 11 . On the other hand, if it is no less than 100 μm in thickness, it cannot fully transfer the heat generated in the heat generation layer, to the sheet P of recording medium and the toner thereon, and therefore, is likely to cause the fixing device 6 to fail to properly fix the toner images.
The pressure roller 21 comprises a metallic core and an elastic layer. The elastic layer which is formed of silicone rubber or the like is for providing the pressure roller 21 with a certain amount of softness (elasticity). The elastic layer of pressure roller 21 may be coated with fluorinated resin such as PTFE, PFA, and FEP in order to improve the pressure roller 21 in surface properties. The pressure roller 21 is rotatably supported by its lengthwise ends, in terms of the direction parallel to the axial line of the metallic core, by the chassis (unshown) of the fixing device 6 , with a pair of bearings positioned between the lengthwise ends of the metallic core and the left and right walls (metallic plates) of the chassis. In this embodiment, the pressure roller 21 is 30 mm in diameter.
The pressure roller 21 and pressure pad 13 are kept pressed against each other with the presence of the fixation film 11 between the roller 21 and pad 13 , forming thereby the fixation nip N (compression nip) between the fixation film 11 and pressure pad 13 . While the sheet P of recording medium, on which the unfixed toner images are present, is conveyed through the fixation nip N while remaining pinched by the pressure roller 21 and fixation film 11 , the toner images are heated and compressed. Consequently, the toner images become fixed to the sheet P.
The pressure pad 13 , which is one of the nip forming members, is formed of a substance which is heat resistant and is rigid enough to compress the fixation film 11 against the pressure roller 21 . In this embodiment, the pressure pad 13 is formed of heat resistant engineering plastic. Further, the surface of the pressure pad 13 , which faces the metallic substrate of the fixation film, is covered with a slippery sheet, such as a glass sheet coated with PTFE, in order to make the surface slipperier. Incidentally, it may be simply coated with lubricant such as silicon oil.
FIG. 3( a ) is a schematic sectional view of the pressure pad 13 in this embodiment. FIG. 13( b ) is a perspective view of the pressure pad 13 in this embodiment. The pressure pad 13 comprises a base 13 B and a ridge 13 A. The base 13 B is the lengthwise direction of which is roughly perpendicular to the direction in which the sheet P of recording medium is conveyed. The ridge 13 A is on the surface 13 B 1 (which faces pressure roller 21 ) of the base 13 , on which the fixation film 11 slides as it is circularly moved. The ridge 13 A extends in the lengthwise direction of the base 13 B, across virtually entire range of the base 13 B. The surface 13 B 1 of the base 13 B, on which the fixation film 11 slides, is roughly parallel to the direction in which the sheet P of recording medium is conveyed through the fixation nip N. In this embodiment, it is roughly horizontal. The ridge 13 A is triangular in cross section, and is at the downstream edge of the base 13 B in terms of the recording medium conveyance direction.
To describe in more detail, in this embodiment, the width of the pressure pad 13 , that is, the dimension of the pressure pad 13 in terms of the direction in which the sheet P of recording medium is conveyed, is 10 mm. As for the size and position of the ridge 13 A, the distance between the upstream edge of the ridge 13 A and the center of the pressure pad 13 in terms of the recording medium conveyance direction is 3.5 mm, whereas the distance between the tip of the ridge 13 A and the downstream edge of the base 13 B is 1.5 mm. Further, the height of the ridge 13 A is 0.75 mm. That is, in this embodiment, the tip of the ridge 13 A, which corresponds to the top of the triangular cross section of the ridge 13 A, is located 4.25 mm downstream of the center of the pressure pad 13 in terms of the recording medium conveyance direction. The angle a of the tip portion of the ridge 13 A is 90 degrees, and the angle β, which is the angle between the upstream lateral surface of the ridge 13 A and the surface 13 B 1 of the base 13 B is 45 degrees.
In this embodiment, the ridge 13 A is an integral part of the pressure pad 13 . However, all that is necessary here is that the ridge 13 A is on the surface of the base 13 B, which faces the fixation nip N and protrudes toward the fixation nip N. In other words, the ridge 13 A may be such a section of the pressure pad 13 that is formed independently from the base 13 B of the pressure pad 13 and then, is attached to the surface 13 B 1 of the base 13 B with the use of an optional ridge attaching means such as adhesive.
In this embodiment, the height of the ridge 13 A (distance between tip of triangular cross section of ridge 13 A and surface 13 B 1 ) is set to 0.75 mm to locally increase the fixation nip N in internal pressure. Also in this embodiment, the ridge 13 A of the pressure pad 13 is changed in its position relative to the fixation nip N, according to the type of recording medium. This feature of the fixing device 6 is described later in detail.
The pressure pad supporting member 12 is formed of a metallic substance such as stainless steel, aluminum, or the like. It has the function of keeping the pressure pad 13 pressed against the pressure roller 21 with the presence of the fixation film 11 between the pressure pad 13 and pressure roller 21 .
The IH coil 31 is in connection to an exciter circuit (unshown), which is capable of outputting high frequency waves which are 20 kHz-100 kHz in frequency with the use of a switching electric power source.
The side core 32 and center cores 33 are formed of highly magnetic substance such as ferrite. They are in magnetical connection to each other because of the presence of the magnetic field generated by the IH coil 31 . Positioning the center core 33 and side cores 32 so that the center of the center core 33 coincides with the center of the IH coil, and also, so that the side cores 32 are in the adjacencies of the lengthwise edges of the HI coil 31 , one for one, strengthens the magnetic connection between the center core 33 and side cores 32 .
Incidentally, in this embodiment, the IH coil 31 is used as the means to heat the fixation film 11 . That is, the fixation film 11 is internally heated. However, the fixation film 11 may be externally heated by placing an external heating member in contact with the fixation film 11 . Further, in this embodiment, the unfixed toner images become fixed to the sheet P of recording medium by being placed in contact with the fixation film 1 which is being heated by the IH coil 31 as a heat source. However, the present invention is also applicable to a fixing device, the fixation film of which is heated by a halogen heater as a heat source. The effects of such an application are the same as those obtained by the fixing device 6 in this embodiment.
3. Operation of Fixing Device
The unfixed toner images on the sheet P of recording medium are made up of toner particles. Thus, as the sheet P on which the unfixed images are present is conveyed through the fixation nip N of the fixing device 6 , the unfixed toner images are heated and compressed in the fixation nip N, whereby they becomes solidly fixed to the sheet P as the sheet P is conveyed out of the fixing device 6 (fixation nip N).
As alternating electrical current is flowed through the IH coil 31 of the fixing device 6 , an alternating magnetic field is generated, which in turn generates eddy current in the metallic substrate layer of the fixation film 11 . This eddy current generates heat in the metallic substrate layer. Consequently, the fixation film 11 becomes hot. As the temperature of the fixation film 11 becomes high enough for fixation, the pressure roller 21 is pressed against the pressure pad 13 with the presence of the fixation film 11 between the pressure roller 21 and pressure pad 13 , forming thereby the fixation nip N between the pressure roller 21 and fixation film 11 . As the pressure roller 21 is rotated, the fixation film 11 is circularly moved by the rotation of the pressure roller 21 . Then, as the sheet P of recording medium is conveyed through the fixation nip N of the fixing device 6 while remaining pinched by the fixation film 11 and pressure roller 21 , heat and pressure are applied to the toner particles, of which the toner images on the sheet P are formed. Thus, the toner particles, of which the unfixed toner images are formed, solidly adhere to the surface of the sheet P; the toner images become fixed to the sheet P.
In this embodiment, an operator is allowed to select the type and size of the sheet P of recording medium with the use of the control panel 1 of the image forming apparatus 100 . Thus, as the operator makes a selection, the ridge 13 A of the pressure pad 13 is automatically moved to a preset position according to the selection, before the starting of the actual fixing operation, as will be described later in detail.
Next, the method for changing the position of the heating unit 10 (that is, position of ridge 13 A of pressure pad 13 ) is described. FIG. 4 depicts the control sequence for moving the heating unit 10 which comprises the fixation film 11 , pressure pad 13 (which are within fixation film loop), and pressure plate supporting member 12 (which also are within fixation film loop), etc.
First, an operator is to select the type of the recording medium to be used for outputting images, using the control panel 1 of the image forming apparatus 100 . Then, the information regarding the selected recording medium type is transferred to a CPU 2 as the controlling means of the control portion 7 . The CPU 2 determines whether or not the selected sheet P of recording medium is no less than 80 g/m 2 in basis weight, with the reference to the information in a memory 5 as the storage means of the control portion 7 . The memory 5 stores the preset relationship between the type and basis weight of recording medium.
Then, the information regarding the decision made by the CPU 2 is transferred to the control portion 4 of the control portion 7 , which is for controlling the motor 3 for moving the heating unit 10 . Then, the control portion 4 determines whether or not it is necessary for the heating unit 10 of the fixing device 6 to be moved.
If the sheet P of recording medium selected to be used for outputting an image is no less than 80 g/m 2 in basis weight, the motor control portion 4 does not activate the motor 3 as the means for moving the heating unit 10 , and causes the fixation film 11 and pressure roller 21 to press upon each other. Then, it rotationally moves both the fixation film 11 and pressure roller 21 at 300 mm/s of peripheral velocity (normal mode).
On the other hand, if the sheet P of recording medium selected to be used for outputting an image is no more than 80 g/m 2 , the motor control portion 4 moves the heating unit 10 by activating the motor 3 , in order to change the position of the ridge 13 A of the pressure pad 13 relative to the fixation nip N. As the heating unit 10 is moved, the fixation film 11 , pressure pad supporting member 12 , and pressure pad 13 move together relative to the pressure roller 21 which makes up the pressure unit 20 . Then, the CPU 2 causes the fixation film 11 and pressure roller 21 to press upon each other, and begins to rotationally move both the fixation film 11 and pressure roller 21 at 300 mm/s of peripheral velocity (thin paper mode).
As the heating unit 10 is moved, the information regarding the movement of the heating unit 10 is stored in the memory 5 , so that the motor control portion 4 can know the current state of the fixing device 6 .
When the motor control portion 4 activates the motor 3 after it activated the motor 3 to move the heating unit 10 of the fixing device 6 from the default position of the heating unit 10 , it controls the motor 3 in such a manner that the heating unit 10 is moved back into the default position. That is, the motor control portion 4 rotates in reverse by reversing the voltage to be applied to the motor 3 .
In this embodiment, the “normal mode (image heating first mode)” is for outputting such an image that is highly glossy and brilliant in color, with the use of a sheet P of recording medium which is no less in basis weight than a referential value (which in this embodiment is 80 g/m 2 ). The “thin paper mode (image heating second mode)” is for reliably delivering a fixed image from the fixing device 6 reliably, that is, without allowing a sheet of recording medium to wrap around the fixation film 11 , even when the sheet of recording medium is no more in basis weight than a preset value, being therefore low in rigidity.
FIG. 5 is a flowchart of the operational sequence for moving the heating unit 10 .
As an operator sets the type for the sheet P of recording medium to be used for outputting an image, with the use of the control panel 1 of the image forming apparatus 100 (S 101 ), the information regarding the selected type is transmitted to the CPU 2 of the control portion 7 (S 102 ). Then, based on this information, the CPU 2 determines whether or not the selected sheet P of recording medium is no more than 80 g/cm 2 in basis weight (S 103 ). If the CPU 2 determines that the selected sheet P of recording medium is no less than 80 g/m 2 in basis weight, it places a flag 0 in the memory 5 (S 110 ). In this case, the heating unit 10 is kept in the default position, which corresponds to the normal mode in which the ridge 13 A of the pressure pad 13 is kept within the fixation nip N in terms of the recording medium conveyance direction. Then, image formation is started (S 106 ), and the fixation process is carried out (S 107 ).
On the other hand, if the CPU determines that the selected sheet P of recording medium is no more than 80 g/m 2 in basis weight in S 103 , it places a flag 1 in the memory 5 (S 104 ). Then, the motor control portion 4 moves the heating unit 10 by 1.0 mm in the recording medium conveyance direction by activating the motor 3 in response to the information from the CPU 2 (S 105 ). With this movement of the heating unit 10 , the ridge 13 A of the pressure pad 13 is moved out of the fixation nip in terms of the recording medium conveyance direction, and is placed in the thin paper position. Then, image formation is started (S 106 ), and then, the resultant unfixed toner images are fixed (S 107 ).
Therefore, if the job (operational sequence started in response to single start signal to form image on two or more sheets of recording medium) has not been completed (S 108 ), the CPU 2 returns to S 106 , in which images are formed and fixed. On the other hand, if the job has been completed (S 108 ), the CPU 2 determines whether or not the heating unit 10 is in the thin paper mode position, with reference to the flag in the memory 5 (S 109 ). If the CPU 2 determines that the heating unit 10 is not in the thin paper mode position, it ends the image outputting operation. On the other hand, if it determines that the heating unit 10 is in the thin paper mode position, it sends this information to the motor control portion 4 . Then, the motor control portion 4 controls the motor 3 according to the information. Thus, the motor 4 moves the heating unit 10 by 1.0 mm in the opposite direction to the recording medium conveyance direction (S 111 ). Thus, the ridge 13 A of the pressure pad 13 of the heating unit 10 is moved back into the normal mode position, which is in the fixation nip N in terms of the recording medium conveyance direction. Then, the CPU 2 ends the image outputting operation.
Normally, a sheet P of recording medium (such as sheet of ordinary paper) which is no less than 80 g/m 2 in basis weight is thicker and more rigid than a sheet P of recording medium which is no more than 80 g/m 2 in basis weight, and therefore, it is unlikely to jam the fixing device 6 by wrapping around the fixation film 11 . Therefore, in this embodiment, the “normal mode (image heating first mode)” may be deemed as a mode for outputting a highly glossy and highly brilliant color image with the use of a sheet P of recording medium, the thickness of which is the first thickness, whereas the “thin paper mode (image heating second mode) may be deemed as the mode for ensuring that even if a sheet P paper, film, or the like, the thickness of which is the second thickness which is less than the first thickness, is used as recording medium, a fixed image is delivered from the fixing device 6 without allowing the sheet P to jam the fixing device 6 by wrapping around the fixation film 11 . More specifically, if an operator selects the recording medium type with the use of the control panel 1 of the image forming apparatus 100 , the CPU 2 determines whether or not the thickness of the sheet P of the selected recording medium is the first thickness, with reference to the information in the memory 5 as the storage means of the control section 7 . The memory 5 stores the preset relationship between the recording medium type and recording medium thickness. If the CPU 2 determines that the thickness of the selected sheet P of recording medium is the first one, it controls the fixing device 6 in the same manner as it does when it determines that the sheet P of selected recording medium is no less than 80 g/m 2 , whereas if it determines that the thickness is the second one, it controls the fixing device 6 in the same manner as it does when it determines that the basis weight of the selected sheet P of recording medium is no more than 80 g/m 2 , as described above.
As described above, the fixing device 6 is provided with the image heating first mode (normal mode) in which the ridge 13 A is kept in the range of the fixation nip N in terms of the recording medium conveyance direction, to heat the unfixed image formed on a sheet P of recording medium which is no less in basis weight than a referential value (or on recording medium having first thickness). It is also provided with the image heating second mode (thin paper mode), in which the ridge 13 A is positioned downstream side of the downstream end of the range of the fixation nip N in terms of the recording medium conveyance direction, to heat an image formed on the sheet P of recording medium, which is no more in basis weight than a referential value (or recording medium having second thickness which is less than first thickness). In this embodiment, the control portion 7 plays the role of making the image heating device 6 to operate in the image heating first mode or image heating second mode.
Incidentally, in this embodiment, the movement of the heating unit 10 is controlled based on the basis weight (or thickness) of a sheet P of recording medium. However, this embodiment is not intended to limit the present invention in terms of the parameter based on which the movement of the heating unit 10 is controlled. For example, the movement of the heating unit 10 may be controlled based on a table which shows the relationship between the recording medium type and how easily a sheet of recording medium of each type wraps around the fixation film 11 , which is predetermined based on the correlation between the recording medium type, such as “ordinary”, “photographic”, “OHP film”, and “thin” and the recording medium properties, such as basis weight, thickness, resiliency, rigidity, etc. That is, all that is necessary for the present invention to be applicable is that recording mediums are classified based on how easily each recording medium wraps around the fixation film 11 .
4. Function of Ridge
In this embodiment, the ridge 13 A of the pressure pad 13 is changed in position relative to the fixation nip N, based on the recording medium type. That is, it is placed within or outside the range of the fixation nip N in terms of the recording medium conveyance direction, based on the recording medium type. Further, the ridge 13 A of the pressure pad 13 has two functions.
FIG. 6( a ) is a schematic sectional view of the fixing device 6 in the normal mode, and FIG. 6( b ) shows the distribution of the internal pressure (placed on sheet P of recording medium) in the fixation nip N, and the distribution of the internal temperature (applied to sheet P of recording medium) of the fixation nip N, when the image forming apparatus 100 is in the normal mode. FIG. 7( a ) is a schematic sectional view of the fixing device 6 when the image forming apparatus 100 is in the thin paper mode, and FIG. 7( b ) shows the distribution of the pressure placed on the sheet P of recording medium in the fixation nip N, and the temperature distribution in the fixation nip N, when the image forming apparatus 100 is in the thin paper mode. FIG. 8 shows the manner in which the sheet P of recording medium P is discharged from the fixation nip N when the image forming apparatus 100 is in the thin paper mode.
Referring to FIG. 6( a ), one of the aforementioned functions of the ridge 13 A of the pressure pad 13 is for when the ridge 13 A of the pressure pad 13 is in the range of the fixation nip N in terms of the recording medium conveyance direction (normal mode). In this case, the pressure distribution of the fixation nip N in terms of the recording medium conveyance direction is as shown in FIG. 6( b ). That is, in this case, the peak of the pressure distribution is in the fixation nip N, and on the downstream side of the center of the fixation nip N in terms of the recording medium conveyance direction. Thus, a large amount of pressure is applied to the sheet P while the surface temperature of the sheet P is high. Therefore, the toner particles are efficiently spread, raising thereby the level at which the glossiness of the fixed image will be as the fixed image comes out of the fixing device 6 . In the normal mode, the highest amount of pressure to which the sheet P of recording medium is subjected in the fixation nip N is 0.4 Mpa, and the surface temperature of the sheet P of ordinary paper with a basis weight of 80 g/m 2 , is 100° C.
Next, referring to FIG. 7( a ), the second function of the ridge 13 A of the pressure pad 13 is for when the ridge 13 A of the pressure pad 13 is outside the fixation nip N in terms of the recording medium conveyance direction (thin paper mode). In this case, the fixation film 11 is deformed downward (toward pressure roller 21 ) by the ridge 13 A of the pressure pad 13 in a pattern which reflects the cross section of the ridge 13 A. Therefore, as the sheet P of recording medium is conveyed out of the fixation nip N, it is slightly downwardly angled, being thereby facilitated in terms of its separation from the fixation film 11 .
Incidentally, it is not that a glossy image cannot be outputted in the thin paper mode. That is, a sheet P of thin paper is relatively small in basis weight, being therefore, smaller in thermal capacity, than a sheet P of ordinary paper which is thicker, being therefore greater in basis weight, than thin paper. Therefore, the amount by which heat is robbed from the fixation nip N by the sheet P of thin paper is smaller than that by the sheet P of ordinary paper. Thus, when the sheet P of thin paper is conveyed through the fixation nip N, the temperature of the center portion of the fixation nip N is higher than when the sheet P of ordinary paper is conveyed through the fixation nip N. Thus, the toner particles on the sheet P of thin paper are as well spread in the thin paper mode as the toner particles on the sheet P of ordinary paper are in the normal mode. This is why it is not that a glossy image cannot be outputted in the thin paper mode. In the thin paper mode, the amount of pressure placed on the sheet P of recording medium at the peak of the pressure distribution of the fixation nip N was 0.3 Mpa, and the surface temperature of the sheet P of thin paper which is 64 g/m 2 in basis weight was 110° C. Also in the thin paper mode, the heating unit 10 (ridge 13 A of pressure pad 13 ) is positioned downstream by a distance D of 1.0 mm in terms of the recording medium conveyance direction, from the position in which the heating unit 10 (ridge 13 A of pressure pad 13 ) is positioned in the normal mode.
The temperature in the fixation nip N can be measured by conveying a sheet P of recording medium with a pasted thermocouple (micro thin film thermocouple KFST-10-100-200: product of Anbesmt Co., Ltd.). As for the pressure distribution in the fixation nip N, it can be measured with the use of a tactile sensor (Sealer: product of Nitta Co., Ltd).
Referring to FIG. 6( a ), in this embodiment, in the normal mode, the ridge 13 A of pressure pad 13 is kept in the range of the fixation nip N in terms of the recording medium conveyance direction. Thus, an image outputted in the normal mode is higher in glossiness. Also in this embodiment, in the thin paper mode, the heating unit 10 is positioned 1.0 mm downstream of the position in which the heating unit 10 is positioned in the normal mode, in terms of the recording medium conveyance direction, so that the ridge 13 A of the pressure pad 13 is positioned on the downstream side of the downstream end of the fixation nip N in terms of the recording medium conveyance direction, as shown in FIG. 7( a ). With this placement of the heating unit 10 (ridge 13 A), the path of the fixation film 11 dips downward (toward pressure roller 21 ) on the downstream side of the downstream end of the fixation nip N, in terms of the recording medium conveyance direction, causing thereby the sheet P of recording medium to be discharged from the fixing device 6 at a slightly downward angle. Thus, it is easier for the sheet P to separate from the fixation film 11 .
5. Movement of Heating Unit
Next, the method for moving the heating unit 10 is described. FIG. 9 is a schematic side view of the fixing device 6 , and FIG. 10 is a schematic top plan view of the fixing device 6 .
First, referring to FIG. 9 , the fixation film 11 is rotatably held by a fixation film flange 14 , which has a gear 15 which is an integral part of the flange 14 . The fixation film flange 14 is held by a flange supporting first metallic plate 40 , which has a gear 41 (rack gear), which meshes with a gear 15 (pinion gear), which is an integral part of the fixation film flange 14 . Further, the pressure roller 21 is rotatably supported by a second metallic plate 50 .
Next, referring to FIG. 10 , the fixation film flange 14 , first metallic plate 40 , second metallic plate 50 , gear 15 , and motor 3 are at each of the lengthwise edges (which is roughly perpendicular to circular movement of fixation film 11 ). Those components which are at one of the lengthwise edges of the fixation film 11 are synchronous in movement with the counterparts which are at the other lengthwise edge.
As the motor 3 is driven, the gear 15 is rotated by the rotation of the motor 3 , whereby the heating unit 10 is moved along the first metallic plate 40 in the direction parallel to the recording medium conveyance direction. Consequently, the ridge 13 A of the pressure pad 13 is moved out of the fixation nip N in terms of the recording medium conveyance direction. In this embodiment, as the thin paper mode is selected, the heating unit 10 is moved by 1.0 mm in the recording medium conveyance direction by the rotation of the motor 3 , and kept there. In this embodiment, the heating unit moving means of the image heating device 6 , which is for moving the ridge 13 A of the pressure pad 13 relative to the fixation nip N, comprises: the fixation film flange 14 , gear 15 , first metallic plate 40 having teeth 41 (rack gear), motor 3 , motor control portion 4 , etc.
FIGS. 11( a ) and 11 ( b ) show the timings with which the motor 3 and fixing device 6 are turned on or off during an image forming operation carried out in the normal and thin paper modes, respectively.
As the motor 3 is turned on for the first time in an image outputting job, the heating unit 10 is moved by 1.0 mm in the recording medium conveyance direction by the rotation of the motor 3 . Then, as the motor 3 is turned on for the second time, the heating unit 10 is moved by 1.0 mm in the opposite direction to the recording medium conveyance direction by the rotation of the motor 3 . On the other hand, as long as the motor 3 is kept turned off, the heating unit 10 remains where it is. During the period in which the “image forming operation” is ON, a toner image is formed through the charging process, exposing process, developing process, first transferring process, and second transferring process. During the period in which the “image forming operation” is OFF, no image is formed on a sheet P of recording medium. Further, during the period in which the “fixing operation” is ON, the fixation film 11 and pressure roller 21 are kept pressed against each other, and the fixation film 11 is circularly moved at 300 mm/s of peripheral velocity, to process the toner (particles) on the sheet P of recording medium to fix the toner image to the sheet P. On the other hand, during the period in which the “fixing operation” is OFF, the fixation film 11 and pressure roller 21 are kept separated from each other, and the fixation film 11 is circularly moved at 100 mm/s of peripheral velocity. Therefore, no image is fixed. A “post rotation period” means the period in which the image forming apparatus 100 (fixing device 6 ) is adjusted or prepared to end the on-going image forming operation. It is during this period that the operation for putting the heating unit 10 back into its default position (normal mode position) is carried out.
Referring to FIG. 11( a ), in the normal mode, the heating unit 10 is positioned so that the ridge 13 A of the pressure pad 13 of the fixing device 6 is positioned in the downstream end portion of the fixation nip N in terms of the recording medium conveyance direction. This state of the fixing device 6 is the default state of the fixing device 6 . That is, in the normal mode, the motor 3 is not turned on. In other words, in the normal mode, images are formed and fixed without turning on the motor 3 .
Next, referring to FIG. 11( b ), in the thin paper mode, first the motor 3 is turned on, whereby the heating unit 10 is moved by 1.0 mm in the recording medium conveyance direction. Then, images are formed and fixed. Then, the motor 3 is again turned on, whereby the heating unit 10 is moved by 1.0 mm in the opposite direction to the recording medium conveyance direction.
Incidentally, all that is necessary is for the movement of the heating unit 10 to be completed before an image begins to be fixed. That is, the period in which the “image forming operation” is ON may overlap with the period in which the motor 3 is ON.
In this embodiment, the target temperature level for the fixation film 11 in the normal mode, that is, the level at which the temperature of the fixation film 11 is kept in the normal mode, is set to 180° C., whereas that in the thin paper mode is set to 165° C. Although in this embodiment, the level at which the temperature of the fixation film 11 is kept in the normal mode is different from that in the thin paper mode, both modes may be the same in the target temperature level for the fixation film 11 . Further, in this embodiment, the dimension (width) of the fixation nip N in terms of the recording medium conveyance direction is set to 10 mm regardless of whether the image forming apparatus 100 (fixing device 6 ) is in the normal or thin paper mode.
Also in this embodiment, in the normal mode, the peak of the pressure distribution of the fixation nip N is on the downstream side of the center of the fixation nip N in terms of the recording medium conveyance direction. Thus, the image forming apparatus 100 (fixing device 6 ) in this embodiment is superior to any of the conventional image forming apparatuses (fixing devices 6 ), in terms of the glossiness level at which an image is outputted. Let's assume, for comparison, that a sheet P of recording medium which is greater in basis weight (no less than 80 g/m 2 ) than a sheet of ordinary paper is used, and the target temperature level for the fixation film 11 is adjusted without adjusting the fixing device 6 in the pressure distribution of the fixation nip N to change the position of the peak, in order to ensure that images to be outputted will be as glossy as the images outputted on a sheet P of ordinary paper. In this case, it is possible that the toner particles on the fibers of the sheet P of recording medium excessively melt, and therefore, “hot offset”, that is, a problematic phenomenon that the toner particles on the sheet P of recording medium transfer onto the fixation film 11 , will occur.
6 . Modification of First Embodiment
The shape of the pressure pad 13 does not need to be limited to the one in this embodiment. That is, it may be shaped so that its cross section looks as shown in FIGS. 12 and 13 .
The pressure pad 13 shown in FIG. 12 has a ridge 13 A which is on the surface of the base 13 B of the pressure pad 13 , which faces the fixation film 11 . The ridge 13 A is shaped so that its peak is at the downstream end of the base 13 B in terms of the recording medium conveyance direction. That is, the downstream surface of the ridge 13 A is perpendicular to the base 13 B, whereas the upstream surface of the ridge 13 A gently declines from its downstream end toward its upstream end. Further, the shape of the ridge 13 A is such that in terms of cross section, its upstream surface has a curvature, which is equal to the curvature of a circle which is 17.5 mm in radius. That is, the ridge 13 A is zero in height at its upstream end, and very gradually increases in height toward the downstream end, being highest at the downstream end. Further, the ridge 13 A faces downward. In the case of the pressure pad 13 shown in FIG. 12 , the height of the tip of its ridge 13 A from the base 13 B is 0.75 mm. Further, the dimension (width) of the pressure pad 13 in terms of the recording medium conveyance direction is 10 mm.
The pressure pad 13 shown in FIG. 13 has a ridge 13 A, which is rectangular in cross section. The ridge 13 A is on the surface of the base 13 B, on which the fixation film 11 slides. The ridge 13 A is positioned so that it is located 3.5 mm downstream from the center of the base 13 B. It is 0.5 mm in height and 1.0 mm in width (dimension in terms of recording medium conveyance direction).
Further, in the first embodiment, the heating unit 10 is moved to move the ridge 13 A of the pressure pad 13 into the fixation nip N. However, the first embodiment is not intended to limit the present invention regarding the movement of the ridge 13 A. For example, it may be the pressure roller 21 that is moved to move the ridge 13 A of the pressure pad 13 into, or out of, the fixation nip N.
Also in this embodiment, the type of the recording medium to be used for outputting an image is selected by an operator with the use of the control panel 1 of the image forming apparatus 100 . However, this embodiment is not intended to limit the present invention in terms of the method for setting the recording medium type. For example, the image forming apparatus 100 may be provided with an automatic recording medium type detecting means so that the recording medium type is automatically determined by detecting the thickness, surface properties, basis weight, and the like parameters of a sheet P of recording medium, with the use of the sensors with which the image forming apparatus 100 is provided.
As described above, in this embodiment, the ridge 13 A of the pressure pad 13 is switched in the position relative to the fixation nip N according to the type of recording medium. Thus, it is possible to make the fixing device 6 to satisfactorily separate a sheet P of recording medium from the fixation film 11 even if the sheet P of recording medium is such a sheet of recording medium that tends to wrap around the fixation film 11 , without sacrificing the function of outputting a highly glossy image. That is, as is evident from the description of this embodiment given above, the present invention can provide a fixing device 6 capable of separating even a sheet P of recording medium, which is low in rigidity, from the fixation film 11 , without sacrificing glossiness.
[Embodiment 2]
Next, the second preferred embodiment of the present invention is described. The image forming apparatus in this embodiment is the same in basic structure and operation as the image forming apparatus in the first preferred embodiment. Therefore, the components of the image forming apparatus in this embodiment, which are the same in function and structure as, or equivalent in function and structure to, the counterparts in the first embodiment, are given the same referential codes as those given to the counterparts, one for one, and are not described in detail.
In the first embodiment, it was assumed that the sheets P of recording medium which are being used for an image forming job is not replaced with sheets P of recording medium of a different type during the same image forming job. In comparison, in this embodiment, however, the sheets P of recording medium which are being used for an image forming job are replaced with sheets P of recording medium of a different type during the same image forming job.
Also in this embodiment, the “normal mode (image heating first mode)” is for outputting such an image that is highly glossy and brilliant in color, with the use of a sheet P of recording medium which is no less in basis weight than 80 g/m 2 , as it was in the first embodiment. Further, the “thin paper mode (image heating second mode)” is for delivering a fixed image from the fixing device 6 reliably, that is, while preventing the sheet P of recording medium from jamming the fixing device 6 by wrapping around the fixation film 11 even when a sheet P of thin paper, film, etc., which is no more in basis weight than 80 g/m 2 , being therefore very low in rigidity, is used as recording medium. In other words, the “normal mode (image heating first mode)” may be deemed as a mode in which a highly glossy and highly brilliant color image can be outputted with the use of a sheet P of recording medium, the thickness of which is the first thickness, whereas the “thin paper mode (image heating second mode)” may be deemed as the mode in which even if a sheet P recording medium, the thickness of which is the second thickness which is less than the first thickness, is used for image formation, a fixed image is delivered from the fixing device 6 reliably, that is, without causing the sheet P to jam the fixing device 6 by wrapping around the fixation film 11 .
Referring to FIG. 1 , in this embodiment, the first cassette 109 a stores sheets P of ordinary paper, and the second cassette 109 b stores sheets P of thin paper. The relationship between the cassette number and the type of the sheet P of recording medium in the cassette is registered in the memory 5 of the control portion 7 of the image forming apparatus 100 through the control panel 1 of the image forming apparatus 100 .
FIG. 14 is a flowchart of the operational sequence, in this embodiment, for moving the heating unit 10 .
As an operator sets the image forming apparatus 100 through the control panel 1 of the image forming apparatus 100 so that the image forming apparatus 100 automatically selects proper recording medium (S 201 ), the information regarding the recording medium in the first cassette 109 , which is the first to be used, is transmitted to the CPU 2 of the control portion 7 (S 202 ). Then, based on this information and the information stored in advance in the memory 5 , the CPU 2 determines whether or not the recording medium to be used for a given image formation job has to be no less than 80 g/m 2 in basis weight (S 203 ). If the CPU 2 determines in S 203 that the recording medium P is no less than 80 g/m 2 in basis weight, it places a flag 0 in the memory 5 (S 211 ). At this stage in the operation, the position of the heating unit 10 is the default position, that is, such a position that the ridge 13 A of the pressure pad 13 is within the range of the fixation nip N in terms of the recording medium conveyance direction. Then, the image forming operation is started (S 206 ), and the image fixing process is carried out (S 207 ).
On the other hand, if the CPU 2 determines that the recording medium P is no more than 80 g/m 2 in basis weight, it places a flag 1 in the memory 5 (S 204 ). Then, it causes the motor control portion 4 to control the motor 3 according to the information from the CPU 2 so that the heating unit 10 is moved by 1.0 mm in the recording medium conveyance direction (S 205 ). In other words, the heating unit 10 is moved to the thin paper mode position, in which the ridge 13 A of the pressure pad 13 of the heating unit 10 is on downstream side of the downstream end of the fixation nip N in terms of the recording medium conveyance direction. Then, the image forming operation is started (S 206 ), and the image fixing process is carried out (S 207 ).
During the image forming operation, the CPU 2 checks whether or not the first cassette 109 a has run out of a sheet of recording medium P, that is, whether or not the recording medium delivery is to be switched from the first cassette 109 a to the second cassette 109 b (S 208 ). If it determines that recording medium delivery does not need to be switched from the first cassette 109 a to the second cassette 109 b , it checks whether or not the current job has been completed (S 209 ). On the other hand, if the CPU 2 determines that the recording medium delivery has to be switched from the first cassette 109 a to the second cassette 109 b , it switches the recording medium delivery from the first cassette 109 a to the second cassette 109 b, and returns to S 203 , in which it again determines the type of the recording medium P to start the subsequent control sequence.
If the CPU 2 determines in S 209 that the current job has not been completed, it returns to S 206 , in which it makes the image forming apparatus 100 form images. Then, it makes the fixing device 6 fix images (S 207 ). On the other hand, if the CPU 2 determines in S 209 that the current job has been completed, it determines, with reference to the flag in the memory 5 , whether or not the heating unit 10 is in the thin paper mode position (S 210 ). If it determines that the heating unit 10 is not in the thin paper position, it ends the image outputting operation. On the other hand, if it determines that the heating unit 10 is in the thin paper mode position, it sends the information regarding the position of the heating unit 10 to the motor control portion 4 , causing thereby the motor control portion 4 to control the motor 3 according to the information. Thus, the heating unit 10 is moved by the motor 3 in the direction opposite to the recording medium conveyance direction by 1.0 mm (S 212 ). In other words, the heating unit 10 is returned to the normal mode position, in which the ridge 13 A of the pressure pad 13 of the heating unit 10 is within the range of the fixation nip N in terms of the recording medium conveyance direction. Then, the CPU 2 ends the on-going image outputting operation.
Referring to FIG. 6( a ), in this embodiment, in the normal mode, the fixing device 6 is in the state in which the ridge 13 A of the pressure pad 13 is within the fixation nip N in terms of the recording medium conveyance direction. Therefore, the image forming apparatus 100 can output an image at a higher level of glossiness than when the fixing device 6 is in the state in which the ridge 13 A is out of the fixation nip N. Next, referring to FIG. 7( a ), also in this embodiment, in the thin paper mode, the fixing device 6 is in the state in which the heating unit 10 has been moved downstream by 1.0 mm in the recording medium conveyance direction, and therefore, the ridge 13 A of the pressure pad 13 is on the downstream side of the downstream end of the fixation nip N. Thus, the fixation film path sharply dips (bend toward pressure roller 21 ) on the downstream side of the downstream end of the fixation nip N, causing thereby the sheet of recording medium P to be discharged at a downward angle (toward pressure roller 21 ). In other words, in the thin paper mode, the sheet of recording medium P is better facilitated to separate from the fixation film 11 than in the normal mode.
FIG. 15( a ) is a timing chart of an image forming operation in which the image forming apparatus 100 (fixing device 6 ) is switched in operational mode from the normal mode to the thin paper mode during an image forming operation, whereas FIG. 15( b ) is a timing chart of an image forming operation in which the image forming apparatus 100 (fixing device 6 ) is switched in operational mode from the thin paper mode to the normal mode during an image forming operation. FIGS. 15( a ) and 15 ( b ) show the timing with which the motor 3 , image forming stations, and fixing device are turned on and off. The timing with which the abovementioned components of the image forming apparatus 100 in this embodiment are turned on or off in an operation in which switching is done between the two cassette 109 a and 109 b is the same as the timing with which the abovementioned components of the image forming apparatus 100 in the first embodiment are turned on or off, as shown in FIGS. 11( a ) and 11 ( b ).
In the first period in which the motor 3 is ON, the heating unit 10 is moved by 1.0 mm in the recording medium conveyance direction. In the second period in which the motor is ON, the heating unit 10 is moved by 1.0 mm in the opposite direction to the recording medium conveyance direction. On the other hand, in the periods in which the motor 3 is OFF, the heating unit 10 is not moved. In the periods in which the image forming stations are ON, an image is being formed on a sheet of recording medium P through the charging, exposing, developing, first transferring, and second transferring processes. In the periods in which the image forming stations are OFF, no toner image is being formed on a sheet of recording medium P. In the periods in which fixing device 6 is ON, the toner (toner image) on a sheet of recording medium P is being processed (fixed) by keeping the fixation film 11 and pressure roller 21 pressed upon each other, and circularly moving the fixation film 11 at 300 mm/s of peripheral velocity. On the other hand, in the periods in which the fixing device 6 is OFF, the fixation film 11 and pressure roller 21 are kept separated from each other, and the fixation film 11 is circularly moved at 100 mm/s of peripheral velocity. In other words, no image is being processed (fixed) by the fixing device 6 . A “post-rotation period” is a period in which adjustments or preparations are made to end the on-going image formation operation. It is during the post-rotation period that the operation for moving the heating unit 10 back into the default position (normal mode position) is carried out.
In this embodiment, the target temperature for the fixation film 11 in the normal mode is set to 180° C., and the target temperature for the fixation film 11 in the thin paper mode is set to 165° C. In this embodiment, the normal mode and thin paper mode are made different in the target temperature for the fixation film 11 . However, they do not need to be made different in the target temperature for the fixation film 11 . Further, the dimension (width) of the fixation nip N in terms of the recording medium conveyance direction is set to 10 mm regardless of whether the image forming apparatus 100 (fixing device 6 ) is in the normal mode or thin paper mode.
Next, referring to FIG. 15( a ), the operational sequence for switching from the normal mode to the thin paper mode in the midst of an image formation job is described. Since the image forming apparatus 100 is in the normal mode, the heating unit 10 is in the default position, in which the ridge 13 A of the pressure pad 13 of the heating unit 10 is in the range of the fixation nip N in terms of the recording medium conveyance direction. In the normal mode, an image is fixed while the heating unit 10 is in the default position. Therefore, the motor 3 is not turned on to move the heating unit 10 . That is, in the normal mode, an image is formed while the fixing device 6 is in the above-described state. Thereafter, if the cassette 109 a for the ordinary paper, that is, the cassette 109 from which sheets of recording medium P has been fed, becomes empty, the cassette 109 from which recording medium P is to be fed is switched to the cassette 109 b for thin recording medium. Thus, as the cassette 109 a becomes empty, an adjustment period is provided, during which the motor 3 is activated to move the heating unit 10 by 1.0 mm in the recording medium conveyance direction, and also, the target temperature for the fixation film 11 is reduced from 180° C. to 165° C. Then, the interrupted image forming operation is restarted, and the image fixing process is carried out. As soon as the on-going image formation job is completed, the motor 3 is activated again to return the heating unit 10 to the default position.
Next, referring to FIG. 15( b ), the operational sequence for switching from the thin paper mode to the normal mode in the midst of an image formation job is described. At the beginning of a given image formation job, the heating unit 10 is in its default position, in which the ridge 13 A of the pressure pad 13 of the heating unit 10 is in the fixation nip N in terms of the recording medium conveyance direction. In the thin paper mode, however, the ridge 13 A of the pressure pad 13 has to be outside the fixation nip N, and on the downstream side of the downstream end of the fixation nip N in terms of the recording medium conveyance direction. Therefore, as the operational mode of the image forming apparatus 100 is switched from the normal mode to the thin paper mode, the motor 3 is activated to move the heating unit 10 by 1.0 mm in the recording medium conveyance direction. Then, the image forming processes are carried out, and then, the image fixing process is carried out. In such a situation that the cassette 109 b from which sheets of thin recording medium P have been fed becomes empty, and therefore, the cassette 109 from which sheets of recording medium P is to be fed has to be switched from the cassette 109 b to the cassette 109 a which stores sheets of ordinary paper, an adjustment period is provided as soon as the cassette 109 b becomes empty. In the adjustment period, the motor 3 is activated to move the heating unit 10 in the opposite direction to the recording medium conveyance direction by 1.0 mm. In addition, the target temperature for the fixation film 11 is raised from 165° C. to 180° C. Then, the interrupted image forming job is restarted, and then, the image fixing process is carried out. Thus, at the end of the job, the heating unit 10 is in its default position, and therefore, the motor 3 is not activated.
As described above, in this embodiment, if recording medium is switched from one type to another in the midst of an image formation job, the fixing device 6 is switched in the position of the ridge 13 A of the pressure pad 13 according to recording medium type. Therefore, even if recording medium is switched from one type to another in the midst of an image formation job, the image forming apparatus 100 (fixing device 6 ) can output a glossy image while preventing recording medium from failing to properly separate from the fixation film 11 .
[Embodiment 3]
Next, another preferred embodiment of the present invention is described. The image forming apparatus in this embodiment is the same in basic structure and operation as the image forming apparatus in the first preferred embodiment. Therefore, the components of the image forming apparatus in this embodiment, which are the same in function and structure as, or equivalent in function and structure to, the counterparts in the first embodiment, are given the same referential codes as those given to the counterparts, one for one, and are not described in detail.
The first and second embodiments of the present invention were described with reference to a case in which the amount by which toner is transferred (deposited) on recording medium P to form a monochromatic image is relative large. In this embodiment, the present invention is described with reference to a case in which the amount by which toner is transferred onto a sheet of recording medium P to form a monochromatic image on the sheet is relatively small.
In recent years, concern regarding environment has been increasing, and also, consumers are demanding further reduction in the cost of an image forming apparatus. Thus, the technologies for reducing an image forming apparatus in toner consumption have become very important. The technologies for reducing an image forming apparatus in toner consumption have come to play an important role from the standpoint of reducing an image forming apparatus in the amount of energy used to fix toner to recording medium.
One of the methods which can be used to reduce an image forming apparatus in toner consumption is to increase the filler of toner in terms of its ratio to coloring agent of toner, in order to reduce an image forming apparatus in the overall amount of toner consumption per sheet of recording medium. This method, however, is problematic for the following reason. That is, reducing the amount by which toner is adhered to recording medium per unit area of recording medium means reducing the amount by which toner is adhered (transferred) onto a sheet of recording medium per unit area to form a solid monochromatic. Thus, if the amount by which toner is adhered to recording medium is reduced, it is possible that spaces may remain among the toner particles which make up the solid monochromatic image. Thus, the image bearing area of the surface of recording medium may fail to be fully covered with toner while the image is fixed, because the surface of recording medium is microscopically irregular in texture.
In particular, if a sheet of recording medium P used for image formation is greater in irregularity in terms of texture and thermal capacity, toner is unlikely to fully melt. Therefore, the image forming apparatus 100 (fixing device 6 ) is likely to output an image which is low in reflection density.
At this time, the amount by which toner is adhered to recording medium to form a monochromatic solid image is described. It is assumed here that a monochromatic solid image is formed under the condition in which toner particles idealistically align as they are transferred onto recording medium.
FIG. 16 is a list which shows the parameters of toner, which are related to the idealistic toner particle alignment. Letters L [μm] and V [μm3] stand for the average particle size (diameter) of the toner and the average particle volume of the toner, respectively. A letter S [μm3] stands for the average projected area of the toner particles. Further, a letter Sb [μm2] stands for the average size of the recording medium surface per toner particle. There are following mathematical relationships among the abovementioned parameters.
V
=
4
3
π
(
L
2
)
3
Sa
=
π
(
L
2
)
2
Sb
=
3
2
L
2
When a monochromatic toner image is formed on a sheet of recording medium under the condition in which toner particles align with the presence of virtually no gap between adjacent two toner particles, the amount H [μm] (volume per unit area=average height of toner layer) of toner on a portion of recording medium which corresponds to an actual image, which is formed of a single layer of toner particles, can be obtained from Mathematical Formula 4.
H
=
V
Sb
=
4
3
π
(
L
2
)
3
·
2
3
L
2
=
π
L
3
3
In the case of Mathematical Formula 4 given above, in consideration of the state of toner particle alignment, it is assumed that “toner volume [μm] per unit area” equals “average height”. Normally, however, the weight per unit area [mg/m 2 ] of toner is used to control the amount by which toner is transferred onto recording medium. Therefore, Formula 4 which is for calculating the amount of toner on a portion of recording medium which corresponds to an actual image, which is formed of a single layer of toner particles, when the toner particle alignment is idealistic (toner particles are truly spherical and align with virtually no gap between adjacent to toner particles), is converted into the following Mathematical Formula (1) as the formula for obtaining the amount A [mg/m 2 ] of toner per unit area of the actual image portion of a monochromatic image on a sheet of recording medium. Incidentally, a term 1/10 in the following Mathematical Formula (1) is for the measurement unit normalization.
A
=
ρ
×
H
=
ρ
×
1
10
×
π
L
3
3
3
L
2
=
ρπ
L
30
3
(
1
)
If the amount by which toner is transferred onto a sheet of recording medium per unit area (amount of toner, per unit area, of solid area of monochromatic image) to form a monochromatic image on the sheet of recording medium is less than the value calculated by Formula (1) given above, that is, if it satisfies Mathematic Formula (inequity) (2) given below, the resultant monochromatic image will be insufficient in reflection density.
A<ρπL /(30√{square root over ( )}3)
This embodiment is described with reference to a case in which the amount by which toner is transferred onto a sheet of recording medium, per unit area of the sheet of recording medium, is less than the value calculated with the use of Mathematical Formula (1) given above. More concretely, the toner used in this embodiment is 5.5 μm in average particle diameter, and 1.1 g/cm 3 in specific gravity. The amount by which toner is transferred onto a sheet of recording medium to form a solid monochromatic portion of the image is 0.3 mg/m 2 . The maximum amount by which toner is transferred onto a sheet of recording medium is 0.6 mg/m 2 .
As described above, if the amount by which toner is transferred onto a sheet of recording medium (paper in particular) to form a solid portion of the monochromatic image of the primary color is insufficient, the toner delivered to this portion of the sheet of recording medium fails to completely cover the surface of each of the fibers of which the sheet of recording medium is made of. Thus, the resultant image is insufficient in reflection density. Thus, in order to output an image which is satisfactory (sufficient) in reflection density, it is desired that each toner particle is spread wider by the fixing device 6 than if the aforementioned amount is sufficient.
In this embodiment, therefore, in order to spread each toner particle wider, the fixing device 6 is provided with a pressure pad 13 , the cross sectional shape of which is shown in FIG. 17 . The pressure pad 13 used in this embodiment is roughly the same in structure as that used in the first embodiment. That is, it has a base 13 B and a ridge 13 A. The ridge 13 A is on the surface 13 B 1 of the base 13 B, on which the fixation film 11 slides.
To describe in more detail, in this embodiment, the dimension (width) of the pressure pad 13 in terms of the recording medium conveyance direction is 10 mm. The ridge 13 A is triangular in cross section. The dimension (width) of the ridge 13 A in terms of the recording medium conveyance direction is 1.8 mm. The downstream edge of the ridge 13 A coincides with the downstream edge of the base 13 B, whereas the upstream edge of the ridge 13 A is located 3.2 mm downstream from the center of the pressure pad 13 . Further, the ridge 13 A is 0.9 mm in height. That is, in this embodiment, the tip of the ridge 13 A in terms of the triangular cross section of the ridge 13 A is located 4.1 mm downstream from the center of the pressure pad 13 . Further, the apex angle α of the ridge 13 A is 90 degrees, and the angle β between the two lateral surfaces of the ridge 13 A is 45 degrees.
In this embodiment, the ridge 13 A is made taller than in the first and second embodiments. Therefore, the fixation nip N in this embodiment is greater in internal pressure than those in the first and second embodiments, and therefore, the fixing device 6 in this embodiment can spread a toner particle wider, being therefore higher in the level at which the reflection density of the fixed image will be, than the fixing devices 6 in the first and second embodiments.
Shown in Table 1 are the amount of the maximum pressure in the fixation nip N, that is, the pressure between the tip (peak) of the ridge 13 A of the pressure pad 13 , which is 0.9 mm in height, and fixation film 11 , in this embodiment, and the maximum internal pressure of the fixation nip N, that is, the pressure between the tip (peak) of the ridge 13 A of the pressure pad 13 , which is 0.75 mm in height, and the fixation film 11 , in the first embodiment. Table 1 shows also the reflection density of the solid portion of the image fixed with the use of the pressure pad 13 in this embodiment, and the reflection density of the solid portion of the image fixed with the use of the pressure pad 13 in the first embodiment.
The pressure distribution was measured with the use of a tactile sensor (Sealer: product of Nitta Co., Ltd.). As for the reflection density, it was measured with the use of a spectral densitometer 503 (product of X-Rite Co., Ltd.).
TABLE 1
Ridge height
Peak
Reflection
(mm)
pressure (Mpa)
density
0.9
0.5
1.45
0.75
0.4
1.32
According to Table 1, the fixing device 6 , in this embodiment, which used the pressure pad 13 , the height of the ridge 13 A of which was 0.9 mm, was higher in the maximum internal pressure of the fixation nip N, that is, the pressure between the tip (peak) of the ridge 13 A and the fixation film 11 than the fixation device 6 in the preceding embodiments. Thus, the fixing device 6 in this embodiment can spread wider each toner particle than the fixing devices 6 in the preceding embodiments, and therefore, the fixing device 6 is compensated in glossiness, for the insufficiency in the amount by which toner is transferred onto a sheet of recording medium.
Also in this embodiment, in a case where a sheet of recording medium P used for outputting an image is a sheet of ordinary paper or the like (which is no less than 80 g/m 2 in basis weight; first thickness), the heating unit 10 is positioned as follows: That is, the heating unit 10 is positioned so that the ridge 13 A of its pressure pad 13 is positioned in the downstream end portion of the fixation nip N in terms of the recording medium conveyance direction. In this embodiment, therefore, a larger amount of pressure than the amount of pressure applied to the toner particles on a sheet of recording medium in the fixation nip N in the preceding embodiment is applied to the toner particles on the sheet of recording medium, in the area of fixation nip N, which is higher in temperature. Therefore, the toner particles are spread wider, being enable to satisfactorily hide (cover) each of the fibers of which the recording medium P is made.
On the other hand, in a case where the recording medium P used for image formation is a sheet of thin paper or the like (which is no more than 80 g/m 2 in basis weight, or the thickness of which is the second thickness which is less than the first thickness), the recording medium P is smaller in thermal capacity, and therefore, the toner particles on the recording medium P quickly increase in temperature. Therefore, even if the amount of the pressure applied to the toner particles in the downstream end portion of the fixation nip N is no larger than the normal one, the toner particles are spread wider anyway. In this case, the heating unit 10 is positioned so that the ridge 13 A of its pressure pad 13 is positioned on the downstream side of the downstream end of the fixation nip N in terms of the recording medium conveyance direction. This placement of the heating unit 10 improves the fixing device 6 in terms of the recording medium separation from the fixation film 11 .
As for the method for changing the fixing device 6 in terms of the position of the ridge 13 A of the pressure pad 13 relative to the fixation nip N, the method similar to those used in the first and second embodiments can be used.
As described above, according to this embodiment, even if an image forming apparatus ( 100 ) is designed to be smaller in the amount by which toner is adhered to a sheet of recording medium to form a monochromatic solid portion of an image than a conventional image forming apparatus, the image forming apparatus can be made to output a desirably glossy image without sacrificing the separation of recording medium from the fixation film, by structuring the image forming apparatus so that the ridge 13 A of the pressure pad 13 of the heating unit 10 of its fixing device can be switched in position relative to the fixation nip N of the fixing device 6 according to recording medium type.
[Miscellaneous Embodiments]
The present invention has been described with reference to the preferred embodiments of the present invention. However, the preferred embodiments are not intended to limit the present invention in scope.
For example, in each of the preferred embodiments of the present invention described above, the image heating device was provided with two rotationally movable members which are kept pressed upon each other. Further, one of the rotationally movable members was an endless film and the other was a roller. However, this setup is not intended to limit the present invention in scope. For example, the present invention is also applicable to an image heating device which employs a pair of endless belts suspended and stretched by multiple rollers, and which is structured so that the pair of belts are kept pressed upon each other by the rollers.
Also in each of the preferred embodiments described above, the image forming apparatus 100 had only one image heating-and-pressing device. However, the present invention is also applicable to an image forming apparatus having multiple image heating-and-pressing devices, for example, two image heating-and-pressing devices. In the case of an image forming apparatus having two image heating-and-pressing devices, it is possible to use one of them as an ordinary fixing device, and the other as a glossiness enhancement device. In such a case, the present invention is applicable to each of the image heating-and-pressing devices. The resultant effects of such application are the same as those obtained by the image heating devices in the preceding embodiments.
Also in each of the preferred embodiments described above, the image forming apparatuses had four image forming stations. However, this setup is not intended to limit the present invention in terms of the number of image forming stations with which an image forming apparatus is provided. That is, the applicability of the present invention to an image heating device has nothing to do with the number of the image forming stations of the image forming apparatus.
Not only is the present invention applicable to an image forming apparatus such as those in the preceding preferred embodiments of the present invention, but also a printer, a copying machine, a facsimile machine, etc., and a multifunction image forming apparatus capable of performing two or more functions of the preceding image forming apparatuses.
The measurements, materials, and shapes of the structural components of the image forming apparatus (image heating device), and the positional relationship among the structural components, in each of the preferred embodiments of the present invention described above, are not intended to limit the present invention in these attributes, unless specifically noted. That is, the present invention is applicable to image forming apparatuses which are different from those in the preferred embodiments, in terms of these attributes.
As will be evident from the description of the preferred embodiments of the present invention given above, the present invention can provide an image heating device which is superior to any of the image heating devices in accordance with the prior art, not only in that its heating performance is high enough to reliably yield a highly glossy image, but also, in that it can reliably separate a sheet of recording medium from the image heating rotational members of the image heating device, even if the sheet of recording medium is such a sheet of recording medium that is likely to remain wrapped around the rotational heating members of the image heating device.
While the invention has been described with reference to the structures disclosed herein, it is not confined to the details set forth, and this application is intended to cover such modifications or changes as may come within the purposes of the improvements or the scope of the following claims.
This application claims priority from Japanese Patent Application No. 136540/2010 filed Jun. 15, 2010 which is hereby incorporated by reference.
|
An image heating apparatus includes a rotatable belt member for heating an image on a recording material; a rotatable member pressing against said belt member; a nip forming member, provided inside said belt member, for cooperating with said rotatable member to form a nip for nipping and feeding the recording material; a projection provided on a side of said nip forming member near the nip and projecting toward the nip; and an executing portion for executing a first image heating mode operation in which an image formed on the recording material having a first thickness with said projection projected into a nip region and a second image heating mode operation in which an image formed on the recording material having a second thickness which is smaller than the first thickness with said projection is outside the nip region.
| 6
|
The invention described herein was made in the performance of work under NASA contract number NAS8-39000 and is subject to the provisions of Section 305 of the National Aeronautics and Space Act of 1958 (42 U.S.C. 2457).
FIELD OF THE INVENTION
The present invention relates to digital communications, and more particularly to the transmission of byte-organized data to a receiving station that may employ byte boundaries different than the transmitting station.
BACKGROUND AND SUMMARY OF THE INVENTION
For expository convenience, the present invention is illustrated with reference to the transmission of a disabling tone to an echo canceller apparatus on a digital communication circuit. However, the invention is not so limited and is useful in numerous other applications.
Echo cancellers are commonly used on long distance communication circuits to suppress echoes that may be caused by various delays and impedance mismatches along the path. Echo cancellers add greatly to the intelligibility of voice transmissions.
In certain circumstances, echo cancellers are undesirable. Such is the case, for example, when transmitting digital data. Accordingly, echo canceller apparatuses often include provisions whereby they can be disabled upon receipt of a predetermined command signal. In most systems, this command signal takes the form of a 2100 hertz tone.
An illustrative application of the use of this command signal is found in 300 baud computer modems. 300 baud modems generally encode the data being transmitted in frequency shift keying format. A space (logic 0) is transmitted as a 2000 hertz tone and a mark (logic 1) is transmitted as a 2200 hertz tone. A transmission of data at 300 baud using these tones includes a 2100 hertz component that is sufficient to disable any echo cancellers along the circuit. Thus, 300 baud modems act automatically to disable any echo cancellers that may interfere with their accurate transmission of data.
In other data transmission applications, a 2100 hertz tone can be transmitted continuously with other data tones. In still other applications, a 2100 hertz tone can be transmitted for a few hundred milliseconds when the data link is first established and discontinued thereafter. Both techniques have been used to disable echo cancellers on digital circuits.
Most of the prior art systems employing the disabling feature of echo cancellers are analog communications circuits in which data is encoded as a series of audio tones. A more difficult situation arises on true digital lines in which "1"s and "0"s are transmitted directly, without being first encoded into tone form. Exemplary of such systems is the Accunet® 56 kbit/sec. service offered by AT&T. In this system, the only means of transmitting the 2100 hertz tone to the echo canceller is in digital form. That is, the analog 2100 hertz tone must be digitized and the digitized samples then transmitted serially along the circuit. In an exemplary system, the samples are in the form of 7-bit bytes.
The problem encountered in disabling echo cancellers on purely digital circuits is that it requires knowledge of the byte boundaries used by the digital network to which the echo canceller is coupled. This information is generally not available to end users of the system. End users simply apply serial data to the circuit without regard to the framing information that is later added to the data by the network. (In networks such as the Accunet® 56, serial data is sent without any framing information from the user to the switching office. A digital switch at the switching office then frames this serial data stream into bytes for further transmission by adding an eighth signalling bit after every seven bits received from the user. Th data then maintains this byte-organization until it is relayed finally to the receiving station, at which time the framing information is stripped off and an undelimited string of serial data is provided.)
The echo cancellers of concern are in the byte-framed portion of the digital network and thus require that the digitized 2100 hertz tone have the proper byte boundaries. Since the originating station operates without reference to the framing boundaries employed by the network, the originating station has heretofore been unable to disable the network echo cancellers.
To disable the echo cancellers on digital networks, it has previously been necessary to call a network operator and ask the operator to disable the echo cancellers. The operator is able to perform this operation because the telecommunications carrier can introduce the digitized 2100 hertz disabling signal into the network after it has been framed into known eight bit bytes.
This technique of calling the operator whenever disabling of the echo cancellers is desired is unsatisfactory. The only alternative has been to lease dedicated lines that do not include echo cancellers. This option, of course, is expensive.
Accordingly, there remains a need for a technique to permit byte-organized data to be sent to a byte-synchronous receiving system from an originating station that has no information about the framing boundaries employed by the receiving system.
Consequently, it is an object of the present invention to permit the successful transmission of byte-organized data from an originating station to a receiving station without regard to the byte boundaries employed by said stations.
It is a more particular object of the present invention to permit the disabling of echo cancellers on digital networks by transmission of control signals from originating stations that have no information about the framing boundaries employed by the echo canceller.
According to one embodiment of the present invention, an apparatus associated with the originating station on a digital data network transmits a burst of digitally encoded 2100 hertz tone to the network for a brief period, such as 500 milliseconds. The data comprising the burst is then bit-shifted one bit relative to the prior transmission and is retransmitted. This process is repeated until bursts of the 2100 hertz data have been transmitted with each possible alignment of the byte boundary (i.e. until bursts of the data have been transmitted N times where N is the number of data bits in a byte.) The byte boundaries employed by one of these bursts will coincide with the byte boundary employed by the digital network of which the echo cancellers of concern are a part. Thus, one burst will be successful in disabling the echo cancellers without intervention of an operator and without resort to use of dedicated lines.
The foregoing and additional objects, features and advantages of the present invention will be more readily apparent from the detailed description, which proceeds with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a map showing the organization of seven 80 byte patterns of digitized 2100 hertz information stored in a ROM according to one embodiment of the present invention.
FIG. 2 is a flow chart indicating the steps performed by the terminal interface equipment during the initiation of a data link according to one embodiment of the present invention.
FIG. 3 is a flow chart of the TONE21 routine called by the program of FIG. 2.
FIG. 4 is a flow chart of an interrupt routine that is executed during the TONE21 routine of FIG. 3.
FIG. 5 is a block diagram showing the interconnection of hardware elements employed in the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As noted above, the illustrated embodiment of the present invention relies on the transmission of several different 2100 hertz data bursts. Each burst is a bit-shifted version of the others. The burst is transmitted with all possible bit shifts, so one is certain to be framed by the carrier's digital switching circuitry into frames that will appear to the echo cancellers as bytes of 2100 hertz tone data. When the echo cancellers receive the properly-framed data burst, the echo cancelling feature is disabled.
In the illustrated embodiment, the 2100 hertz data which comprises these bursts is stored in a ROM memory 18 (FIG. 5). This data takes the form of 80 digitized samples of a 2100 hertz waveform, each sample of which is stored as a 7-bit byte. Seven different versions, or patterns of this digitized information are stored in the ROM memory. Referring to FIG. 1, the first memory location (0000 hex) contains the first byte of the first pattern. Byte two is stored at location 0001, byte three at location 0002, etc. (The ROM employed is organized with eight bit bytes, so the least significant bit of each byte is masked and is ignored in the present embodiment). Each 80 byte pattern corresponds to 100 cycles of the 2100 hertz tone.
The second pattern is stored in ROM beginning immediately following the eightieth byte of the first pattern. This second pattern is identical to the first pattern except it has been shifted right one bit, as illustrated in FIG. 1. Each succeeding pattern is similarly a bit-shifted version of the preceding pattern.
In operation, the 80 bytes of the first pattern are transmitted sequentially. At a 56 kilobit per second transmission rate, a single pass through the pattern takes ten milliseconds. Most echo cancellers require a tone burst of at least 350 milliseconds to guarantee activation. Consequently, at least 35 repetitions of a pattern are required to provide a 350 millisecond tone duration. To provide an error margin, the preferred embodiment cycles through the pattern 50 times, thus producing 500 milliseconds worth of digitally encoded 2100 hertz data.
After this first 500 millisecond transmission (which consists of fifty repetitive passes through the 80 bytes comprising the first pattern), the second pattern is transmitted similarly. At the conclusion of 50 cycles through the second pattern, the third, fourth, fifth, sixth and seventh patterns are transmitted. The entire echo canceler disabling routine thus takes 500 milliseconds per pattern times seven patterns, or 3.5 seconds.
Most of the circuitry needed to implement this technique is already incorporated in terminal interface equipment conventionally used with digital networks. Foremost among this circuitry is a microprocessor, which already finds application in existing terminal interface equipment to control operation of the terminal. Such a microprocessor can be programmed in accordance with the flow charts of FIGS. 2-4 to perform the sequence of echo canceller disabling steps employed by the present invention.
The routines illustrated by the flow charts of FIGS. 2-4 use a number of counters, flags and address pointers during the course of their operation. These variables are described below:
ADDRESS TO TRANSMIT--contains an address pointer to the next byte that the system is to transmit.
BYTES LEFT TO TRANSMIT--a counter indicating the number of bytes in the 80 byte pattern that remain to be transmitted in the current pass through the pattern.
PASSES PER PATTERN--contains the number of passes the process is to make through each pattern. This variable is set to 50 in the illustrated embodiment.
PATTERN ADDRESS--contains the address of the first byte of the current pattern. This address is a base from which counters can increment and the stopping point can be determined.
PATTERNS SENT--a counter indicating the number of patterns that have been sent to completion (i.e. the number of patterns that have been sent fifty times).
TRANSMISSION COMPLETE FLAG--a flag that is set to "1" when all seven patterns have been sent to completion.
Referring now to FIG. 2, in typical AT&T Accunet operation, an originating station dials a receiving station through a digital switch. The switch transmits data to the receiving terminal interface equipment, putting it into "data mode". (A corresponding signal is sent from the switch to the originating terminal interface equipment when the receiving terminal answers).
Upon receipt of the "data mode" signal, the terminal indicates to the user that a data connection has been established and that the echo cancellers are being disabled. The terminal interface equipment then determines whether the call is originating or being answered by the equipment. If originating, a routine named TONE21 is called. If answering, a routine named TONEQ is called. The process executed by these routines is identical and follows the flow chart of FIG. 3. For convenience of illustration, the flow chart of FIG. 3 is labelled TONE21, it being understood that the same steps are followed in the TONEQ routine with different (null) data.
Referring now to FIG. 3, the routine TONE 21 first determines at block A whether the system has been configured to send an echo cancelling 2100 hertz tone. (A tone may not be desired if, for example, the circuit is known to not include echo cancellers. By avoiding the tone transmission in such instances, the connect time can be decreased by approximately 3.5 seconds.) Assuming, as is usually the case, that the tone transmission is desired, the process proceeds into block B.
In block B, the process first loads the beginning address of the tone patterns into the memory location PATTERN ADDRESS. For purposes of illustration, this address is 0000 hex. (In actual practice, the ROM generally includes other coding so the tone patterns are offset from this address.)
The process next loads PASSES PER PATTERN with 50. (As noted, a single pass through the 80 byte pattern takes ten milliseconds. To transmit each bit-shifted tone for 500 milliseconds, fifty passes must be made through each pattern.) The PATTERNS SENT counter and the TRANSMISSION COMPLETE FLAG are reset from any previous use. An interrupt vector offset is then set and the interrupt enabled. (The interrupt vector offset indicates to the interrupt service routine the address to which it should go when calling the interrupt routine. The offset directs the interrupt service routine to the address of an interrupt routine named NTONE TX, discussed below.) After enabling interrupts, the process drops into a repetitive looping through block C, which checks whether the TRANSMISSION COMPLETE FLAG has been set to "1".
The looping through block C is suspended whenever a system interrupt occurs. In the preferred embodiment, an interrupt occurs every 17.85 microseconds. When this occurs, the microprocessor passes once through the interrupt routine NTONE TX shown in FIG. 4. NTONE TX sends out one byte of data. (The bulk of the complexity of NTONE TX in the figure is due to preparing the various memory locations for the next interrupt.)
Referring now to FIG. 4, interrupt routine NTONE TX first disables any further interrupts (many microprocessors automatically disable further interrupts by hardware when an interrupt occurs) and then saves all of the microprocessor's registers, as shown in block E. The routine then loads ADDRESS TO TRANSMIT and reads the byte stored at that location. ADDRESS TO TRANSMIT is then incremented.
In block F, the apparatus transmits the current data byte in the 2100 hertz pattern. In block G the counter BYTES LEFT TO TRANSMIT is decremented. The process then drops into block H to determine whether the counter BYTES LEFT TO TRANSMIT equals 0. If it does not, the process skips several steps and exits from the routine through block Q, which restores all of the registers and reenables the interrupts. The process then returns to the TONE21 routine shown in FIG. 3.
The TONE21 routine resumes its checking to determine whether the TRANSMISSION COMPLETE FLAG has been set by the interrupt routine. It continues this checking until the next system interrupt occurs.
At the next system interrupt, the NTONE TX routine of FIG. 4 is again called. This routine transmits the next byte in the first pattern and again decrements BYTES LEFT TO TRANSMIT as above. Provided there are still bytes left in the pattern that have not been transmitted, the interrupt routine terminates as described above, simply restoring the registers and reenabling the interrupts.
On the eightieth interrupt call, the byte transmitted will be the last byte in the first pattern. The decrementing of BYTES LEFT TO TRANSMIT will indicate that no bytes remain. The interrupt routine will then continue for the first time into block I, where it decrements the counter PASSES PER PATTERN from its initial value of 50 to 49. The process then checks, at box J, whether any more passes through the pattern are still required. In this instance, there are still 49 passes left to send. Consequently, the pattern is reinitialized, as indicated in block K. This consists of loading the memory location ADDRESS TO TRANSMIT from the memory location PATTERN ADDRESS (in this case 0000 hex). The interrupt routine is then left by restoring the registers and reenabling the interrupts.
At the next system interrupt, the process begins again by transmitting the first byte in the first pattern. The above-described process repeats until all 80 bytes have been transmitted a second time.
When the last byte of the first pattern has again been sent, the memory location PASSES PER PATTERN is again decremented, completing the second pass through the first pattern. The third pass is then begun.
On the fiftieth pass through the first 80 byte pattern, after the last byte has been transmitted, the routine decrements PASSES PER PATTERN and determines at block J that there are no passes left. At this point, the first pattern has been repeated fifty times, thus transmitting a total of 500 seconds of digitized 2100 hertz tone to the network. The routine then increments the PATTERNS SENT counter from 0 to 1, as indicated in block L. It then checks, in block M, whether the counter PATTERNS SENT is greater than seven. Since it is not, the pointer ADDRESS TO TRANSMIT (which now points to the first byte in the second pattern) is stored in PATTERN ADDRESS (as shown in block N), reinitializing this latter memory for use with the second pattern. The memory location PASSES PER PATTERN is reloaded in block 0 with the value 50 and the memory location BYTES LEFT TO TRANSMIT is reloaded with 80. The interrupt routine then terminates through block Q and the process loops idly through black C of FIG. 3 until the next system interrupt occurs.
The above-described process repeats to send the 80 bytes comprising the second pattern 50 times. The PATTERN SENT memory location is then incremented and patterns 3, 4, 5, 6 and 7 are then sent.
After the eightieth byte of the seventh pattern is transmitted for the fiftieth time, the interrupt routine proceeds all the way through to block P, where it stores a "1" in the TRANSMISSION COMPLETE FLAG memory location. The NTONE TX routine is then exited for the last time.
The TONE21 routine, which has been checking the TRANSMISSION COMPLETE FLAG as a background process between interrupts, now notices that the TRANSMISSION COMPLETE FLAG has been set. Consequently, it restores the interrupt vector offset in block D and exits. This exit sends the process back to the last block in the program of FIG. 2, in which the hardware indicates to the user (via a "CONNECT" message and LEDs on the interface panel) that the echo cancellers have been disabled and that the system is ready to send data.
Routine TONEQ mentioned above is identical to routine TONE21 except that the data transmitted is all "1"s. The TONEQ routine is used when the terminal interface equipment is receiving, rather than originating a call. It delays initiation of the normal data phase of operation for a period, 3.5 seconds, sufficient for the terminal interface equipment at the originating station to send the tone to disable the echo cancellers.
FIG. 5 shows a schematic block diagram of a representative terminal interface unit 10 that can employ the principles of the present invention. The microprocessor 12 is a Z80 and is connected to an 16-bit address bus 14 and an 8-bit data bus 16. ROM 18 contains the pattern information and firmware programming, such as the TONEQ and TONE21 routines. RAM 20 serves as a scratch pad for saving address and counter values.
A digital interface 22 serves as an interface between the Z80 microprocessor 12 and analog circuitry 24. The analog circuitry 24 translates the digital information from the digital interface 22 into Accunet format.
The terminal interface equipment 10 further includes serial and parallel I/O ports 26, 28. A command port interface 30 couples to RS232C or RS366 data lines and indicates to the user various parameters of system operation. It is, in many respects, redundant of the front panel display 32 that is conventional with such units. A data port interface 34 interfaces with the source of digital data, typically a computer. The front panel LCD display 32, which includes a keypad, LED indicators and an LCD message display, comprises the controls the user operates to effect dialing functions, etc.
The serial I/O 26 is used both with serial data from both the data port interface and the command port interface 30. The parallel I/O 28 is used with RS366 format data.
Having illustrated the principles of our invention with reference to a preferred embodiment, it should be obvious that the invention can be modified in arrangement and detail without departing from such principles. For example, while the invention has been described with reference to the particular application of disabling an echo canceller on a digital communications circuit, the invention has many other data communications applications. Similarly, while the invention has illustrated with reference to a ROM pattern memory that stores several bit shifted patterns of the 2100 hertz tone, alternative embodiments can be used. For example, a single tone pattern can be bit-shifted "on the fly" as necessary. Still other schemes may also be used. Accordingly, we claim all such variations as may come within the scope and spirit of the following claims and equivalents thereof.
|
A method and apparatus for disabling an echo canceller in a framed digital network from a remote terminal that is copuled to the network through an unframed data link. Control is effected by sending N different bit sequences from the remote terminal, where N is the number of different framing alignments that may be imposed on the unframed data by the network. The different sequences are chosen so that one will be framed by the network as the requisite control tone regardless of which framing alignment is actually imposed.
| 7
|
FIELD OF THE INVENTION
The present invention relates generally to charging devices and in particular to charging devices that include grid elements such as scorotron charging devices used in imaging systems.
BACKGROUND AND SUMMARY
In electrostatographic-type copiers and printers in common use, a charged imaging member such as a photoconductive insulating layer of a photoreceptor may be electrically charged and thereafter exposed to a light image of an original document or a laser exposure of a digitally stored document. The exposure discharges the photoconductive insulating surface in exposed or background areas and creates an electrostatic latent image on the member which corresponds to the image areas contained within the original document. Subsequently, the electrostatic latent image on the photoconductive insulating surface is made visible by developing the image with toner. During development, the toner particles are attracted from carrier particles by the charge pattern of the image areas on the photoconductive insulating surface to form a powder image on the photoconductive insulating surface. This image may be subsequently transferred to a support surface such as a copy substrate to which it may be permanently affixed by heating or by the application of pressure. Following transfer of the toner image to the support surface, the photoconductive insulating surface may be discharged and cleaned of residual toner to prepare for the next imaging cycle. The imaging processes described above are well known in the art.
Various types of charging devices have been used to charge or precharge charge retentive surfaces such as the photoconductive insulating layers of photoreceptors or such as copy substrates prior to transfer of toner images. These charging devices include corotrons, dicorotrons, pin corotron, scorotron, discorotron, and pin scorotron. See, generally, R. M. Schaffert, “Electrophotography,” The Focal Press, New York, 1965.
A scorotron device, included within the list above, it typically comprised of one or more corona wires or pin arrays with a conductive control grid or screen of parallel wires or apertures in a charge plate positioned between the corona producing element and the photoreceptor. A potential is applied to the control grid of the same polarity as the corona potential but with a much lower voltage, usually several hundred volts, which suppresses the electric field between the charge plate and the corona wires and markedly reduces the ion current flow to the photoreceptor.
The pin array variety of scorotron has proved to be a particularly inexpensive, durable, and effective device. Pins are often formed by forming “saw teeth” in a conductive metal sheet mounting these saw teeth edgewise facing the scorotron grid. In this arrangement, however, certain difficulties have been observed. One such difficulty is a sinusoidal wave pattern of charging thought to result from the increased charge potential located at the peaks of each pin when compared to each “valley” between pins. The scorotron grid is known to ameliorate the problem by diffusing the charge pattern through the grid pattern. Another method of ameliorating this problem is using at least two pin arrays arranged in parallel fashion such that the peaks of pins in the first array align with the valleys of the second array along the imaging path. Use of conventional scorotron grids with such dual pin arrays is known to produce charge uniformity across a process width of about plus or minus 25 volts for mid-range process speeds. In high quality printing, however, even relatively minor fluctuations in charge potential across the charged imaging surface, such as plus or minus 25 volts, cause undesirable printing irregularities.
A typical prior art scorotron device with dual pin arrays and a scorotron grid is shown in FIG. 1 ( FIG. 1 is adapted from U.S. Pat. No. 4,725,732 which is hereby incorporated herein in its entirety.) In this perspective exploded view, scorotron charging device 100 is shown with two spaced apart, generally parallel pin arrays, 200 and 202 , each supported on support projections 204 . The distance between arrays 200 and 202 is chosen to be as large as possible consistent with the need for a compact device since smaller spacing between the arrays results in the need to increase power levels to drive the scorotron. Locator pin 208 is provided to correctly position pin array 202 while another locator pin (not shown) positions pin array 200 in a position offset by a spacing of ½pitch in order that each peak of pin array 200 laterally corresponds to a valley of pin array 202 and vice versa. Frame members 206 , 238 , 212 , 230 , and 214 contain the corona field emitted from pin arrays 200 and 202 while providing support and means for mounting the arrays. Scorotron grid member 247 attaches to appropriate frame members. Openings in grid member 247 enable the corona field to emerge from charging device 100 and to interact with the charge retentive elements of a charged imaging surface (not shown). Electrically insulated wire 222 conducts charging DC current to pin arrays 200 and 202 while insulated wire 220 conducts regulating current to grid member 247 .
As shown in FIG. 2 , charging device 100 is assembled into printing system 300 . Typical uses within printing system 300 include charging of any charge retentive surface such as that of a photoreceptor 301 as shown in FIG. 2 or other imaging surface prior to image development as well as charging of a copy substrate 302 prior to toner transfer as well as detaching of the copy substrate 302 after toner transfer. Printing system 300 may be any number of electrostatographic imaging systems including, without limitation, electrophotographic monochrome or color systems and including without limitation printers, copiers, and various multifunctional systems.
One approach to improving charge uniformity using scorotron charging devices is set forth in U.S. Pat. No. 6,459,873, issued to Song et al., where a pair of scorotrons cooperatively charge the charged imaging surface. The first scorotron device initially charges the imaging surface to an intermediate overshoot voltage and the second scorotron device thereafter uniformly charges the imaging surface to the final voltage. Improved uniformity is created because the first scorotron device provides a generally high percent open control grid area (a range above 70% is claimed in Song) while the second scorotron device provides a generally lower percent open grid area (a range below 70% is claimed in Song). The higher percent of opening in the first scorotron grid correlates to a greater rate of charging, or slope, while the smaller percent of scorotron grid opening correlates to a lesser slope, or lesser rate of charging. The lesser slope of the second scorotron device enables more precise control of the charging process and, as a result, greater uniformity. Song is hereby incorporated herein by reference in its entirety.
The dual scorotron device taught in Song improves charge uniformity due to the differential in percentage of openings between the first and second grids. It would be desirable, however, to further improve charging uniformity.
One embodiment of the invention is a charging system for charging a charge retentive surface, comprising: at least one corona producing element, spaced from the charge retentive surface and arranged generally along the width dimension; and grid elements, interposed between said corona producing element and the charge retentive surface, wherein the grid elements are arranged generally parallel to each other along the width dimension and comprise differentiated grid feature patterns.
Another embodiment of the invention is an electrostatographic imaging system, comprising: a charge retentive surface having a width dimension; at least one corona producing element, spaced from the charge retentive surface and arranged generally along the width dimension; and grid elements, interposed between the corona producing element and the charge retentive surface, wherein the grid elements are arranged generally parallel to each other along the width dimension and comprise differentiated grid feature patterns.
Yet another embodiment of the invention is a method for charging a charge retentive surface having a width dimension, comprising: electrically charging at least one corona producing element, spaced from the charge retentive surface and arranged generally along the width dimension, sufficiently to emit a corona field; affecting the corona field by interposing, between the corona producing element and the charge retentive surface, grid elements that are arranged generally parallel to each other along the width dimension and that comprise differentiated grid feature patterns.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may take physical form in certain parts and arrangements of parts, an embodiment of which will be described in detail in this specification and illustrated in the accompanying drawings which form a part hereof, and wherein;
FIG. 1 is a perspective exploded and section view of a scorotron system of the prior art.
FIG. 2 is a schematic drawing of an exemplary imaging system embodying a scorotron system.
FIG. 3 is a raised perspective view of an embodiment of the invention having one grid with a plurality of differentiated patterns.
FIG. 4 shows a raised perspective view of two scorotron grids operating cooperatively in a two scorotron device system.
FIG. 5 is a bar chart comparing charge uniformity achievable with one embodiment of the invention with charge uniformity achieved with a comparable scorotron system without the advantages of the present invention.
DESCRIPTION
For a general understanding of the present invention, reference is made to the drawings. In the drawings, like reference numerals have been used throughout to designate identical elements.
An exemplary electrostatographic system comprising an embodiment of the present invention is a multifunctional printer with print, copy, scan, and fax services. Such multifunctional printers are well known in the art and may comprise print engines based upon electrophotography and other imaging electrostatographic technologies. The general principles of electrophotographic imaging are well known to many skilled in the art. Generally, the process of electrophotographic reproduction is initiated by substantially uniformly charging a photoreceptive member, followed by exposing a light image of an original document thereon. Exposing the charged photoreceptive member to a light image discharges a photoconductive surface layer in areas corresponding to non-image areas in the original document, while maintaining the charge on image areas for creating an electrostatic latent image of the original document on the photoreceptive member. This latent image is subsequently developed into a visible image by a process in which a charged developing material is deposited onto the photoconductive surface layer, such that the developing material is attracted to the charged image areas on the photoreceptive member. Thereafter, the developing material is transferred from the photoreceptive member to a copy sheet or some other image support substrate to which the image may be permanently affixed for producing a reproduction of the original document. In a final step in the process, the photoconductive surface layer of the photoreceptive member is cleaned to remove any residual developing material therefrom, in preparation for successive imaging cycles.
The above described electrophotographic reproduction process is well known and is useful for both digital copying and printing as well as for light lens copying from an original. Since electrophotographic imaging technology is so well known, further description is not necessary. See, for reference, e.g., U.S. Pat. No. 6,069,624 issued to Dash, et al. and U.S. Pat. No. 5,687,297 issued to Coonan et al., both of which are hereby incorporated herein by reference.
Referring now to FIG. 3 , one embodiment of the invention is shown in the form of scorotron grid 400 . As shown, grid 400 contains two major shapes of openings. In region 401 , the pattern comprises an intersecting set of diamonds. Approximately at the mid-line of grid 400 , the feature pattern transitions to a triangular shape of region 402 . In the embodiment shown, the percent opening of the grid 400 is greater than 70 percent in region 401 and less than 70 percent in region 402 . Pin array 404 emits a corona charge primarily affected by region 401 while pin array 406 emits a corona charge primarily affected by region 402 . Since pin arrays 404 and 406 are staggered by ½pitch, grid 400 combines into one scorotron device three separate means for rendering scorotron corona fields more uniform: 1) the pin arrays 404 and 406 are staggered by ½pitch; 2) the percent openings in grid 400 vary by percent; and 3) the feature pattern of the grid wires themselves is altered. Since the substrate path, as indicated by arrow 410 , takes the imaging width of the substrate (not shown) past both regions 401 and 402 , the result is more uniform charging than if the same feature pattern were used in region 401 and in region 402 .
Referring to FIG. 4 , a second of many possible embodiments of the invention is shown in the form of dual scorotron grids 501 and 502 indicating two separate scorotron devices. Placed side-by-side across the width dimension of the substrate path indicated by arrow 510 , the dual scorotron devices may function in the manner described above in relation to U.S. Pat. No. 6,459,873, issued to Song et al. Grid 501 , having at least a 70 percent opening, is intended to operate as part of a scorotron charging device having a high slope. Grid 502 , having about a 50 percent opening, is intended to operate as part of a scorotron charging device having a lower slope. Together, they operate to bring the charged imaging substrate (not shown) to the desired charging potential, with the scorotron charging device 504 associated with grid 501 delivering the majority of the charging potential and the scorotron charging device 506 associated with grid 502 providing a lesser charge while leveling any charge non-uniformity.
As seen in FIG. 4 , the grid feature patterns in grid 501 differs from the grid pattern in grid 502 . Whereas the grid feature patterns in FIG. 3 differed due to varying geometric shapes, the grid feature patterns in FIG. 4 both have the same geometric shape but differ in feature size. Specifically, the mesh of grid 501 is comprises of mesh wire 0.3±0.07 millimeters wide with each hexagon being 2.0±0.1 millimeters across. As shown, this combination results in a 1.73 millimeter distance between two parallel lines that each are orthogonal to a hexagon side and that intersect the centers of two adjoining hexagons. In contrast, comparable measurements of the embodiment shown as grid 502 are 0.41±0.07 for mesh wire size, 1.5±0.1 millimeters for hexagon size, and 1.3 millimeters between comparable parallel lines intersecting the centers of adjoining hexagons.
The impact upon charging uniformity of using scorotron grid elements having differentiated patterns is shown in the bar charge of FIG. 5 . In this Figure, results using two scorotron grid element arrangements are compared. In both arrangements, two scorotron charging devices were mounted side-by-side in a manner similar to that shown in FIG. 4 . In both instances, the first scorotron grid of the first scorotron device in the pair corresponded to the grid parameters of grid 501 shown in FIG. 3 , i.e., 70% hexagonal openings. For the bar labeled “Same Hex”, the second scorotron grid utilized the same 1.73 millimeter feature spacing between parallel lines intersecting adjoining hexagon centers but used thicker wire mesh to reduce the openings to fifty (50) percent openings. In other words, the feature pattern was the same size but the line thickness was greater within each feature. For the bar labeled Different Hex, the dimensions of grid 502 from FIG. 4 were used. In other words, both scorotron sets were identical 70:50 percent grid opening pairs but the “Different Hex” achieved its 50% opening grid using a different scorotron grid feature pattern while the “Same Hex” used the identical size and shape hexagon in both first and second grids.
The results confirm the advantages of using different grid patterns. Whereas the bar in FIG. 5 corresponding to the “Same Hex” grid configuration shows detectable charging non-uniformities in excess of 0.14 L* amplitude as measured in 1976 CIE L*a*b space. The bar corresponding to the “Different Hex” grid configuration showed no discernible defects.
In sum, use of scorotron grid elements having differentiated grid patterns across the width dimension of an imaging substrate result in more uniform charging of the charge retentive surface. Embodiments of the invention apply to charging systems utilizing grids positioned between the charge retentive surface and the corona generating elements. Such charging systems include, without limitation, wire-based scorotrons, pin-array scorotrons, and discorotrons. Pin array scorotrons become particularly attractive with embodiments of the invention by combining the high charge uniformity achievable with the present invention with the relative inexpensiveness and robustness of pin array corona devices. Differentiated patterns can be achieved in any manner, including varying the grid pattern by geometric shape or by feature size.
While particular embodiments have been described, alternatives, modifications, variations, improvements, and substantial equivalents that are or may be presently unforeseen may arise to applicants or others skilled in the art. Accordingly, the appended claims as filed and as they may be amended are intended to embrace all such alternatives, modifications variations, improvements, and substantial equivalents.
|
A charging system for uniform charging of charge retentive surfaces such as photoreceptors in imaging systems. The charging system includes corona producing elements and grid elements such as scorotron screens wherein the grid elements are arranged generally parallel to each other and have differentiated grid feature patterns. The differentiated grid feature patterns enable more uniform charging.
| 6
|
This is a continuation of co-pending application Ser. No. 07/063,430 filed on June 18, 1987 now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to control of an automotive vehicle equipped with an electronic control unit for controlling devices mounted on the vehicle.
The appearance of electronically controlled vehicles controlled by an electronic control unit (commonly referred to as an "ECU") comprising a microcomputer has increased in recent years. In addition to control of the rotational speed of the internal combustion engine, control of gear changeover in a transmission and control of a clutch, these vehicles also have various accessories controlled by the electronic control unit. Based on signals from various sensors provided on a variety of actuators, which drive devices to be controlled, the electronic control unit calculates control variables for the various actuators that are controlled and then outputs the corresponding signals to these actuators to control the operation of each device. Such a system is illustrated in Japanese Patent Application No. 60-217471 filed by the present applicant. This electronically controlled vehicle not only includes an electronic control unit (main electronic control unit) for controlling various actuators that is also equipped with emergency actuators for back-up purposes in the event that any actuator or the main control unit itself develops an abnormality such as breakage of a wire or short circuit, and an emergency electronic control unit for controlling the emergency actuators. If the main electronic control unit should happen to malfunction, the system is switched over to the emergency electronic control unit to assure that the vehicle will continue to travel safely.
In this electronically controlled vehicle, however, the emergency electronic control unit is not used when the various actuators are operating normally, so that it is impossible for the driver to know whether the emergency electronic control unit has developed an abnormality.
Since the emergency electronic control unit must operate without failure if the main electronic control unit malfunctions, it is necessary that some form of warning means be provided to inform the driver of whether the emergency electronic control unit is operating abnormally, even when the vehicle is operating in the normal traveling mode, i.e. under the control of the main electronic control unit.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide an electronic automotive vehicle control system equipped with a fault detector that indicates to a driver that an whether the emergency electronic control unit is operating abnormally.
Another object of the present invention is to provide an automotive vehicle control system equipped with a fault detector capable of detecting whether the main electronic control unit is operating abnormally.
According to the present invention, the foregoing and other objects of the present invention are attained by providing an automotive vehicle control system equipped with a control unit for controlling devices mounted on the vehicle. The control system comprises a main electronic control unit for controlling the devices mounted on the vehicle, an emergency electronic control unit for backing up the main electronic control unit, and fault detecting means provided in each of the electronic control units for diagnosing faults in the other.
Thus, the automotive vehicle control system of the invention includes fault detecting means provided in the main electronic control unit for diagnosing faults in and monitoring the emergency electronic control unit, and fault detecting means provided in the emergency electronic control unit for diagnosing faults in and monitoring the main electronic control unit. As a result, safe operation of the vehicle is assured at all times since constant monitoring is performed to determine whether both the main electronic control unit and emergency electronic control unit are operating normally or abnormally.
Other features and advantages of the present invention will be apparent from the following description taken in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the figures thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a vehicle control system according to the present invention;
FIGS. 2A-C illustrate communication during fault diagnosis;
FIG. 3 is a block diagram illustrating the details of actuators for various components;
FIG. 4 is a flowchart of the control logic in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An automotive vehicle control system according to the invention will now be described in detail with reference to the drawings.
In FIG. 1, numeral 101 denotes a main electronic control unit comprising a microcomputer. The main electronic control unit 101 includes internal such as a central processor, memory and input/output means. It further includes waveform shaping means 51 which produces a communication waveform to initiate emergency electronic control unit 102, for self-diagnosis transmitting means 52 for transmitting the communication waveforms to the energency electronic control unit 102; receiving means 71 for receiving the fault diagnosis waveform from the emergency electronic control unit 102; and diagnostic means 72 for diagnosing the received waveform.
The emergency electronic control unit 102 comprises a microcomputer and, like the main electronic control unit 101, includes internal devices such as a central processor, memory and input/output means. Also included in the emergency electronic control unit 102 are waveform shaping means 81 which produces a communication waveform to initiate main electronic control unit 101 for self-diagnosis; transmitting means 82 for transmitting the communication waveform; receiving means 61 for receiving the fault diagnosis waveform from the main electronic control unit 101; and diagnostic means 62 for diagnosing the received waveform. The transmitting means 52 and receiving means 61 are connected by a communication line 103, and the transmitting means 82 and receiving means 71 are connected by a communication line 104.
Numeral 3 denotes an engine for which an engine actuator 11 is provided. The actuator 11 comprises an engine actuator 11a for normal operation, and an emergency engine actuator 11b. Numeral 4 denotes a clutch having a clutch actuator 10 comprising a clutch actuator 10a for normal operation, and an emergency clutch actuator 10b. Numeral 5 denotes a transmission having a transmission actuator 9 comprising a transmission actuator 9a for normal operation and an emergency transmission actuator 9b. Numeral 6 denotes a stator, and numeral 12 represents a stator drive unit comprising a stator drive 12a for normal operation and an emergency stator drive 12b.
Numeral 7 designates a select lever and numeral 8 designates a velocity sensor. Numeral 13 denotes an accelerator sensor comprising an accelerator sensor 13a for normal operation, and an emergency accelerator sensor 13b. The accelerator sensor 13b comprises a potentiometer which, when a fault occurs, generates an input signal for controlling the clutch actuator 10 and a motor 25 (FIG. 3) simultaneously, or for controlling solely the motor 25, as will be described below. Numeral 14 denotes a power supply changeover switch for changing over a power supply between the main electronic control unit 101 and emergency electronic control unit 102.
Numeral 15 denotes an emergency gear switch by which the driver designates a gear stage when the vehicle is traveling during an abnormality. The switch 15 allows selection of reverse, neutral or first gear.
Numeral 28 denotes an engine rotation sensor, and numerals 29 denotes an input shaft rotation sensor.
When operation is normal, the main electronic control unit 101 receives signals from the selector lever 7, vehicle velocity sensor 8, accelerator sensor 13a for normal operation, engine rotation sensor 28 and input shaft rotation sensor 29, as well as other input signals such as a clutch stroke signal and gear position signal, not shown. The main electronic control unit 101 responds by driving the transmission actuator 9a for normal operation, the clutch actuator 10a for normal operation, the engine actuator 11a for normal operation and the stator drive 12a for normal operation, thereby performing suitable transmission control, clutch control and engine control.
Meanwhile, if the main electronic control unit 101 malfunctions, power is cut off from the main electronic control unit 101 and the emergency electronic control unit 102 is energized simultaneously by the power supply changeover switch 14. The emergency electronic control unit 102 turns on the emergency state drive 12b to prepare for engine start and, at the same time, responds to signals from the emergency gear switch 15 and emergency accelerator sensor 13b by shifting the gears of the transmission, engaging and disengaging the clutch and controlling the engine.
Numeral 30 denotes a key switch provided between the power supply changeover switch 14 and battery B. When the key switch 30 is closed, a voltage is applied to both the main electronic control unit 101 and emergency electronic control unit 102 by the power supply changeover switch 14, which is in contact with the main electronic control unit 101 at all times, and a line 105 connected to the emergency electronic control unit 102.
FIGS. 2A-C illustrate diagnostic communications provided between the main electronic control unit 101 and emergency electronic control unit 102. FIG. 2(A) is a simple block diagram, and FIG. 2(B) illustrates an output waveform of a diagnostic signal generated by the main electronic control unit 101 and emergency electronic control unit 102. The output waveform is a pulsed waveform having a high-level pulse width T 1 and a low-level pulse width T 2 . FIG. 2(C) illustrates a waveform of the aforementioned diagnostic signal, which is generated by the main electronic control unit 101 and emergency electronic control unit 102, as it appears when received by the receiving means 61, 71 (FIG. 1). The received waveform is a pulsed waveform having a high level pulse width t 1 and a low level pulse width t 2 . In the present invention, abnormalities are judged in the following manner:
A. Fault diagnosis of the main electronic control unit 101
The waveform shaping means 51 of the main electronic control unit 101 constantly produces, by means of software, a pulsed waveform having a cycle T 1 =T 2 =10 msec (duty cycle: 50%), by way of example. The waveform is applied, without interruption, to the emergency electronic control unit 102 via the transmitting means 52. The dianostic signal comprising these pulses is received by the receiving means 61 of the emergency electronic control unit 102. The diagnostic means 62 of the emergency electronic control unit 102 checks whether pulse widths t 1 , t 2 fall within predetermined pulse width limits whenever the diagnostic signal is received by the receiving means 61. When a predetermined number of diagnostic signals having pulse widths not within the predetermined limits are received, or when a predetermined number of the pulses are missing, the emergency electronic control unit 102 determines that the main electronic control unit 101 cannot form pulses within the predetermined pulse width limits because of some malfunction. The main electronic control unit 101 is therefore determined to be faulty at such time.
B. Fault diagnosis of the emergency electronic control unit 102
The waveform shaping means 81 of the emergency electronic control unit 102 produces, by means of software, one period of a pulsed waveform having a cycle T 1 =T 2 =10 msec (duty cycle: 50%) every 200 msec, by way of example. The waveform is applied to the main electronic control unit 101 via the transmitting means 82. The diagnostic signal comprising these pulses is received by the receiving means 71 of the main electronic control unit 101. The diagnostic means 72 of main electronic control unit 101 checks whether pulse widths t 1 , t 2 fall within predetermined pulse width limits whenever the diagnostic signal is received by the receiving means 71. When a diagnostic signal having pulse widths not within the predetermined limits is received, or when the diagnostic signal cannot be received despite the fact that it is time for the signal to be generated, the main electronic control unit 101 determines that the emergency electronic control unit 102 cannot form pulses within the predetermined pulse width limits, or that the diagnostic signal itself cannot be generated, because of some malfunction. The emergency electronic control unit 102 is therefore determined to be faulty at such time.
The details of the actuators will now be described with reference to FIG. 3. Described first will be the construction of the actuators for control when operation is normal. Numeral 17 denotes a selector actuator for the transmission 5. The selector actuator 17 includes a piston that is stoppable at three positions, and is adapted to detect three select positions, namely a first speed--R position, a second speed--third speed position, and a fourth speed--fifth speed position, by a combination of electromagnetic valves V 1 , V 2 . In the illustrated embodiment, the first speed--R position is selected by turning on the electromagnetic valve V 1 and turning off the electromagnetic valve V 2 . The second speed--third speed position is selected by turning on the electromagnetic valves V 1 , V 2 . This fourth speed--fifth speed position is selected by turning on the electromagnetic valve V 2 and turning off the electromagnetic valve V 1 . Numeral 18 denotes a shift actuator having a structure similar to that of the select actuator 17, and determines a shift position by a combination of electromagnetic valves V 3 , V 4 . The select actuator 17, shift actuator 18, electromagnetic valves V 1 , V 2 , V 3 and V 4 comprise the aforementioned transmission actuator 9a for normal operation (FIG. 1).
Numeral 19 denotes an actuator for actuating the clutch 4. The actuator 19 is biased in one direction by the force of a spring provided on the clutch 4 and is of the type in which pressure is applied to one side of a piston so as to overcome the biasing force. The clutch is engaged and disengaged by electromagnetic valves V 5 , V 6 . In the illustrated embodiment of FIG. 3, the clutch is disengaged by turning on the electromagnetic valves V 5 , V 6 and is engaged by turning off these electromagnetic valves. The actuator 19 and electromagnetic valves V5, V6 comprise the clutch actuator 10a for normal operation (FIG. 1).
Numeral 20a denotes an engine actuator having a structure similar to that of the clutch actuator 10a and controls engine rotation by a combination of electromagnetic valves V 7 , V 8 . The engine actuator 20 and electromagnetic valves V 7 , V 8 comprise the engine actuator 11a for normal operation (FIG. 1). It should be noted that the actuator 11a for normal engine operation is comprises a pulse motor.
Numeral 26 denotes a stator relay turned on by an engine start enable signal from the main electronic control unit 101 when operation is normal, thereby establishing an engine start preparatory state. The stator relay 26 comprises the stator drive 12a for normal operation (FIG. 1).
The construction of the emergency actuators will be described next. In FIG. 3, an electromagnetic valve V e0 is a main valve for switching the hydraulic pressure source from the actuators for normal operation to the emergency actuators. The valve V e0 is turned on in an emergency to cut off the supply of pressure to the actuators for normal operation and to supply pressure to the emergency actuators.
An electromagnetic valve V e1 is an emergency electromagnetic valve associated with the gear select actuator 17. When the valve is turned on, the select actuator 17 selects the first speed--R position in accordance with the illustrated embodiment.
Electromagnetic valves Ve 2 , Ve 3 are emergency electromagnetic valves associated with the gear shift actuator 18. These valves operate in the same manner as the electromagnetic valves V 3 , V 4 of the actuator for normal operation.
The electromagnetic valves V e1 , V e2 , V e3 , the selector actuator 17 and the shift actuator 18 comprise the emergency transmission actuator 9b (FIG. 1).
An electromagnetic valve V e4 is an emergency electromagnetic valve associated with the clutch actuator 19. The clutch is disengaged when the valve is turned on and engaged when the valve is turned off. The electromagnetic valve V e4 and the clutch actuator 19 comprise the emergency clutch actuator 10b (FIG. 1).
The motor 25 is an actuator for emergency control and is connected to a rod control lever (or rack) of the engine. The motor 25 comprises the emergency engine actuator 11b (FIG. 1).
An emergency stator relay 27 is similar to the stator relay 26 for control during normal operation, and comprises the emeregency stator drive 12b (FIG. 1). It should be noted that an emergency hydraulic pressure system 23 is indicated by the dashed lines, and that a hydraulic pressure system 24 for normal operation is indicated by the solid lines. Numerals 21, 22 denote a hydraulic pressure source and a tank, respectively.
The operation of the system shown in FIG. 3 will now be described. When the main electronic control unit 101 and emergency electronic control unit 102 are both operating normally, oil merely flows through the emergency electromagnetic valves and the actuators operate in the usual manner. When the main electronic control unit 101 is diagnosed to be faulty, the driver operates the power supply changeover switch 14 to switch the supply of power from the main electronic control unit 101 to the emergency electronic control unit 102 via line 106. In response, the emergency electronic control unit 102 actuates the emergency electromagnetic valves. The hydraulic system switches over to the emergency hydraulic circuit, and each actuator operates in an emergency state.
The control operation of the vehicle control system equipped with a fault detector will now be described with reference to the flowchart of FIG. 4.
When the key switch 30 is closed to supply voltage to the main electronic control unit 101 and emergency electronic control unit 102, these control units generate diagnostic signals. The diagnostic signal from the main electronic control unit 101 is always delivered to the emergency electronic control unit 102 first (step s1).
Next, the diagnostic signal generated in the emergency electronic control unit 102 is read in by the main electronic control unit 101 (step S2). In response, the main routine of the main electronic control unit 101 is interrupted and is judged whether the diagnostic signal is normal or abnormal (step S3). If the decision rendered at step S3 is that the diagnostic signal is abnormal, then it is determined at a step S4 whether the abnormality is detected at least n consecutive times. If the answer at step S4 is YES, then an alarm is issued at step S5 to inform the driver of the fact that the emergency electronic control unit 102 is faulty. If the decision rendered at step S3 is that the diagnostic signal is normal, or if an abnormality is not detected n consecutive times at step S4, then it is decided that the emergency electronic control unit 102 is operating normally and the alarm is not issued (step S6).
Meanwhile, at the same time that a voltage is applied to the emergency electronic control unit 102, i.e., when key switch 30 is closed, the emergency electronic control unit 102 starts operating and a diagnostic signal comprising a set number of pulses is generated and outputted to the main electronic control unit 101 e.g. every 200 msec (step S11). Further, the diagnostic signal being transmitted at all times by the main electronic control unit 101 is read in (step S12) and it is decided whether the diagnostic signal is normal (step S13). If the signal is found to be abnormal, it is determined whether the signal is abnormal for at least m consecutive times (step S14). If the answer at step S14 is YES, a decision is rendered to the effect that the main electronic control unit 101 is faulty, an alarm is issued (step S15) and the engine is placed in an idling state (step S16). This is followed by switching over to back-up operation to cope with the emergency. If the signal is found to be normal or an abnormality is not detected at least m consecutive times, no alarm is issued (step S17). If the engine is running in the idling state, the engine is returned to the former running condition (step S18).
Thus, as described in detail above, the main electronic control unit is provided with fault detecting means for monitoring the emergency electronic control unit and the emergency electronic control unit is provided with fault detecting means for monitoring the main electronic control unit. Therefore, both the main electronic control unit and emergency electronic control unit can be monitored at all times to determine whether they are operating normally or abnormally. This assures safe vehicle operation at all times. Furthermore, the driver is immediately informed of an abnormality in either of the electronic control units to prevent the occurrence of an accident.
As many apparently widely different embodiments of the present invention can be made without departing from the spirit and scope thereof, it is to be understood that the invention is not limited to the specific embodiments thereof except as defined in the appended claims.
|
An automotive vehicle control system is equipped with a main electronic control unit for controlling devices mounted on the vehicle, and an emergency electronic control unit for backing up the main electronic control unit. Both electronic control units transmit diagnostic signals, receive the diagnostic signals from each other and diagnose them for abnormalities, whereby a fault in the main electronic control unit is diagnosed by the emergency electronic control unit and a fault in the emergency electronic control unit is diagnosed by the main electronic control unit.
| 5
|
FIELD OF THE INVENTION
[0001] The invention relates to a technique for interconnecting communication networks, more particularly for providing a traffic protecting though loop free interconnection between layer 2 Ethernet and/or VPLS-packet networks.
BACKGROUND OF THE INVENTION
[0002] An Ethernet network is composed of Ethernet switches connecting local area network (LAN) or IEEE 802.1Q virtual LAN (VLAN) segments containing end stations. A switch forwards packets between its interfaces (ports) based on media access control (MAC) destination address contained in each packet. An incoming packet may be forwarded to one or more outgoing ports, where the latter case is referred to as multicasting or broadcasting.
[0003] FIG. 1 illustrates one possible example of inter-network connectivity where a customer access network ( 10 or 12 ) is connected to a provider network ( 14 ) via switches referred to as gateway customer edge (CE) switches ( 11 or 13 ) and gateway provider edge (PE) switches 15 or 17 , 19 , respectively. The term gateway indicates that the node belongs to one network and has connection to another network.
[0004] The CE-PE connection can carry Ethernet or Ethernet-VLAN packets. The provider may map the customer traffic into Provider Service VLANs (SVLANs) using VLAN stacking techniques (so called Q-in-Q encapsulation) in order to partition customer's traffic from the others.
[0005] A newly emerging technology has become known in the prior art, called virtual private LAN service (VPLS). A VPLS network emulates the functionality of a LAN, making it possible to interconnect multiple access networks over a VPLS network while all these access networks together behave as one single LAN or virtual LAN (VLAN). With VPLS, all these access networks would be assigned the same virtual private network (VPN) identification, this is analogous to assigning them the same SVLAN in an Ethernet-based provider network. With VPLS, the Ethernet packets arriving from the access network are appended with multi-protocol label switching (MPLS) headers, based on which they are forwarded across the provider network towards the remote LAN segments. This use of MPLS forwarding within the VPLS provider network allows to build networks that excel in performance, quality of service (QoS) for service differentiation, high resiliency (particularly fast rerouting, FRR), and scalability.
[0006] For convenience, we will refer to both SVLANs and VPLS VPNs used within the provider network as VPNs (Virtual Private Networks). VPLS architecture implements full-mesh connectivity between the PE nodes that connect the customer access networks, this allows each access network to communicate with any other access network belonging to the same VPN. Each PE-PE path carrying VPN traffic is called pseudo-wire (PW).
[0007] As an alternative to using Ethernet-VLAN on a CE-PE connection to classify customer traffic to specific VPN, a CE-PE connection (say, 20 ) can be a so-called spoke Pseudowire (spoke PW). With this method, known as hierarchical VPLS (H-VPLS), Ethernet packets already arrive encapsulated with MPLS headers (a.k.a., Martini encapsulation) on the CE-PE connection to the provider network. H-VPLS can be preferred over Ethernet-VLAN on the CE-PE connection, because it provides the aforementioned MPLS advantages also on the CE-PE connection and not only within the provider network.
[0008] A key aspect in Ethernet networks is avoiding layer 2 loops. A layer 2 loop occurs when multiple data routes exist between two end stations connected to an Ethernet network. A multicast or broadcast traffic introduced into Ethernet network with a layer 2 loop, will indefinitely keep circulating in the network, and might steadily consume more and more resources until the network overloads. Assuring loop-free topology is therefore essential to proper operation of Ethernet networks.
[0009] An important feature in packet-based applications is effective redundancy. The financial costs associated with unexpected downtime is leading service providers to build fault-tolerant networks. One option for achieving fault tolerant connectivity comes in the form of so-called dual homing or dual homing configurations. Dual homing adds reliability by allowing a device or a network to be connected to another device or network via two connections, such that when one connection fails the other one serves for carrying the traffic. The general case of dual homing is referred to as multi homing, with which redundancy is achieved via multiple rather than only two connections. This application mainly deals with dual homing for the sake of clarity, but it can be extended straightforwardly to support multi homing. Therefore, the term dual homing should be understood as “at least dual homing”, i.e. as a network interconnection configuration providing two or more alternative traffic paths therebetween.
[0010] FIG. 2 shows various dual-homing connections of an access network to a provider network:
Case (a) illustrates a dual homing configuration (dual homing) from a single CE to a single PE, thereby providing protection against CE-PE connection failure. Case (b) illustrates a dual homing from a single CE to two PEs (or, alternatively, from a single PE to two CEs), thereby providing protection against failure of a CE-PE link, as well as against failure of a PE (or, alternatively, CE). Case (c) illustrates dual homing from two CEs to two PEs, thereby providing protection against CE-PE, CE, and PE failure. This case is referred to as offering full redundancy since the traffic can flow between the two networks if CE or PE or CE-PE connection fails. Full redundancy is often preferred over partial redundancy as it can support fail-safe operation of the applications in the event of single failure (multiple simultaneous failures—e.g., both CEs or both PEs—are more scarce). Case (d) illustrates a fully-redundant multi-homing configuration actually being a triple-homing one. This case offers more robust connectivity than dual-homing at the cost of another CE-PE connection and possibly more complicated means for regulating the traffic between the networks
[0015] A major concern in dual homing is avoiding the unbroken layer 2 loop that is created by the dual (or multi) homed connections, i.e., connections having two or more communication lines between the two networks. Breaking this loop can be done in various ways, that can be classified to two approaches:
(A) Running signaling protocol, dedicatedly designed for this purpose, among the involved switches. The standard protocol designed for this purpose is the Spanning Tree Protocol (STP) that is defined in IEEE 802.1, including its variations such as RSTP (IEEE 802.1w) or MSTP (IEEE 802.1s), and all of them are referred hereby as xSTP. The xSTP algorithm calculates a logical tree that spans all of the switches in a network, forcing redundant paths into a blocked state, and leaving only one active path at a time between any two end stations. In case a network path becomes unavailable, the spanning tree algorithm can recalculate a new tree and then reactivate blocked paths to enable the connectivity between any two end stations.
[0017] A notable advantage of xSTP is that it can break a loop for any arbitrary Ethernet topology. A drawback of this method is the need to maintain xSTP signaling interaction between the switches. This is especially complicated when the dual homing connectivity is created between two networks running under different administrations, due to the xSTP provisioning and maintenance burden it inflicts upon the parties involved.
[0018] This prior art, described in http://www.alcatel.com/doctypes/opgapplicationbrochure/pdf/Resilient_HVPLS_an.pdf (hereby referred to as “Alcatel's”), requires that xSTP would run among CEs and PEs (see our FIG. 2 ) to break the loop. Note that the provider would have to run a separate xSTP instance with each access network. This could be especially undesired when the connecting parties are VPLS networks that use H-VPLS on the CE-PE connection.
(B) Forcing one of the dual homing connections to a standby mode, during which it does not actively carry traffic. This prior art, described in section 10.2.1 of draft-ietf-12vpn-vpls-ldp-08.txt, assumes that the dual homed connections originate at a single CE (or a single PE). A notable advantage of this method is its simplicity as it does not mandate signaling between the switches for achieving loop-free topology. This configuration also enables quite fast recovery time (sub-50 milliseconds). A drawback of this method is that it does not support full-redundancy as shown in FIG. 2( c ). US 2006/0047851 (Further referred as “Cisco's”) proposes a method in which a local node u-PE (analogous to the left-side CE in FIG. 1 of the present application) is dual homed to two local nodes Agg-PEs (analogous to the left-side two PEs in FIG. 1 of the current application) and can communicate with remote nodes u-PE (analogous to right-side CE in FIG. 1 of the present application) in a loop-free manner, wherein all of the involved local/remote u-PEs and Agg-PEs run together a protocol xSTP in order to break the layer 2 loop. The method of US 2006/0047851 is rather complicated because (a) it uses xSTP protocol to assure the loop-free communication; (b) it requires (xSTP) signaling interaction between the u-PE and Agg-PE; (c) the (xSTP) signaling is not a local matter on the border of the two connected networks, since it involves both the local and remote u-PEs and Agg-PEs.
OBJECT OF THE INVENTION
[0020] The object of the present invention is providing a simple technique for connecting Ethernet and/or VPLS networks, that would be capable of preventing traffic loops at layer 2, combine advantages of the above-mentioned two prior art approaches, while avoiding their drawbacks.
SUMMARY OF THE INVENTION
[0021] The Inventor has found that the above object can be achieved by
a method for providing interconnection between a first and a second networks, each being either a layer 2 Ethernet-based network or a VPLS network, using a fully or partially redundant dual homing configuration including
at least three network elements where at least two of them (so-called peer elements) belong to the second network, and at least two traffic lines (preferably, in the form of spoke pseudowires PW) respectively associated with said peer elements and connecting said first and said second networks via said at least three network elements,
the method comprising steps of:
establishing non-xSTP bi-directional signaling between said peer elements of the dual homing configuration belonging to the second network; deciding, at one of said peer elements at a time, that only its associated traffic line (preferably, its spoke PW) should be forwarding traffic, based on information obtained from said signaling.
[0028] According to a second aspect of the invention, there is provided a software product, comprising computer implementable software instructions and/or data, suitable to be installed in any of said peer elements, and capable of implementing the two last steps of the above-described method (in particular, by providing exchange of signaling, or Hello, messages between the peer nodes). There is also provided a suitable computer readable medium where the software product is stored.
[0029] According to a third aspect of the invention, there is also provided a peer element (such as a gateway node) operative to implement the steps of the above described method, whenever said peer element is activated as part of the dual-homing configuration.
[0030] Alternatively, the proposed peer element can be defined as a network element suitable for serving as a peer in the dual homing configuration and provided with the above-mentioned software product, pre-installed therein.
[0031] Coming back to the above-proposed method, it should firstly be noted that it enables drastically simplifying the problem of interconnecting Ethernet and/or VPLS networks. No xSTP is required neither in the first network (say, an access network) nor in the second network (say, a provider network) for correct operation of the dual homing, and that is in contrast with the prior art approach (A) which requires xSTP at one or both of the connecting networks.
[0032] The above method renders the configuration fast protected and simple simultaneously. Those skilled in the art understand the term “fast protected” as being capable of performing switchover to its protection traffic line during a time period, which is much shorter than that could be ensured by previously known techniques.
[0033] For example, such a prior technique is RSTP protocol activated in a relatively large network such as an access network having multiple nodes. According to the proposed method, the time of the dual homing switchover can be of about 0.1 sec, i.e., much less than 1-2 sec provided by using a standard RSTP technology.
[0034] On the other hand, though the proposed method is comparable by its switchover time with a method where a separate xSTP protocol is activated per dual homed connection (as described in Alcatel's), it is much simpler than the Alcatel's technique since the proposed method does not require applying xSTP protocol for each multi/dual-homing configuration in the provider's network.
[0035] In comparison with the US 2006/0047851 (Cisco's), the proposed invention avoids drawbacks of the Cisco's, by: (a) using rather simple signaling (such as Hello signaling) eliminating the need for xSTP (b) avoiding signaling interaction between the CE and PEs (c) exchanging the Hello signaling only between the two PEs (peers) to which the CE is dual homed.
[0036] Let us assume as a condition, that both the access network and the provider network are a-priory loop-free, i.e., in the frame of the present application we do not take care of removing traffic loops pre-existing in any of the networks before they are interconnected by the dual-homing configuration. The task of the invention is to prevent loops which may be introduced/caused by the dual-homing connection.
[0037] As has been mentioned, the first of the mentioned networks can be an access (customer's) network, and the second network—a provider network. However, it can be just vise versa, it can also be that the two mentioned networks have nothing in common with an access and provider's network. Each of the two networks can be a network utilizing raw Ethernet traffic, Ethernet VLAN traffic or encapsulated Ethernet traffic, Martini encapsulation inclusive. In particular, each of them can be an Ethernet network or a VPLS network.
[0038] The mentioned at least three elements of the dual-homing (or multi-homing) configuration are preferably edge nodes or gateways of the two connected networks. Preferably, for a case when one of the networks is an access (customer) network and the other is a provider network, each of the elements is either a Customer's Edge node (CE) or a Provider's Edge node (PE). Further, said at least two elements belonging to one and the same (second) network—let them be called peer elements—will be either PE-s belonging to a provider network, or CE-s belonging to a customer's (access) network.
[0039] Usually, the peer elements are gateway PEs. (Keeping in mind that the term gateway indicates that the node belongs to one network and has connection to another network.)
[0040] It is understood, that said two or more elements belonging to one and the same network (the peer elements) form the basis of the required protected interconnection (i.e., the basis of multiple alternative communication lines). Therefore, each of these two or more elements must be prepared (provisioned) to receive and forward traffic from the second network to the first network and vice versa.
[0041] Let, for example, a loop-free access network is “dual homed” to a provider network. Let the dual homing configuration comprises two PE-s belonging to the provider network, and a single CE belonging to the access network. The configuration comprises two CE-PE traffic lines, and only one of them is supposed to be active at a time. From the access network's point of view, the provider network emulates the functionality of a LAN. Traffic over an active CE-PE connection is raw Ethernet or Ethernet-VLAN (either customer VLAN or SVLAN) or encapsulated Ethernet such as H-VPLS spoke PW. In order for the dual homing to operate correctly, at both gateway PEs there is provisioned the VPN (Virtual Private Network) assigned for the customer traffic.
[0042] Further preferably, for organizing the bidirectional signaling, the method comprises provisioning a bidirectional virtual link (VL) between each pair of said two or more peer elements belonging to the second network, and ensuring exchange of signaling messages between said peer elements pairwise. Preferably, the VL is dedicated for the signaling traffic.
[0043] The VL may be implemented by a dedicated provider S-VLAN or PW, or even by a physical link, as long as it assures that the signaling messages for the dual homing connection are exchanged between these two PEs.
[0044] To increase the VL reliability and assure low message delivery delay, the VL—or the means that are used to carry the signaling traffic, e.g., MPLS tunnels—may be protected (e.g., with MPLS fast rerouting mechanism-FRR) against failure of an intermediate node or links along the VL, use the shortest path available between the two PEs, have high traffic priority and/or packet error detection/protection means.
[0045] Specifically, the method may comprise prioritizing the signaling traffic over other traffic transmitted via the VL (if such other traffic is at all conveyed via the VL).
[0046] For establishing and maintaining the bi-directional signaling, the peer elements preferably should exchange periodic signaling messages (referred hereby as “Hello” messages) over the VL. The Hello messages may be implemented with standard or modified standard means, e.g. Ethernet or MPLS or PW Operations Administration and Maintenance (OAM) messaging, such as those described in ITU-TY.1710 and Y.1711.
[0047] Yet further preferable, that the above messages serve to elect the peer element which should be a “designated forwarder” in the dual-homing configuration.
[0048] The Inventor proposes the following way of performing the step of establishing the bi-directional signaling and the step of making the decisions:
a) periodically exchanging the signaling messages (Hellos) between peer elements (say, between PEs over the VL), while introducing in said Hellos information on status of the communication line associated with respective PEs, and on the hierarchical status of said PEs. b) based on the information received with the aid of said Hellos, electing one of the peer elements (PEs) to be Designated (i.e., designated to forward the traffic over its CE-PE connection), while blocking all the remaining (in a particular case of dual homing, the second one) of the traffic lines. c) transmitting traffic between the networks via the elected PE (and its corresponding traffic line) of the dual homing configuration.
[0052] According to the proposed concept, only one of the peer elements (say, PEs) is elected to be the designated PE (D-PE) at a time. The peers “agree” which one of them is the elected D-PE, this is indicated in the Hello messages. Only the D-PE puts its traffic line (CE-PE connection) in the forwarding state, i.e. it does receive and transmit packets through the connection, while the non-designated PE (N-PE) blocks its CE-PE connection, i.e. it does not send nor receive any packet on the connection. The blocking can also be implemented by deactivating the physical link between the PE and CE, or by putting the residing spoke PWs in standby state. It should be emphasized that, in the present patent application, blocking of a traffic line means that the line does not send nor receive any traffic on its CE-PE connection, unlike xSTP protocols where blocking still allows receiving BPDU packets.
[0053] Specific solutions of how the hierarchical status of the particular peer element can be reflected in the Hello messages, and how the status of the suitable traffic line can be introduced in the Hello messages sent from the particular PE will be described below with reference to the attached drawings.
[0054] The hierarchical function of the peer (D-PE or N-PE) can be re-elected during the operation, based on the mentioned information, which can be obtained using the Hello messages.
[0055] Re-election of the Designated element (say, D-PE) and consequently, re-election of the forwarding traffic line can be performed, for example, according to the following possible version of the sub-step (b): upon missing at a non-elected peer element N-PE a predetermined number of Hello messages from the D-PE, or upon receiving a defect indication (DI) from the D-PE, the N-PE becomes a D-PE itself; the new D-PE puts its associated traffic line (CE-PE connection) into a forwarding state.
[0056] It should be noted, that decisions on status change of a peer element should be regulated by a logical mechanism (for example, by a logical state machine) where various events affecting such decisions are prioritized to prevent racing (say, electing two D-PEs) and mis-election (e.g., no D-PE elected) in the absence of failures or the presence of up to one traffic line failure and/or up to one VL direction failure.
[0057] More information on the re-election procedure will be disclosed in the detailed description.
[0058] The new D-PE then optionally (and preferably) flushes the forwarding databases (comprising the previously learned Media Access Control addresses or MAC addresses) of the affected VPNs and initiates a MAC flushing message per VPN, ordering this flushing to all the provider nodes where these VPNs were provisioned, to facilitate transition of the traffic, outgoing from the provider to the access network, to the new CE-PE connection. This flush message can use standard means, like the one proposed in ietf-draft-12vpn-ldp-08.txt.
[0059] The new D-PE optionally (and preferably) triggers corresponding MAC flushing in the access network as well, to facilitate transition of the traffic, arriving from the access to the provider network, to the new CE-PE connection. This flushing can be triggered by either of the following (1) Reactivating the physical link towards the CE (2) In case of H-VPLS CE-PE connection, reactivation of the former standby spoke PWs towards the CE (3) Re-enabling the sending and receiving traffic through the interface (4) In case the access network runs xSTP, the new D-PE may send an xSTP topology change notification (TCN) to the CE (5) Sending MAC flushing message to the CE. In the absence of MAC flush messages, the traffic would anyway be transitioned to the new CE-PE based on the following ordinary layer 2 Ethernet switching means: (1) MAC address aging (2) MAC address re-learning.
[0060] It should be emphasized that, in the proposed technique, only the peer elements (usually, two PEs attached to the CEs) need to participate in the Hello messaging, because the customer traffic is ‘terminated’ there, meaning that these two peer PEs apply MAC address lookup onto an arriving customer packet in order to find out where the packet should go. In other known techniques (for example, Alcatel's), the signaling for dual homing connection is much more extensive—xSTP, contrary to the proposed simple Hello messages, is run among all the CEs and PEs involved (two CEs and two PEs.) The proposed Hello mechanism eliminates signaling interaction between the access and provider networks (xSTP inclusive) required by most of the prior art references to assure a loop-free inter-network connectivity. In fact, both networks need not run xSTP at all, as may be desired when the networks involved are VPLS networks. Moreover, simplicity of the Hello mechanism and its being exchanged between only the peer (usually, two provider) nodes allows switchover times much faster than those of prior art, typically 100-200 ms compared to 1-2 seconds with standard RSTP.
[0061] When speaking about the switchover time, it should be noted that in case the VL is protected (say with FRR), it should recover faster than the dual homing configuration decides about switchover due to missing a predetermined number of Hellos at one of the peer elements. In other words, the time it takes to miss the predefined number of Hellos should be larger than the recovery time for a failure in the VL path (e.g., 200 ms compared to 50 ms), in order to avoid an unnecessary switch to a new PE while the Vt is recovering.
[0062] The invention will be described in additional details as the description proceeds.
BRIEF DESCRIPTION OF THE DRAWINGS
[0063] The invention will further be described with references to the following non-limiting drawings, in which:
[0064] FIG. 1 illustrates an example of two access networks interconnected via a provider network through gateway nodes.
[0065] FIGS. 2 a, 2 b, 2 c, 2 d illustrate various embodiments of a dual homing configuration and a multi-homing configuration.
[0066] FIGS. 3 a, 3 b, 3 c, 3 d, 3 e, 3 f, 3 g, 3 h illustrate three exemplary scenarios of operation of one specific dual homing configuration.
[0067] FIG. 4 illustrates a simplified block diagram of a state machine of a particular peer element in the proposed dual homing configuration.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0068] FIGS. 1 and 2 have been described in the background of the invention.
[0069] FIG. 3 a schematically illustrates a steady-state operation of an exemplary dual-homing configuration 30 connecting an access Ethernet-based network 32 to a provider Ethernet-based or VPLS network 34 via edge customer nodes CE 1 , CE 2 and edge provider nodes (let them be called peer nodes) PE 1 , PE 2 , where CE 1 (CE 2 ) is directly connected to PE 1 (PE 2 ) via a physical link or spoke PW. PE 1 and PE 2 may also be connected for the purpose of exchanging customer traffic (in case of a VPLS provider network, there is a PW 36 per VPN between PE 1 and PE 2 ). The nodes CE 1 , CE 2 in the access network 32 are connected via a traffic line within the access network, to visualize that if both CE-PE connections are forwarding, then a layer 2 loop will occur in the access network which might not be running xSTP (as is typically the case if the access network is a VPLS network). In such cases the technique proposed by the Inventor is most advantageous. To implement the inventive technique, a bi-directional virtual link VL ( 38 ) is established between the nodes PE 1 and PE 2 for the purpose of Hello signaling.
[0070] It is to be noted that the proposed multi-homing configuration (the dual-homing one 30 in this case) is provisioned per each specific access network to be connected to another (say, provider) network, and the suitable procedures (which will be described below) should be implemented per each multi-homing configuration.
[0071] The configuration 30 in FIG. 3 a is presently failure-free. It is also loop-free, since the node PE 1 is elected to be a designated or forwarding node (D-PE), the node PE 2 thus remains to be a non-elected node (N-PE) and therefore a traffic line CE 1 -PE 1 is active, while a traffic line CE 2 -PE 2 is blocked by the PE 2 to avoid a loop. (The blocked line is marked with a double strip. It should be kept in mind that to avoid a layer 2 loop, only one of the CE-PE connections must be forwarding at a time).
[0072] For the configuration 30 to work loop-free, at least one CE-PE connection and at least one direction of the VL 38 must be operational, i.e. fault free. Therefore, the VL 38 is preferably protected (e.g., with MPLS FRR mechanism) against failure of an intermediate node or link along the VL, to increase its reliability. The VL is preferably implemented as a dedicated pseudo-wire (PW) in case of VPLS provider network. VL can even be a physical link, as long as the Hello signaling can be exchanged between the peer PEs.
[0073] The bi-directional VL 38 serves for periodically exchanging Hello messages (so-called Hellos) between the gateway PEs, to elect the designated forwarder (D-PE) as described below and thus to establish and maintain a loop-free dual homing.
[0074] The D-PE can be elected based on a dedicated or conventional identification sent in the Hello message and unambiguously identifying each peer (i.e., the two peers have different identifications so this can serve to elect the D-PE unambiguously). An example for a conventional identification could be the IP address of the PE being a router-switch where a D-PE could be selected based on having a higher (or a lower) IP address. The PEs establish an agreement regarding the elected D-PE, this agreement is suitably indicated in the Hello messages. In a rare case where the IP address of any of the peer elements is changed, the D-PE will be automatically re-elected. ( FIG. 3 e illustrates a case where PE 2 is elected as D-PE in the configuration 30 .)
[0075] FIGS. 3 b, 3 c, 3 d, 3 f, 3 g, 3 h show how the proposed dual-homing configuration 30 will operate in cases of a single fault or multiple simultaneous faults within the configuration.
[0076] FIG. 3 b illustrates a group of scenarios where the traffic line associated with the designated peer element (D-PE) fails due to failure of at least one of its components (marked with three crosses on CE 1 , CE 1 -PE 1 connection and PE 1 respectively). It is also possible that one direction of the VL 38 fails (marked with an additional cross).
[0077] The status of the traffic line becomes known to the D-PE and is normally introduced in the Hello messages sent from the D-PE. When its associated CE-PE connection fails, the PE 1 starts sending Hello messages provided with a defect indication (DI). (The PE 1 would clear the DI from the Hello messages a predefined time after these failures are repaired). In case the D-PE itself fails, it stops sending Hello messages to the N-PE (PE 2 ). When N-PE receives a DI over the VL or when it fails to receive a predefined number of consecutive Hellos from the D-PE, it becomes a D-PE itself and puts its CE 2 -PE 2 connection into a forwarding state. The alternative connection CE 1 -PE 1 is anyway non-operational, and thus the failure of the VL in the direction from PE 2 to PE 1 cannot keep PE 1 as D-PE.
[0078] The new D-PE may optionally and preferably flush the forwarding databases (learned MAC addresses) of the affected VPNs of the access network and initiate a MAC flushing message per VPN ordering this flushing to all the provider nodes where these VPNs were provisioned. This operation is schematically illustrated by a batch of arrows 31 . The new D-PE (PE 2 ) may optionally and preferably trigger such MAC flushing ( 33 ) also in the access network, using one of the previously suggested methods (e.g., sending xSTP TCN or MAC flush message or by activating the standby spoke PW per VPN).
[0079] FIG. 3 c illustrates a situation which differs from that in FIG. 3 b in that the other direction of the VL optionally fails. This situation is simpler, since in any failure in the upper traffic line and/or the marked direction of the VL the result is the same—the lower traffic line will become the forwarding one. (Even in case a DI indication is not received at PE 2 due to failure of PE 1 or of the indicated VL direction, absence of a predetermined number of Hello messages at PE 2 will make the job). When the VL failure is not accompanied with a failure in the D-PE or its CE-PE connection or its attached CE, the N-PE (PE 2 ) will fail to receive PE 1 's Hellos and will assume the role of the D-PE. The former D-PE (PE 1 ) will figure a disagreement on which one is the D-PE and hence become the N-PE.
[0080] FIG. 3 d illustrates a situation where both CE-PE connections are operational and the virtual link fails in the direction to the D-PE. PE 1 thus remains D-PE as it does not receive Hellos from PE 2 .
[0081] FIG. 3 e illustrates a situation which differs from that in FIG. 3 a in that the PE 2 is elected to be D-PE in the configuration 30 , and the line CE 1 -PE 1 is blocked.
[0082] FIG. 3 f illustrates a situation which differs from that in FIG. 3 b in that PE 2 remains D-PE because it receives DI from the PE 1 or does not receive PEI's Hellos.
[0083] FIG. 3 g illustrates a situation which differs from that in FIG. 3 c in that PE 2 remains D-PE because it receives DI from the PE 1 or does not receive PE 1 's Hellos.
[0084] FIG. 3 h illustrates a situation which differs from that in FIG. 3 d in that PE 1 will become the D-PE because it does not receive PE 2 's Hellos, while PE 2 will become N-PE because PE 1 no longer agrees for PE 2 to be the D-PE.
[0085] The above examples demonstrate that the proposed method and the suitable dual homing configuration are able to function correctly even if only one traffic line of the configuration is in order and/or only one direction of the virtual link VL is operational.
[0086] FIG. 4 illustrates a simplified block diagram of a logical state machine of a particular peer element PE in the proposed dual homing configuration. Let us indicate the particular peer element as PE or “our PE”. The PE can be in one of two states:
(State I) It is a non-designated peer N-PE and its associated connection CE-PE is either blocked or non-operational. (State II) It is a designated peer D-PE.
[0089] In both states I and II (illustrated as boxes 41 and 45 respectively), the PE normally sends and receives Hellos over the virtual link. The PE must also detect faulty conditions of its own CE-PE connection. (Note that neither Hello messages, nor any alarms of faulty conditions such as “DI”, “Peer Down” and “CE-PE down” are indicated themselves in the state diagram of FIG. 4 )
[0090] Upon initialization (e.g., power up, arrow 40 ), our PE starts at state I (box 41 ). If its CE-PE is non-operational (i.e., faulty, down), that is considered the highest priority event “1”. In response, the PE stays in this same state I and sends a defect indication DI in its Hellos. It is then ineligible to be a D-PE. While in State I, a PE sends Hellos, indicating itself as the N-PE. While in State I, in the absence of the highest priority event “1”, if the PE receives information on the second priority event “2”, it moves to state II (arrow 44 ), and optionally triggers MAC flushing in the provider and the access networks. The second priority event “2” is stated when our PE receives:
a Hello with DI from its peer, or its peer is down (as detected by failing to receive a predefined number of Hellos at our PE), or our PE has been elected as D-PE.
[0094] State II (box 45 ) is characterized in that our PE puts its CE-PE connection in the forwarding state, and sends Hellos indicating itself as the designated peer D-PE.
[0095] When our PE is in state II, and its CE-PE connection fails, it is considered the highest priority event “1” and the PE returns to state I (arrow 46 ). Otherwise (in the absence of the highest priority event), if our PE receives information about events of priority “2” such as: DI from its peer in Hello messages, or its peer is down (detected by failing to receive a predefined number of Hellos from its peer), our PE stays in state II (arrow 48 ). In the absence of events of priorities “1” and “2”, our PE may receive information on events of priority “3”: its peer is elected as D-PE (as would be the case if the peer has, say, a higher IP address), or there is no agreement who is the D-PE (as would be the case if its peer does not receive Hellos and becomes a D-PE even if its IP address indicates it should be N-PE). In this case, our PE returns to state I (arrow 50 ). If none of the above-mentioned events takes place, our PE stays in state II.
[0096] It should be noted that exactly the same state diagram describes the behavior of the peer element of our PE, just when one of them is in state I, the second one would normally be in state II.
[0097] It should be appreciated that other modifications of the proposed multi-homing configurations can be proposed, other suitable versions of the method/software product can be developed and they are to be considered part of the invention. The invention is generally defined below by the following claims, and can be interpreted using the above description.
|
Technique for interconnecting a first communication network and a second communication network, for example layer 2 Ethernet networks, which uses a fully or partially redundant dual homing configuration. The configuration includes: at least three network elements where at least two of them are peer elements belonging to the second network, and at least two traffic lines respectively associated with the peer elements and connecting the first and the second networks via the three network elements. The technique comprises establishing a bi-directional signaling between the peer elements and, based on the signaling information, deciding which traffic line should forward the traffic.
| 7
|
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention relates to etching tools for semiconductor and photomask fabrication, and more specifically, to etching tools for dry etching.
[0003] 2. Related Art
[0004] A conventional fabrication process usually involves the step of dry etching a top surface of a substrate (e.g., a wafer or a photomask). Typically, first, a photoresist layer or any useful masking layer can be applied to the substrate. Then, the mask layer can be patterned using a photolithography process so that only areas of substrate that need to be etched are exposed from underneath the masking layer. The other areas of the substrate that need to be kept intact are covered by the patterned masking layer. Next, the substrate (with the patterned masking layer on top) can be placed on the cathode of an etching chamber. A radio frequency (RF, typically at a frequency of 0.1 MHz to 2.5 GHz) electrical power generator can be applied to the anode of the chamber so as to generate a plasma in the chamber. As a result, etchants generated within the plasma chemically react with the exposed material of the substrate surface to create a volatile product that can easily be removed by the etch system. Thus the pattern of the patterned masking layer is transferred to the substrate surface. Additional RF electrical energy may be coupled into the cathode to both increase the rate of etch processing and to provide directionality to the reactive species generated within the plasma.
[0005] However, different substrate areas facing the anode may be etched at different etch rates and with different profiles because these different substrate areas may have different pattern densities. The pattern density of a substrate can be defined as the percentage of the exposed-to-atmosphere surface of the substrate. For example, assume a 1 cm 2 substrate consists of 0.4 cm 2 being covered by the patterned mask layer and 0.6 cm 2 being exposed to the atmosphere. As the result, the pattern density of the substrate to be etched is 60%. If a substrate consists of a first substrate etch area with a higher pattern density than a second substrate etch area, then the first substrate etch area consumes etchants at a higher rate than the second substrate etch area. As a result, fewer etchants are available for further etching in the first substrate etch area than in the second substrate etch area. Therefore, the etch rate (and other properties such as feature profile) of the first substrate etch area is less than the etch rate of the second substrate etch area.
[0006] As a result, there is a need for a new apparatus (and method for operating the same) which allows etching different substrate etch areas having different pattern densities at essentially the same etch rate.
SUMMARY OF THE INVENTION
[0007] The present invention provides an apparatus, comprising (a) a chamber; (b) an anode and a cathode positioned in the chamber; and (c) a bias power system coupled to the cathode, wherein the cathode comprises N cathode segments electrically insulated from each other, N being an integer greater than 1, and wherein the bias power system is configured to apply N bias powers one-to-one to the N cathode segments.
[0008] The present invention also provides an apparatus operating method, comprising the steps of (a) providing (i) a chamber, (ii) an anode and a cathode positioned in the chamber, and (iii) a bias power system coupled to the cathode, wherein the cathode comprises N cathode segments electrically insulated from each other, N being an integer greater than 1; (b) placing a substrate to be etched between the anode and the cathode, wherein the structure comprises N substrate etch areas facing the anode, and wherein the N substrate etch areas are directly above the N cathode segments in a reference direction and match in size and shape with the N cathode segments, wherein the reference direction is essentially perpendicular to a surface of the anode facing the cathode; (c) determining N bias powers which, when being applied one-to-one to the N cathode segments during an etching of the substrate, will result in essentially a same etch rate for the N substrate etch areas; and (d) using the bias power system to apply the N bias powers one-to-one to the N cathode segments during the etching of the substrate.
[0009] The present invention also provides an apparatus operating method, comprising the steps of (a) providing (i) a chamber, (ii) an anode and a cathode positioned in the chamber, and (iii) a bias power system coupled to the cathode, wherein the cathode comprises N cathode segments electrically insulated from each other, N being an integer greater than 1; (b) placing a substrate to be etched between the anode and the cathode, wherein the substrate comprises N substrate etch areas facing the anode, and wherein the N substrate etch areas are directly above the N cathode segments in a reference direction and match in size and shape with the N cathode segments, wherein the reference direction is essentially perpendicular to a surface of the anode facing the cathode; (c) applying a plasma generation power to the anode sufficiently to generate a plasma in the chamber; and (d) applying N bias powers one-to-one to the N cathode segments
[0010] The present invention also provides a new apparatus (and method for operating the same) which allows etching different substrate etch areas having different pattern densities at essentially the same etch rate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 illustrates an apparatus, in accordance with embodiments of the present invention.
[0012] FIG. 2 illustrates a plasma generation power system of the apparatus of FIG. 1 , in accordance with embodiments of the present invention.
[0013] FIGS. 3A-3E illustrate different embodiments of a cathode of the apparatus of FIG. 1 .
[0014] FIGS. 4A-4B illustrate different embodiments of a bias power system of the apparatus of FIG. 1 .
[0015] FIG. 5 illustrates a bias power subsystem that can be used in the embodiments of FIGS. 4A-4B , in accordance with embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0016] FIG. 1 illustrates an apparatus 100 , in accordance with embodiments of the present invention. Illustratively, the apparatus 100 can comprise a chamber 110 , an anode 120 and a cathode 130 in the chamber 110 . The chamber 110 can include a gas inlet 112 and a gas outlet 114 . The gas inlet 112 can be used to receive gas species into the chamber 110 . The gas outlet 114 can be used to lead gases out of the chamber 110 . The depiction and location of gas inlet 112 and outlet 114 is purely representational in FIG. 1 . An actual inlet and outlet may consist of a plurality of actual openings. Additionally, it is well known to one skilled in the arts that the location of the inlet and outlet can be placed at different locations within the chamber to modify the efficiency of gas flow within the chamber and consequently the gas's influence on a substrate placed within the chamber.
[0017] The anode 120 can be coupled to a plasma generation power system 140 . In one embodiment, the plasma generation power system 140 can be configured to generate a plasma generation power (e.g., a radio frequency voltage) to the anode 120 so as to create a plasma from the gas species in the chamber 110 . The plasma contains etchants necessary for substrate etching.
[0018] The cathode 130 can comprise N cathode segments (not shown, but details of these cathode segments will be described below) matching in size and shape with N substrate etch areas (facing the anode 120 ) of a substrate 160 placed on the cathode 130 , wherein N is an integer greater than one. The N cathode segments can be electrically insulated from each other. The cathode 130 can be coupled to a bias power system 150 which, during the etching of the substrate 160 , can be configured to generate N bias powers (e.g., each can be a radio frequency voltage) to the N cathode segments of the cathode 130 . By adjusting a bias power to a cathode segment, the bias power system 150 can adjust the energy of the ions bombarding the substrate etch area of the substrate 160 directly above the cathode segment. As a result, by adjusting the bias power to the cathode segment, the bias power system 150 can adjust the etch rate for the substrate etch area directly above the cathode segment.
[0019] In one embodiment, the N bias powers can be individually assigned by prior assumptions or by theoretical calculations such that when the N bias powers are applied one-to-one to the N cathode segments during the dry etching of the substrate 160 , the N substrate etch areas experience essentially the same etch rate.
[0020] In another embodiment, the N bias powers can be individually assigned by using a “design of experiments” methodology or a simpler trial-and-error methodology. More specifically, multiple substrates (not shown) identical to the substrate 160 can be etched one after another using essentially the same etching settings (i.e. pressure, etchants, gas flow rate, etc.) while individually varying the N bias powers. The resultant substrates after etching can be examined to determine the etch rate uniformity across the substrate. Then the N bias powers can be individually adjusted until the N substrate etch areas experience essentially the same etch rate. In other words, the results of the etching of a substrate can be used to determine new bias powers for etching the next substrate, and so on until the etch result is satisfactory (i.e., essentially the same etch rate for all the N substrate etch areas).
[0021] Alternatively, the N bias powers can be individually determined by using a database containing correlations between bias powers, pattern densities, and etch rates. In one embodiment, the database is built from empirical data. More specifically, experiments (i.e., etching) can be carried out in a predetermined etch setting (i.e., gas flow rate, etchants, pressures, etc.) for different pattern densities and different applied bias powers, and the resulting etch rates can be recorded and entered into the database. To achieve essentially the same etch rate for all N substrate etch areas with N given pattern densities in the predetermined etch setting, the N bias powers can be individually determined using the database.
[0022] FIG. 2 illustrates one embodiment of the plasma generation power system 140 of the apparatus 100 of FIG. 1 , in accordance with embodiments of the present invention. Illustratively, the plasma generation power system 140 can comprise (i) an RF (radio frequency) power source 142 , a matching network 144 coupled to the RF power source 142 , and, for a capacitively-coupled plasma source, a blocking capacitor 146 coupling the matching network 144 to the anode 120 . For inductively-coupled plasma sources, blocking capacitor 146 is optional. The RF power source 142 produces an electrical voltage of the desired frequency. The matching network 144 matches the variable impedance of the plasma to the desired fixed impedance of the RF power source 142 so as to maximize the transfer of electrical power from RF power source 142 into the chamber 110 . Blocking capacitor 146 serves to prevent the flow of direct current (DC) power from RF power source 142 into chamber 110 , only allowing the passage of alternating current (AC) power.
[0023] FIGS. 3A-3E illustrate different embodiments 130 a, 130 b, 130 c, 130 d, and 130 e, respectively, of the cathode 130 of FIG. 1 . More specifically, FIG. 3A shows a top-down view of the cathode 130 a. The cathode 130 a can have the circular shape and can comprise three cathode segments 130 a 1 , 130 a 2 , and 130 a 3 . In one embodiment, the cathode segments 130 a 1 , 130 a 2 , and 130 a 3 can be electrically insulated from each other. In general, there can be N (N being an integer greater than one) concentric cathode segments having ring form as in FIG. 3A .
[0024] FIG. 3B shows a top-down view of the cathode 130 b. The cathode 130 b can have the rectangular shape and can comprise four (or any integer number greater than one) cathode segments 130 b 1 , 130 b 2 , 130 b 3 , and 130 b 4 . The cathode segments 130 b 1 , 130 b 2 , 130 b 3 , and 130 b 4 can be electrically insulated from each other.
[0025] FIG. 3C shows a top-down view of the cathode 130 c. The cathode 130 b can have the rectangular shape and can comprise 12 (or any integer number multiple of 4 and at least 4) cathode segments of trapezoidal and triangular shapes. The cathode segments of the cathode 130 c can be electrically insulated from each other.
[0026] FIG. 3D shows a top-down view of the cathode 130 d. The cathode 130 d can have the rectangular shape and can comprise cathode segments arranged in 4 rows and 4 columns (i.e., 16 cathode segments in total). In general, the number of rows and the number of columns can be any positive integer (but can not be 1 simultaneously) and do not have to be the same. The cathode segments of the cathode 130 d can be electrically insulated from each other.
[0027] FIG. 3E shows a top-down view of the cathode 130 e. The cathode 130 e can have the circular shape and can comprise cathode segments arranged in 7 rows and 7 columns (i.e., 49 cathode segments in total). In general, the number of rows and the number of columns can be any positive integer (but can not be 1 simultaneously) and do not have to be the same. The cathode segments of the cathode 130 e can be electrically insulated from each other.
[0028] In general, the cathode 130 of FIG. 1 can have any shape and can comprise any number (more specifically, any integer greater than 1) of cathode segments. Each of the cathode segments can have any size and shape.
[0029] FIGS. 4A-4B illustrate two different embodiments 150 a and 150 b, respectively, of the bias power system 150 of FIG. 1 . More specifically, with reference to FIG. 4A , assume the cathode embodiment 130 a of FIG. 3A is used as the cathode 130 of FIG. 1 (in FIG. 4A , a cross-section view of the cathode 130 a is shown). Because the cathode 130 a has three cathode segments 130 a 1 , 130 a 2 , and 130 a 3 , the bias power system 150 a can comprise the same number of (i.e., three) independent bias power subsystems 150 a 1 , 150 a 2 , and 150 a 3 coupled one-to-one to the cathode segments 130 a 1 , 130 a 2 , and 130 a 3 , respectively. The three bias power subsystems 150 a 1 , 150 a 2 , and 150 a 3 can be configured to generate three independent bias powers (e.g., radio frequency voltages) one-to-one to the three cathode segments 130 a 1 , 130 a 2 , and 130 a 3 , respectively.
[0030] In general, if the cathode 130 of FIG. 1 has M cathode segments (M being an integer greater than 1), then M bias power subsystems similar to the bias power subsystems 150 a 1 , 150 a 2 , and 150 a 3 of can be used to generate M independent bias powers one-to-one to the M cathode segments.
[0031] With reference to FIG. 4B , assume the cathode embodiment 130 a of FIG. 3A is again used as the cathode 130 of FIG. 1 (in FIG. 4B , a cross-section view of the cathode 130 a is shown). In one embodiment, the bias power system 150 b can comprise a bias power subsystem 150 b′ and an impedance dividing circuit 152 coupling the bias power subsystem 150 b′ to the cathode segments 130 a 1 , 130 a 2 , and 130 a 3 . The bias power subsystem 150 b′ can be configured to generate a total bias power to the impedance dividing circuit 152 . In response to receiving the total bias power from the bias power subsystem 150 b′, the impedance dividing circuit 152 can be configured to generate three different bias powers one-to-one to the three cathode segments 130 a 1 , 130 a 2 , and 130 a 3 . The simplest example of an impedance divider circuit is a voltage divider circuit. In this case, an input voltage is put through two resistors (fixed or variable) in series. The output voltage is taken off between the two resistors. In general, a series of M voltage dividers may be constructed to drive M cathode segments. By applying the same input voltage to each of the M voltage dividers, the output to each of the M cathode segments can be individually adjusted.
[0032] FIG. 5 illustrates a bias power subsystem 500 that can be used as the bias power subsystems 150 a 1 , 150 a 2 , and 150 a 3 of FIG. 4A and the bias power subsystems 150 b′ of FIG. 4B . In one embodiment, the bias power subsystem 500 can comprise (i) an RF power source 502 , a matching network 504 coupled to the RF power source 502 , and, for a capacitively-coupled plasma source, a blocking capacitor 506 coupling the matching network 504 either to the cathode 130 a of FIG. 4A or to the impedance dividing circuit 152 of FIG. 4B . Generator 502 produces an electrical voltage at the desired frequency. Matching network 504 matches the variable impedance of the plasma across the substrate 160 ( FIG. 1 ) to the desired fixed impedance of generator 502 so as to maximize the transfer of electrical power from generator 502 into substrate 160 ( FIG. 1 ). Blocking capacitor 506 serves to prevent the flow of direct current (DC) power from generator 502 into substrate 160 and chamber 110 ( FIG. 1 ), only allowing the passage of alternating current (AC) power. Modulation of the output of generator 502 produces a modulation in the bias voltage on substrate 160 ( FIG. 1 ).
[0033] In summary, with reference to FIG. 1 , by using the N-segment cathode 130 , N bias powers can be individually determined such that when these N bias powers are applied to the N cathode segments (not shown), the N substrate etch areas of the substrate 160 directly above the N cathode segments experience essentially the same etch rate. The N bias powers can be individually determined by trials and errors, or alternatively, by using a database built through experiments.
[0034] In a similar manner, the present invention can be used to etch a variety of substrates 160 ( FIG. 1 ). For example, the present invention can be used to etch a wafer or a photomask.
[0035] While particular embodiments of the present invention have been described herein for purposes of illustration, many modifications and changes will become apparent to those skilled in the art. Accordingly, the appended claims are intended to encompass all such modifications and changes as fall within the true spirit and scope of this invention.
|
An apparatus (and method for operating the same) which allows etching different substrate etch areas of a substrate having different pattern densities at essentially the same etch rate. The apparatus includes (a) a chamber; (b) an anode and a cathode in the chamber; and (c) a bias power system coupled to the cathode, wherein the cathode includes multiple cathode segments. The operation method includes the steps of: (i) placing a substrate to be etched between the anode and cathode, wherein the substrate includes N substrate etch areas, and the N substrate etch areas are directly above the N cathode segments; (ii) determining N bias powers which, when being applied to the N cathode segments during an etching of the substrate, will result in essentially a same etch rate for the N substrate etch areas; and (iii) using the bias power system to apply the N bias powers the N cathode segments.
| 7
|
PRIORITY CLAIM
[0001] This application claims the benefit of German Application Serial No. 102011012461.6 filed on Feb. 25, 2011, contents of which are incorporated herein.
FIELD OF THE INVENTION
[0002] The invention relates on the one hand to a vehicle seat with a seat part, with a backrest and with a belt retention apparatus integrated on the vehicle seat and comprising a belt suspension means, in which the belt suspension means has a fastening means for fastening to the backrest.
[0003] The invention relates on the other hand to a vehicle seat with a seat part, with a backrest and with a belt retention apparatus integrated on the vehicle seat and comprising a belt suspension means, in which an adjustment mechanism is arranged between the seat part and the backrest, in which the belt suspension means has a device for mounting on the backrest, and in which the backrest comprises a device for the retention of the mounting device, the mounting device being arranged on the retention device.
[0004] In addition, the invention relates to a method of reducing the introduction of forces and/or moments on an adjustment mechanism between a seat part and a backrest of a vehicle seat with an integrated belt retention apparatus, and use related thereto.
BACKGROUND OF THE INVENTION
[0005] It is known for a belt retention apparatus for restraining an occupant of a vehicle on a vehicle seat to be integrated directly on or in the vehicle seat. In this case a belt storage means and a device for arresting a belt fitting on a part of the vehicle seat and a belt reversal device is arranged on a backrest of the vehicle seat by means of a possibly vertically adjustable belt suspension means. In this respect it is readily possible in structural terms to be able to produce a vehicle seat with an integrated vehicle occupant protection independently of other features of the bodywork. A drawback in this case, however, is that in the event of a vehicle crash relatively high retention forces are introduced into the backrest of the vehicle seat by means of the belt suspension means. These forces can frequently amount to a multiple of the body weight of the vehicle occupant strapped on the vehicle seat. This leads among other things to an enormous and usually abrupt loading of the adjustment mechanism, by means of which the backrest is fastened to the seat part. It happens not infrequently that the adjustment mechanism is irreparably damaged and has to be replaced.
SUMMARY OF THE INVENTION
[0006] The present invention is directed to remedy the drawback identified in the background.
[0007] In accordance with a first aspect of the invention, the present invention includes a vehicle seat with a seat part, with a backrest and with a belt retention apparatus integrated with the vehicle seat and comprising a belt suspension means, in which the belt suspension means has a fastening means for fastening to the backrest, the vehicle seat being characterized in that the fastening means comprises a crash element with a deformation region for reducing kinetic energy in the event of activation of the belt retention apparatus as a result of an accident.
[0008] The loading occurring in the event of a vehicle crash in particular on the adjustment mechanism, by means of which the backrest is fastened to the seat part, can be reduced by means of the fastening means designed according to the invention, in that kinetic energy is reduced by deformation action which has taken place. As a result, an abrupt loading, in particular of the adjustment mechanism, can be prevented or at least mitigated.
[0009] The term “crash element” describes a component of a belt retention apparatus which is integrated in a vehicle seat and by means of which a deformation region can be formed which is determined structurally and which can perform a deformation action in a purposeful manner in the event of a vehicle crash.
[0010] With a suitable seat structure a deformation region of this type can optionally be formed directly by a sheet metal part of the belt suspension means and/or the backrest.
[0011] In a preferred embodiment, the deformation region is designed in the form of an independent component since a greater flexibility of design can be achieved in this way.
[0012] A preferred variant of embodiment provides that a direction of main deformation, which is directed essentially in the direction of a longitudinal extension of the backrest, is inherent in the deformation region.
[0013] If a deformation of the crash element takes place mainly in the direction of the longitudinal extension of the backrest, in this case a factory-made distance between the belt suspension means and the adjustment mechanism can be additionally reduced, as a result of which a lever path between the belt suspension means and the adjustment mechanism is shortened in an advantageous manner.
[0014] An alternative embodiment includes a vehicle seat with a seat part, with a backrest and with a belt retention apparatus integrated on the vehicle seat and comprising a belt suspension means, in which an adjustment mechanism is arranged between the seat part and the backrest, in which the belt suspension means comprises a device for mounting on the backrest and in which the backrest comprises a device for the retention of the mounting device, the mounting device being arranged on the retention device, and the vehicle seat being characterized by a device for shortening a lever path between the belt suspension means and the adjustment mechanism in the event of activation of the belt retention apparatus as a result of an accident.
[0015] The device for shortening the lever path can be designed in various ways. It is preferable for it to comprise a crash element with a deformation region to reduce kinetic energy with a direction of main deformation, which is directed essentially in the direction of a longitudinal extension of the backrest.
[0016] The term “mounting device” describes a component on the side of the belt suspension means, in particular a component like a metal sheet, by means of which the belt suspension means is capable of being fastened to a backrest structure. In this respect the mounting device can be a component of the belt suspension means.
[0017] The term “retention device” describes a component on the side of the backrest, in particular a component like a metal sheet, to which the belt suspension means with its mounting device is fastened. In this respect the retention device can be a component of the backrest structure.
[0018] The present invention further describes a method of reducing the introduction of forces and/or moments on an adjustment mechanism between a seat part and a backrest of a vehicle seat with an integrated belt retention apparatus, in which a lever path between a belt suspension means of the belt retention apparatus and the adjustment mechanism is shortened in the event of activation of the belt retention apparatus as a result of an accident.
[0019] In an alternative embodiment, the belt suspension means comprises a device for mounting on the backrest and the backrest comprises a device for retaining the mounting device, in which case a crash element capable of being deformed in a resilient or plastic manner substantially in the direction of a longitudinal extension of the backrest is arranged between the mounting device and the retention device.
[0020] If the deformation region of the crash element is formed for example not directly by conventional components or groups of components, such as for example the mounting device and/or the retention device of the seat, it is advantageous for the deformation region to be formed by means of a stand-alone crash element which is preferably arranged between the mounting device and the retention device. In this way, use can be made of conventional mounting devices and retention devices in an advantageous manner, as a result of which it would also be optionally possible for older vehicle seats to be converted.
[0021] In one embodiment, the mounting device describes for example a sheet metal part of the belt suspension means, which as a rule is welded onto a corresponding sheet metal part of a seat structure in the region of the backrest. Here, the retention device designates the corresponding sheet metal part of the seat structure. In a conventional manner the two sheet metal parts are welded to each other in abutment with each other in order to produce a fixed join. In this case the two sheet metal parts are not movable with respect to each other, unless the join is destroyed. If the mounting device is arranged on the retention device at a distance from the latter, a sufficiently large structural space for a necessary deformation path can be provided in a structurally simple manner.
[0022] The crash element can be readily embedded with little effort in a conventional vehicle seat structure using a sheet-like base member with at least one sheet metal rib as well as at least two abutment planes which are at a distance from each other, in which case the at least one sheet metal rib is orientated substantially horizontally. In this respect the sheet metal rib is orientated substantially transversely to the direction of main deformation.
[0023] On account of the sheet-like base member, a mechanical safety device which is easy to construct and which operates in a reliable manner can be provided.
[0024] In one embodiment, the sheet-like base member can be a stamped part. In this respect the crash element can be produced in an easy and inexpensive manner.
[0025] The sheet-like base member can be produced with a thickness of material of between 0.5 mm and 3 mm, depending upon what deformation action is intended to be carried out by the crash element.
[0026] The mounting device and the retention device can be spaced sufficiently far from each other without undue effort by means of a sheet metal rib or preferably a plurality of sheet metal ribs.
[0027] In an alternative embodiment, the at least one sheet metal rib can be welded to the mounting device on the side of the belt suspension means on the first of the abutment planes and to the retention device on the side of the backrest on the second of the abutment planes. As a result, the present crash element can be produced on a vehicle seat with an integrated belt retention apparatus in a particularly inexpensive manner.
[0028] If sheet metal ribs of the crash element are arranged orientated substantially horizontally, the direction of main deformation can be pre-set in an operatively reliable manner in the direction of the longitudinal extension of the backrest, in that the sheet metal ribs of the crash element arranged one behind the other can bend in this direction if the forces acting upon the crash element reach or exceed a critical value as a result of a vehicle crash.
[0029] In an alternative embodiment, the deformation path can be varied in a structurally simple manner depending upon the requirement of application, if of the at least one sheet metal rib is at an angle of more than 10°, preferably of more than 20°, and of less than 170°, preferably of less than 160°, and ideally of 90°, with respect to at least one of the abutment planes.
[0030] It is preferable for a deformation path of more than 10 mm, preferably of 20 mm or more, to be capable of being achieved by means of the crash element according to the invention. In addition, the parameters of the deformation path can also be influenced by the height of the crash element or of a sheet metal rib thereof. By way of example, the height has a value of between 10 mm and 50 mm. These values, however, are not to be understood as being restrictive in an obligatory manner.
[0031] The deformation behaviour of the crash element can be additionally influenced if the sheet-like base member is bent at least once and preferably more than once. In particular, the abutment planes can be chosen to be almost any desired size by bending over ends of the sheet metal rib or ribs in an appropriate manner, as a result of which the crash element can be fastened to the mounting and retention devices over a large area and thus in a particularly intimate manner.
[0032] It is preferable for the sheet-like base member to be designed with double webs or with a plurality of webs, i.e. the crash element makes more than one sheet metal rib available. By way of example, two webs or sheet metal ribs of the crash element are arranged at a distance of between 1 mm and 20 mm from each other.
[0033] In a simple manner the sheet-like base member can be bent into a U shape and can have two additionally bent fastening plates at its ends.
[0034] The two fastening plates can advantageously form two abutment planes on the side of the backrest which are at a distance from each other, whilst the middle arm of the base member bent into a U shape can form a large, advantageously continuous abutment plane on the side of the belt suspension means.
[0035] In an alternative embodiment, the crash element includes a store of material for extending a deformation path, the store of material being arranged in particular at least in part behind a plane of the mounting device and/or a plane of the retention device. A store of material of this type can be produced in a very simple manner structurally just by a base member bent into a U shape forming a shorter and a longer web between the mounting device and the retention device. In this case the longer web can extend in an advantageous manner behind the plane of the mounting device and/or a plane of the retention device. It is preferable for the longer web to be made bent once more, so that further material is available for extending the deformation path.
[0036] In an alternative embodiment, the present invention incorporated the use of a belt suspension fastening means of a vehicle seat belt retention apparatus for shortening a lever path between the belt suspension means and an adjustment mechanism between a backrest and a part of the vehicle seat in the event of activation of the belt retention apparatus integrated on the vehicle seat as a result of an accident.
[0037] It is to be understood that the features of the solutions described above and in the claims respectively can also optionally be combined in order to be able to implement the advantages in a suitably cumulated manner.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] Preferred and alternative examples of the present invention are described in detail below with reference to the following drawings:
[0039] FIG. 1 is a diagrammatic, perspective partial view of a vehicle seat in the region of a belt suspension means with a fastening means comprising a crash element between a mounting device on the side of the belt suspension means and a retention device on the side of the backrest;
[0040] FIG. 2 is a further diagrammatic, perspective partial view of the belt suspension fastening means as shown in FIG. 1 , but without a mounting device on the side of the belt suspension means;
[0041] FIG. 3 is a diagrammatic, perspective view of the vehicle seat as shown in FIG. 1 ;
[0042] FIG. 4 is a diagrammatic view of a further embodiment of the design of a crash element in the original factory-made state;
[0043] FIG. 5 is a diagrammatic view of the crash element as shown in FIG. 4 after a deformation action has been carried out;
[0044] FIG. 6 is a diagrammatic view of a deformation sequence of another crash element;
[0045] FIG. 7 is a diagrammatic view of two sheet-like base members of alternative crash elements;
[0046] FIG. 8 is a diagrammatic view of further sheet-like base members of further alternative crash elements, and
[0047] FIG. 9 shows diagrammatically a further crash element with an angle of the sheet metal rib of 90° indicated.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0048] The vehicle seat 1 shown in FIGS. 1 to 3 has a seat part 2 , a backrest 3 and a belt retention apparatus 4 integrated in the vehicle seat 1 . The belt retention apparatus 4 is formed in this embodiment by a belt 5 and a belt suspension means 6 . It comprises, however, at least one belt store (not shown here) as well as an arresting device (not shown here) for a belt fitting. At the top on the left, as viewed in the direction of the seat, a fastening means 8 is shown, by means of which the belt suspension means 6 is fastened to the backrest 3 . The fastening means 8 provides on the side of the belt suspension means a mounting device 9 and on the side of the backrest a retention device 10 for the mounting device 9 . A receiving means 11 for a belt reversal bracket 12 is positioned substantially centrally on the mounting device 9 .
[0049] According to the invention a crash element 13 , which in this embodiment comprises an upper deformation element 14 and a lower deformation element 15 , is arranged between the mounting device 9 and the retention device 10 . The two deformation elements 14 and 15 have in each case a sheet-like base member 16 and 17 respectively bent substantially into a U shape. The crash element 13 in this embodiment is preferably a plastically deformable crash element 13 .
[0050] The sheet-like base members 16 and 17 respectively are designed in this embodiment in such a way that they form deformation regions 18 (numbered here only by way of example in each case) for the reduction of kinetic energy with respect to an activation of the belt retention apparatus 4 as a result of an accident.
[0051] In the event of an activation of the belt retention apparatus 4 as a result of an accident the multiple of the body weight of a person acts upon the locked belt 5 and, in particular upon the belt suspension means 6 , by way of which corresponding restraining forces are frequently introduced in an abrupt manner into a structure 19 of the backrest 3 .
[0052] The high position of the belt suspension means 6 at the top on the left 4 on the backrest 3 leads to a relatively high loading, in particular on an adjustment mechanism 20 between the seat part 2 and the backrest 3 , since the restraining forces introduced on the belt suspension means 6 act in an additionally amplified manner upon the adjustment mechanism 20 by a lever path 21 between the belt suspension means 6 and the adjustment mechanism 20 .
[0053] In an advantageous manner the restraining forces can be reduced at least in part by deformation action carried out at the crash element 13 , before they can act upon the retention device 10 of the backrest structure 19 .
[0054] It is particularly advantageous, however, for the crash element 13 to have a direction of main deformation 22 substantially in the direction of a longitudinal extension 23 of the backrest. In particular, on account of this feature, the lever path 21 between the belt suspension means 6 and the adjustment mechanism 20 can be shortened in an advantageous manner as soon as the crash element 13 is deformed as a result of an accident. In an advantageous manner, this in turn has the consequence that lower forces or moments act upon the adjustment mechanism 20 , as a result of which the risk of irreparable damage to the adjustment mechanism 20 is substantially reduced. In this case even short deformation paths of less than 50 mm are sufficient to cause an effective release of the adjustment mechanism 20 . In this respect the crash element 13 embodies not only a device for the reduction of kinetic energy but also, in particular, a device 24 for the reduction of the lever path 21 .
[0055] In addition, the crash element 13 is characterized by two abutment planes 25 and 26 (numbered only at the sheet-like base member 16 by way of example) which are at a distance from each other and which are spaced from each other by a rib structure 27 (numbered only at the sheet-like base member 17 by way of example). The first abutment plane 25 is used for fastening to the mounting device 9 and the second abutment plane 26 is used for fastening to the retention device 10 . In this embodiment the fastening means 8 is designed in the form of a welded structure, as a result of which the crash element 13 can be integrated into the structure of the vehicle seat or into the backrest structure 19 in a very inexpensive manner.
[0056] The rib structure 27 is at a right angle a with respect to the two abutment planes 25 and 26 (see in particular also FIG. 9 ) and it preferably extends substantially horizontally. In this respect the rib structure 27 is orientated substantially transversely to the direction of main deformation 22 .
[0057] In order to be able to provide a sufficiently long deformation path in the direction of the direction of main deformation 22 if required, the crash element 13 comprises a store of material 28 which extends at least in part behind the second abutment plane 26 or behind a plane of the retention device. To this end, the sheet-like base members 16 and 17 of the crash element 13 traverse the retention device 10 through corresponding openings 29 (numbered here only by way of example in FIG. 1 ).
[0058] The further crash element 113 shown in FIGS. 4 and 5 has a rib structure 127 with four individual webs 130 (numbered here only by way of example) which are made straight and are welded orientated in their original position (see FIG. 4 ), preferably at a right angle between a mounting device 109 of a belt suspension means 106 and a retention device 110 of a backrest 103 .
[0059] In order to stabilize further the crash element 113 and to orientate the four straight individual webs 130 in a simpler manner during the production of the crash element 113 , offsets 131 in the form of a thickening of material are provided on the mounting device 109 . In this alternative embodiment the crash element 113 comprises at the same time the mounting device 109 and the retention device 110 and is thus particularly compact in design.
[0060] While the crash element 113 is still situated in its original position in the illustration according to FIG. 4 , in accordance with the illustration according to FIG. 5 it is deformed in its direction of main deformation 122 on account of an activation of a belt retention apparatus (not shown here) as a result of an accident. In this case it is clearly evident that the individual webs 130 are inclined and the mounting device 109 has shifted with respect to the retention device 110 by a deformation path 132 . Here, it allows for deformation action to be carried out on the one hand and for a lever path between a belt suspension means and an adjustment mechanism to be advantageously shortened on the other hand.
[0061] In the embodiment shown in FIG. 6 , a crash element 213 has two sheet-like base members 216 and 217 which are bent into a U shape and which connect a mounting device 209 and a retention device 210 to each other at a distance. The crash element 213 has a rib structure 227 and has a first abutment plane 225 on the side of the mounting device and a second abutment plane 226 at a distance from it on the side of the retention device. The first abutment plane 225 is formed by a flat partial region 235 which rests against the mounting device 209 and is welded to it. The second abutment plane 226 is formed by end fastening plates 236 (numbered only by way of example) which rest against the retention device 210 and are welded there.
[0062] According to the deformation sequence 237 shown in FIG. 6 , the crash element 213 is deformed and performs advantageous deformation action on the one hand and provides an advantageous deformation path 232 on the other hand, in order to shorten a lever path between a belt suspension means and a displacement mechanism, as has already been described above. In this embodiment the mounting device 209 always moves closer to the retention device 210 in the course of the deformation sequence 237 and an original structural height 238 of the crash element 213 is reduced in succession. In this respect it is advantageous for the structural height 238 of the crash element 213 also to be selected with a view to the necessary deformation path 232 .
[0063] The embodiments shown in FIG. 7 show, on the left-hand side, a crash element 313 with a sheet-like base member 316 which is bent substantially into a U shape and which holds a store of material 328 on one 340 of its arms 340 , 341 . In this case the store of material 328 is designed conversely in a U shape and is housed inside the arm 340 between a first abutment [plane] 325 and a second abutment plane 326 of the crash element 313 .
[0064] On the right-hand side the embodiments show a crash element 413 which corresponds to the design of the crash element 213 . In this respect, reference is made to the description of FIG. 6 , in order to avoid repetition. The two crash elements 313 and 413 are shown between a plane 342 on the side of the belt suspension means and a plane 343 on the side of the backrest.
[0065] The further crash elements 513 , 613 and 713 illustrated in FIG. 8 display further variants of how a crash element can be designed and orientated in a belt suspension fastening means with respect to the plane 342 on the side of the belt suspension means and a plane 343 on the side of the backrest. The crash elements 513 and 613 have a simple U shape. The crash element 613 is inserted rotated through 90°. In contrast, the crash element 713 has a sheet-like base member 716 bent into an S shape.
[0066] The fastening means 808 shown in FIG. 9 substantially corresponds to the embodiment according to FIG. 6 . A sheet-metal rib angle a of 90° is indicated with respect to a first sheet-like base member 816 of a crash element 813 of the fastening element 808 , in which case the crash element 813 is welded to a mounting device 809 on the side of the belt suspension means and a retention device 810 on the side of the backrest. Depending upon the deformation path required (see reference number 232 , FIG. 6 ), the sheet-metal rib angle a can also be selected with a different value, as has already been described in the introduction.
[0067] It is to be understood that the embodiments described above are merely first arrangements of the invention. In this respect the arrangement of the invention is not restricted to these embodiments. All the features disclosed in the application documents are claimed as being essential to the invention, insofar as they are novel either individually or in combination as compared with the prior art.
[0068] While the preferred embodiment of the invention has been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of the invention. Accordingly, the scope of the invention is not limited by the disclosure of the preferred embodiment. Instead, the invention should be determined entirely by reference to the claims that follow.
|
The present invention is directed to an integrated belt retention apparatus for use with a vehicle seat having a seat part with a backrest and with a belt retention apparatus integrated with the vehicle seat, comprising a belt suspension means having a fastening means for fastening to the backrest, wherein the vehicle seat is characterized in that the fastening means comprises a crash element with a deformation region for reducing kinetic energy in the event of activation of the belt retention apparatus as a result of an accident.
| 1
|
FIELD OF THE INVENTION
The invention relates to composite yarns and processes for producing composite yarns.
BRIEF SUMMARY OF THE INVENTION
The invention provides a process for producing a composite yarn and a composite yarn produced thereby. The process for producing the composite yarn of the invention generally comprises the steps of first wrapping a second yarn around the perimeter of and along the length of a first yarn and then heating the yarn intermediate produced by such wrapping to produce a composite yarn. When a heat-shrinkable yarn is used in producing such a composite yarn, the shrinkage of the heat-shrinkable yarn enables the production of composite yarns possessing aesthetic qualities similar to those exhibited by yarns produced by much more complicated processes, such as bouclé and chenille yarns.
In a first embodiment, the process comprises the steps of (a) providing at least a first yarn and a second yarn, (b) wrapping the second yarn around the perimeter of and along at least a portion of the length of the first yarn to produce a yarn intermediate, (c) overfeeding the yarn intermediate to a heating zone and exposing the yarn intermediate to heat, and (d) collecting the composite yarn.
In a second embodiment, the process comprises the steps of (a) providing at least a first yarn and a second yarn, (b) providing a rotary, hollow spindle assembly, (c) providing a heater assembly, (d) providing a yarn collection assembly, (e) passing the first and second yarns through the spindle assembly so that the second yarn is wrapped around the perimeter of and along at least a portion of the length of the first yarn, the wrapped first and second yarns forming a yarn intermediate, (f) overfeeding the yarn intermediate to the heater assembly and exposing the yarn intermediate to heat, and (g) collecting the composite yarn on the yarn collection assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side, elevation view of an apparatus suitable for performing the process of the invention.
FIG. 2 is a side view of a rotary, hollow spindle assembly suitable for use in the process of the invention.
FIG. 3 is a side view of a composite yarn according to the invention.
FIG. 4 is a drawing of several segments of a composite yarn similar to that depicted in FIG. 3 .
FIG. 5 is a drawing of several segments of a composite yarn according to the invention.
FIG. 6 is a drawing of several segments of a composite yarn according to the invention.
FIG. 7 is a drawing of several segments of a composite yarn according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
The process for producing the composite yarn of the invention generally comprises the steps of first wrapping a second yarn around the perimeter of and along the length of a first yarn and then heating the yarn intermediate produced by such wrapping to produce a composite yarn. In a first embodiment, the process comprises the steps of (a) providing at least a first yarn and a second yarn, (b) wrapping the second yarn around the perimeter of and along at least a portion of the length of the first yarn to produce a yarn intermediate, (c) overfeeding the yarn intermediate to a heating zone and exposing the yarn intermediate to heat, and (d) collecting the composite yarn.
The first and second yarns can be any suitable yarns. The first and second yarns can each independently be a monofilament, multifilament, or spun yarn comprising natural fibers, synthetic fibers, or a combination thereof. For example, in certain possibly preferred embodiments, the first yarn or second yarn can be a thermoplastic yarn comprising fibers selected from the group consisting of polyester fibers, nylon fibers, polyolefin fibers, and combinations thereof. In certain possibly preferred embodiments, the first or second yarn can comprise natural fibers, such as cotton, linen, ramie, jute, hemp, kenaf, sisal, wool, and silk. The first or second yarns can be textured, such as a yarn that has been air-jet or false-twist textured.
In certain possibly preferred embodiments, at least one of the first and second yarns is a heat-shrinkable yarn exhibiting a shrinkage (e.g., a shrinkage in the longitudinal direction of the yarn) upon exposure of the yarn to heat. The heat-shrinkable yarn typically exhibits a shrinkage upon exposure to heat of about 10% or more (e.g., about 15% or more). More specifically, the length of the heat-shrinkable yarn decreases by about 10% or more (e.g., about 15% or more) upon exposure of the yarn to heat. In certain possibly preferred embodiments, the heat-shrinkable yarn exhibits a shrinkage upon exposure to heat of about 20% or more, about 25% or more, about 30% or more, about 35% or more, about 40% or more, or about 45% or more. The shrinkage exhibited by the heat-shrinkable yarn can be measured using any suitable method. For example, the shrinkage can be measured according to the boiling water shrinkage test procedure described in ASTM Standard D2259-02, entitled “Standard Test Method for Shrinkage of Yarns,” and is considered to be within the ranges set forth herein when so determined.
The heat-shrinkable yarn can be any suitable yarn exhibiting the desired degree of shrinkage. Suitable heat-shrinkable yarns include, but are not limited to, thermoplastic, partially-oriented yarns (POY). Suitable partially-oriented yarns include, but are not limited to, partially-oriented polyester yarns, partially-oriented nylon yarns, partially-oriented polyolefin yarns, and partially-oriented yarns comprising a combination of any of such fibers (e.g., polyester, nylon, and polyolefin fibers). In certain possibly preferred embodiments, the heat-shrinkable yarn is a partially-oriented polyester yarn. When the heat-shrinkable yarn is a partially-oriented yarn, the partially-oriented yarn preferably is coated with a suitable lubricating oil to reduce friction during the wrapping process which may otherwise result in unintended drawing of the partially-oriented yarn.
As noted above, the second yarn is wrapped around the perimeter of and along the length of the first yarn. In the process of the invention, the second yarn can be wrapped around the first yarn using any suitable means. For example, the first yarn can be fed through the center of a rotary, hollow spindle assembly where the second yarn is fed from the spindle and wrapped around the perimeter of and along the length of the first yarn as it passes through the rotary, hollow spindle assembly. The second yarn can also be wrapped around the first yarn by twisting the first and second yarns together using any suitable yarn twisting apparatus or by cabling the first and second yarns using any suitable apparatus adapted to cable a plurality of yarns. During this process, the wrapping of the second yarn around the first yarn produces a yarn intermediate which is subsequently processed to produce the composite yarn of the invention.
The second yarn can be wrapped around the first yarn at any suitable rate or with any suitable number of turns or twists of the second yarn per unit length of the first yarn. The second yarn typically is wrapped around the first yarn at a rate sufficient to ensure that the composite yarn remains coherent when the yarn or a fabric containing the yarn are subjected to normal wear and tear. Furthermore, the second yarn typically is not wrapped around the first yarn at such a rate such that each twist or turn of the second yarn is contiguous with the adjacent twists or turns of the second yarn along the length of the first yarn. Typically, the second yarn is wrapped around the perimeter of and along the length of the first yarn at the rate of about 0.5 turns or more per centimeter of the first yarn (about 1.25 turns per inch of the first yarn). In certain possibly preferred embodiments, the second yarn is wrapped around the first yarn at a rate of about 0.75 turns or more per centimeter of the first yarn (about 2 turns per inch of the first yarn), about 1 turns or more per centimeter of the first yarn (about 2.5 turns per inch of the first yarn), about 1.4 turns or more per centimeter of the first yarn (about 3.5 turns or more per inch of the first yarn), or about 1.75 or more turns per centimeter of the first yarn (about 4.5 turns or more per inch of the first yarn).
After the second yarn has been wrapped around the first yarn to produce the yarn intermediate, the yarn intermediate is then fed to a heating zone where the yarn intermediate is heated for a time and under conditions sufficient to at least partially shrink any heat-shrinkable yarn contained in the yarn intermediate. In order to allow the heat-shrinkable yarn to shrink along its length or in the longitudinal direction of the yarn intermediate, the yarn intermediate typically is fed to the heating zone at a rate that is faster than the rate at which the resulting composite yarn is collected from the heating zone. This “overfeeding” of the yarn intermediate to the heating zone provides the “slack” necessary to permit shrinkage of the heat-shrinkable yarn. Typically, the yarn intermediate is overfed to the heating zone at a rate of about 10% or more (i.e., the yarn intermediate is fed to the heating zone at a rate that is about 10% or more faster than the rate at which the composite yarn is collected from the heating zone). In certain possibly preferred embodiments, the yarn intermediate is overfed to the heating zone at a rate of about 15% or more, about 20% or more, about 25% or more, about 30% or more, about 35% or more, about 40% or more, about 45% or more, or about 50% or more.
The yarn intermediate can be heated in the heating zone using any suitable means. Typically, the yarn intermediate is heated by passing the yarn intermediate across the surface of a contact heater assembly. The heater assembly can be operated at any suitable temperature. Typically, the heater assembly is operated at a temperature that is sufficiently high so that, during the time that the yarn intermediate is in the heating zone, the yarn intermediate is heated to a temperature sufficient to at least partially shrink the heat-shrinkable yarn. The heater temperature necessary to heat the yarn intermediate to such a degree may depend upon several factors, such as the composition and structure of the yarn intermediate and the amount of time the yarn intermediate is in contact with the heater assembly. In certain possibly preferred embodiments, the heater assembly is maintained at a temperature of about 200° C. or more, about 210° C. or more, about 220° C. or more, or about 230° C. or more.
After the yarn intermediate has been heated to the desired temperature and/or for the desired amount of time, the resulting composite yarn can be collected by any suitable means. For example, the yarn can be wound onto a suitable package using a commercially-available winding apparatus, such as a precision winder or a drum winder. In certain possibly preferred embodiments, the yarn composite is collected in such a manner that substantially no tension (e.g., less than about 15 grams, less than about 10 grams, or less than about 7 grams of tension) is applied to the composite yarn during the collection step. More particularly, the yarn composite can be collected in such a manner that substantially no tension is applied to the composite yarn while the yarn is still hot or warm from the heating step. By collecting the composite yarn in this manner (i.e., with substantially no tension), any drawing of the heat-shrinkable yarn, which has been at least partially shrunk during the heating step, is minimized. The potential for drawing the heat-shrinkable yarn during collection is especially high when the heat-shrinkable yarn is still hot or warm from the heating step, which makes the heat-shrinkable yarn more susceptible to deformation, such as drawing.
In certain possibly preferred embodiments of the process of the invention, the first or second yarns or the yarn intermediate can be intermittently sprayed with water or other suitable fluid prior to feeding of the yarn intermediate to the heating zone. In such an embodiment, the yarn or yarn intermediate is intermittently sprayed with the water or fluid so that the sprayed portion of the yarn is heated to a temperature less than the temperature of the unsprayed portions of the yarn when the yarn intermediate is fed to the heating zone. The heat-shrinkable yarn in those portions which have been sprayed then shrinks to a lesser extent than the unsprayed portions because of the lower temperature to which they are exposed.
Turning to the Figures in which like reference numerals refer to like elements throughout the several views, an apparatus suitable for performing the process of the invention is depicted in FIG. 1 . The apparatus 100 generally comprises a creel 115 or other suitable assembly for providing a supply of one or more first yarns 110 , a rotary, hollow spindle assembly 120 , a heater assembly 135 , and a yarn collection assembly 150 , such as a precision winder or a drum winder. As depicted in FIG. 1 , the apparatus 100 can be configured to simultaneously produce several composite yarns 145 .
In operation, the first yarn 110 is drawn from the creel 115 and directed by suitable yarn guides 114 (e.g., satin rolls) so that the first yarn 110 passes through a rotary, hollow spindle assembly 120 . As shown in FIG. 2 , the first yarn 110 passes through the rotary, hollow spindle assembly 120 as the second yarn 112 is wrapped around the first yarn 110 . The yarn intermediate 125 that emerges from the rotary, hollow spindle assembly 120 comprises a first yarn 110 having a second yarn 112 wrapped around the perimeter of and along the length of the first yarn 110 . Returning to FIG. 1 , the yarn intermediate 125 is then fed by first drive rolls 130 across a heater assembly 135 , such as a plate-type, contact heater. The composite yarn 145 produced as the yarn intermediate 125 passes over the heater assembly 135 is then taken off of the heater assembly 135 by second drive rolls 140 . The composite yarn is then directed by suitable yarn guides 114 onto a suitable yarn collection assembly 150 , and the composite yarn 145 is wound onto a suitable package 155 to be used in subsequent treatment of the composite yarn or fabric formation. As noted above, the yarn intermediate 125 can be overfed onto the heater assembly 135 by driving the first drive rolls 130 at a speed greater than the second drive rolls 140 . In certain possibly preferred embodiments, the apparatus 100 can comprise a yarn spraying apparatus 160 that is adapted to intermittently spray the first yarn 110 with water or other suitable fluid as described above. Alternatively, the yarn spraying apparatus 160 can be disposed between the rotary, hollow spindle assembly 120 and the first drive rolls 130 so that the yarn intermediate 125 emerging from the rotary, hollow spindle assembly 120 is sprayed with water or other suitable fluid as described above.
The composite yarn of the invention generally comprises a first yarn having a second yarn wrapped around its perimeter and along its length. The first and second yarns of the composite yarn can be any suitable yarn, such as those described above in the description of the process of the invention. A composite yarn according to the invention is depicted in FIG. 3 . The composite yarn 300 comprises a first yarn 310 and a second yarn 320 wrapped around the perimeter and along the length of the first yarn 310 . The first yarn 310 is depicted as a multifilament yarn comprising a plurality of individual filaments 315 that together form the first yarn 310 . As shown in FIG. 3 , the second yarn 320 is a heat-shrinkable yarn, such as those described above, which has been heated so that the second yarn 320 shrinks along its length and along the length of the composite yarn 300 . This shrinkage of the second yarn 320 along its length draws in the first yarn 310 and produces the bulky appearance depicted in FIG. 3 .
FIG. 4 is a drawing of several segments of a composite yarn according to the invention. The composite yarn 400 in FIG. 4 comprises a first yarn 410 and a second yarn (not visible) together forming a core that is wrapped with a third yarn 420 . The first yarn 410 is a 140 denier (160 dtex), 200 filament false twist textured polyethylene terephthalate (PET) yarn, and the second yarn (not visible) is a 255 denier (283 dtex), 34 filament partially-oriented PET yarn. The third yarn 420 is a 115 denier (128 dtex), 34 filament 693T partially-oriented PET yarn that was wrapped around the first yarn 410 and second yarn (not visible) at a rate of about 1.75 turns per centimeter (about 4.5 turns per inch) of the first yarn 410 and second yarn (not visible). After the yarns had been wrapped to produce a yarn intermediate, the intermediate was then heated to produce the composite yarn 400 exhibiting the bulky appearance shown in FIG. 4 .
FIG. 5 is a drawing of several segments of another composite yarn according to the invention. The composite yarn 500 comprises a first yarn 510 , a second yarn (not visible), and a third yarn 520 wrapped around the perimeter of and along the length of the first yarn 510 and second yarn (not visible). The first yarn is a 225 denier (250 dtex), 200 filament 56T partially-oriented PET yarn, and the second yarn (not visible) is a 255 denier (283 dtex), 34 filament partially-oriented PET yarn. The third yarn 520 is a 115 denier (128 dtex), 34 filament 693T partially-oriented PET yarn which was wrapped around the first yarn 510 and second yarn (not visible) at a rate of about 1.75 turns per centimeter (about 4.5 turns per inch) of the first yarn 510 and second yarn (not visible). The composite yarn 500 was heated so that the yarns shrunk along their length and along the length of the composite yarn 500 . This shrinkage of the yarns along their length produces the bulky appearance shown in FIG. 5 .
FIG. 6 is a drawing of several segments of another composite yarn according to the invention. The composite yarn 600 comprises a first yarn 610 , which is black in color, and a second yarn 620 wrapped around the perimeter of and along the length of the first yarn 610 . The first yarn 610 is a 150 denier (170 dtex), 48 filament, warp-drawn, flat core PET yarn, and the second yarn 620 is a 170 denier (190 dtex), 66 filament partially-oriented PET yarn. The second yarn 620 was wrapped around the perimeter of and along the length of the first yarn 610 at a rate of about 1.75 turns per centimeter (about 4.5 turns per inch) of the first yarn 610 . The yarn intermediate produced by the wrapping the yarns was then heated to produce the composite yarn shown in FIG. 6 .
FIG. 7 is a drawing of several segments of another composite yarn according to the invention. The composite yarn 700 comprises a first yarn 710 , which is black in color, a second yarn 715 , which is white in color, and a third yarn 720 wrapped around the perimeter of and along the length of the first yarn 710 and the second yarn 715 . The first yarn 710 is a 170 denier (190 dtex), 66 filament partially-oriented PET yarn, and the second yarn is a 125 denier (139 dtex), 72 filament, cationic dyeable, partially-oriented PET yarn. The third yarn 720 is a 115 denier (128 dtex), 34 filament 693T partially-oriented PET yarn that was wrapped around the first yarn 710 and second yarn 715 at a rate of about 1.75 turns per centimeter (about 4.5 turns per inch) of the first yarn 710 and second yarn 715 . The yarn intermediate produced by the wrapping of the yarns has been heated to produce the composite yarn 700 shown in FIG. 7 .
While the composite yarn has principally been described above as comprising a first yarn and a second yarn, the composite yarn can comprise any suitable number of individual yarns that have been wrapped to produce a composite yarn. For example, the composite yarn can comprise a plurality of individual yarns disposed in substantially parallel relation to form the “core” of the composite yarn, with one or more individual yarns wrapped around the perimeter of and along the length of this core. One or more heat-shrinkable yarns can be disposed in the core of such a composite yarn or can be wrapped around the perimeter of and along the length of this core.
The following examples further illustrate the invention but, of course, should not be construed as in any way limiting its scope.
Example 1
This example demonstrates the production of a composite yarn according to the invention. A first partially-oriented polyethylene terephthalate (PET) yarn and a textured PET yarn were wrapped with a second partially-oriented PET yarn using a commercially-available rotary, hollow spindle assembly at a rate of approximately 1.75 turns per centimeter of the first partially-oriented PET yarn and textured PET yarn (approximately 4.5 turns per inch). The yarn intermediate produced by such wrapping process had a linear density of approximately 2028 dtex (1825 denier) and was comprised of approximately 53 wt. % of the first partially-oriented PET yarn, approximately 41 wt. % of the textured PET yarn, and approximately 6 wt. % of the second partially-oriented PET yarn. The resulting yarn intermediate was then overfed to a contact heater, which was maintained at a temperature of approximately 230° C., at an overfeed rate of approximately 50%. The composite yarn produced by heating the yarn intermediate was withdrawn from the heater at a rate of approximately 12 meters per minute and wound onto a suitable package under substantially no tension using a commercially-available winder. The composite yarn produced by the process had a linear density of approximately 4100 dtex (3700 denier).
Example 2
This example demonstrates the production of a composite yarn according to the invention. A first partially-oriented PET yarn and a textured PET yarn were wrapped with a second partially-oriented PET yarn using a commercially-available rotary, hollow spindle assembly at a rate of approximately 1.75 turns per centimeter of the first partially-oriented PET yarn and textured PET yarn (approximately 4.5 turns per inch). The yarn intermediate produced by such wrapping process had a linear density of approximately 1994 dtex (1795 denier) and was comprised of approximately 52 wt. % of the first partially-oriented PET yarn, approximately 42 wt. % of the textured PET yarn, and approximately 6 wt. % of the second partially-oriented PET yarn. The resulting yarn intermediate was then overfed to a contact heater, which was maintained at a temperature of approximately 230° C., at an overfeed rate of approximately 50%. The composite yarn produced by heating the yarn intermediate was withdrawn from the heater at a rate of approximately 12 meters per minute and wound onto a suitable package under substantially no tension using a commercially-available winder. The composite yarn produced by the process had a linear density of approximately 4204 dtex (3784 denier).
Example 3
This example demonstrates the production of a composite yarn according to the invention. A textured PET yarn and a first partially-oriented PET yarn were wrapped with a second partially-oriented PET yarn using a commercially-available rotary, hollow spindle assembly at a rate of approximately 1.75 turns per centimeter of the textured PET yarn and first partially-oriented PET yarn (approximately 4.5 turns per inch). The yarn intermediate produced by such wrapping process had a linear density of approximately 628 dtex (565 denier) and was comprised of approximately 46 wt. % of the textured PET yarn, approximately 30 wt. % of the first partially-oriented PET yarn, and approximately 24 wt. % of the second partially-oriented PET yarn. The resulting yarn intermediate was then overfed to a contact heater, which was maintained at a temperature of approximately 230° C., at an overfeed rate of approximately 50%. The composite yarn produced by heating the yarn intermediate was withdrawn from the heater at a rate of approximately 30 meters per minute and wound onto a suitable package under substantially no tension using a commercially-available winder. The composite yarn produced by the process had a linear density of approximately 1140 dtex (1026 denier).
Example 4
This example demonstrates the production of a composite yarn according to the invention. A textured PET yarn and a first partially-oriented PET yarn were wrapped with a second partially-oriented PET yarn using a commercially-available rotary, hollow spindle assembly at a rate of approximately 1.75 turns per centimeter of the textured PET yarn and first partially-oriented PET yarn (approximately 4.5 turns per inch). The yarn intermediate produced by such wrapping process had a linear density of approximately 424 dtex (382 denier) and was comprised of approximately 37 wt. % of the textured PET yarn, approximately 33 wt. % of the first partially-oriented PET yarn, and approximately 30 wt. % of the second partially-oriented PET yarn. The resulting yarn intermediate was then overfed to a contact heater, which was maintained at a temperature of approximately 230° C., at an overfeed rate of approximately 50%. The composite yarn produced by heating the yarn intermediate was withdrawn from the heater at a rate of approximately 30 meters per minute and wound onto a suitable package under substantially no tension using a commercially-available winder. The composite yarn produced by the process had a linear density of approximately 993 dtex (894 denier).
Example 5
This example demonstrates the production of a composite yarn according to the invention. A first partially-oriented PET yarn and a solution-dyed, partially-oriented PET yarn were wrapped with a second partially-oriented PET yarn using a commercially-available rotary, hollow spindle assembly at a rate of approximately 1.75 turns per centimeter of the first partially-oriented PET yarn and solution-dyed, partially-oriented PET yarn (approximately 4.5 turns per inch). The yarn intermediate produced by such wrapping process had a linear density of approximately 850 dtex (765 denier) and was comprised of approximately 63 wt. % of the first partially-oriented PET yarn, approximately 22 wt. % of the solution-dyed, partially-oriented PET yarn, and approximately 15 wt. % of the second partially-oriented PET yarn. The resulting yarn intermediate was then overfed to a contact heater, which was maintained at a temperature of approximately 230° C., at an overfeed rate of approximately 50%. The composite yarn produced by heating the yarn intermediate was withdrawn from the heater at a rate of approximately 30 meters per minute and wound onto a suitable package under substantially no tension using a commercially-available winder. The composite yarn produced by the process had a linear density of approximately 2174 dtex (1957 denier).
Example 6
This example demonstrates the production of a composite yarn according to the invention. Two 83 dtex (75 denier), 48 filament disperse-dyed PET yarns and two 290 dtex (260 denier) solution-dyed, PET yarns are wrapped with a 128 dtex (115 denier), 34 filament partially-oriented PET yarn using a commercially-available rotary, hollow spindle assembly at a rate of approximately 1.75 turns per centimeter of the disperse-dyed PET yarns and solution-dyed PET yarns (approximately 4.5 turns per inch). The yarn intermediate produced by such wrapping process has a linear density of approximately 1100 dtex (1000 denier). The resulting yarn intermediate is then overfed to a contact heater, which is maintained at a temperature of approximately 230° C., at an overfeed rate of approximately 50%. The composite yarn is withdrawn from the heater at a rate of approximately 26 meters per minute and is wound onto a suitable package under substantially no tension using a commercially-available winder. The composite yarn produced by the process has a linear density of approximately 2139 dtex (1925 denier).
Example 7
This example demonstrates the production of a composite yarn according to the invention. A nylon yarn and a first solution-dyed, partially-oriented PET yarn were wrapped with a second solution-dyed, partially-oriented PET yarn using a commercially-available rotary, hollow spindle assembly at a rate of approximately 1.75 turns per centimeter of the nylon yarn and the first solution-dyed, partially-oriented PET yarn (approximately 4.5 turns per inch). The yarn intermediate produced by such wrapping process had a linear density of approximately 4300 dtex (3900 denier) and was comprised of approximately 69 wt. % of the nylon yarn, approximately 26 wt. % of the first solution-dyed, partially-oriented PET yarn, and approximately 5 wt. % of the second solution-dyed, partially-oriented PET yarn. The resulting yarn intermediate was then overfed to a contact heater, which was maintained at a temperature of approximately 230° C., at an overfeed rate of approximately 50%. The composite yarn produced by heating the yarn intermediate was withdrawn from the heater at a rate of approximately 12 meters per minute and wound onto a suitable package under substantially no tension using a commercially-available winder. The composite yarn produced by the process had a linear density of approximately 8700 dtex (7800 denier).
Example 8
This example demonstrates the production of a composite yarn according to the invention. A first partially-oriented PET yarn was wrapped with a second partially-oriented PET yarn using a commercially-available rotary, hollow spindle assembly at a rate of approximately 1.75 turns per centimeter of the first partially-oriented PET yarn (approximately 4.5 turns per inch). The yarn intermediate produced by such wrapping process had a linear density of approximately 410 dtex (370 denier) and was comprised of approximately 69 wt. % of the first partially-oriented PET yarn and approximately 31 wt. % of the second partially-oriented PET yarn. The resulting yarn intermediate was then overfed to a contact heater, which was maintained at a temperature of approximately 230° C., at an overfeed rate of approximately 50%. The composite yarn produced by heating the yarn intermediate was withdrawn from the heater at a rate of approximately 40 meters per minute and wound onto a suitable package under substantially no tension using a commercially-available winder. The composite yarn produced by the process had a linear density of approximately 568 dtex (511 denier).
All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.
|
A process for producing composite yarns comprises the steps of first wrapping a second yarn around the perimeter of and along the length of a first yarn and then heating the yarn intermediate produced by such wrapping to produce a composite yarn. When a heat-shrinkable yarn is used in producing such a composite yarn, the shrinkage of the heat-shrinkable yarn enables the production of composite yarns possessing aesthetic qualities similar to those exhibited by yarns produced by much more complicated processes, such as bouclé and chenille yarns.
| 3
|
CROSS-REFERENCE TO RELATED PATENT APPLICATION
[0001] This application is a Continuation-In-Part under 35 U.S.C. §120 of U.S. patent application Ser. No. 13/224,212, filed Sep. 1, 2011, the content of which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to the identification of biomarkers suitable for use in the diagnosis and prognosis of lung adenocarcinoma, and to diagnostic kits for use in such diagnosis.
BACKGROUND OF THE INVENTION
[0003] Early diagnosis and the ability to predict the most relevant treatment option for individuals is essential to increase survival time for non-small cell lung cancer (NSCLC) patients. Adenocarcinoma (ADC), a subtype of NSCLC, is the single biggest cancer killer and so there is an urgent need to identify minimally-invasive biomarkers to enable its early diagnosis.
[0004] Lung cancer is the leading cause of cancer deaths worldwide and the third most common cause of death from all causes. In 2010, in the US alone, 222,520 new cases of lung cancer were diagnosed and 157,300 people died from this disease Approximately 85-90% of all cases of lung cancer are non-small cell lung cancer (NSCLC) (Cataldo et al. (2011) N Engl. J. Med. 364(10):947-55). Until recently, NSCLC was treated as a single disease despite recognition of its molecular and histological heterogeneity. NSCLC includes adenocarcinoma (ADC), squamous cell carcinoma, and large cell carcinoma; with recent reports indicating ADC to account for up to 50% of lung cancers. Efficacy and safety results from recent clinical trials have shown the importance of un-grouping NSCLC into its subtypes to achieve maximum benefit while minimising toxicity for patients as, unfortunately, “one size treatment does not fit all”. In light of this, there is merit in considering subtype when seeking to identify biomarkers.
[0005] Despite the devastating problem of NSCLC and the estimated 51% increased numbers of cases of this disease since 1985, a panel of reliable serum biomarkers has not yet been identified. Existing lung cancer protein biomarkers include tumour-liberated proteins such as CEA, NSE, TPA, Chromogranin, CA125, CA19-9, and Cyfra 21-1. While these are the best options currently available in the clinic, they each have limitations as detailed by Tarro et al. (2004).
[0006] The interest in circulating RNAs as biomarkers is rapidly increasing as their potential is being realised. Three years ago, we published the first whole genome microarray analysis indicating that many hundred messenger RNAs can be detected in serum (O'Driscoll et al. (2008) Cancer Genomics Proteomics. 5(2):94-104). More recently, ourselves and others have published data supporting a role for circulating miRNAs in a range of cancer types including breast (Friel et al. (2010) Breast Cancer Res Treat. 123(3):613-25; Zhao et al. (2010) PLoS One. 5(10):e13735.MCG20605), prostate (Mitchell et al. (2008) Proc Natl Acad Sci USA. 105(30):10513-8; Mahn et al. (2011) Urology. 77(5):1265.e9-1265.e16), liver (Li et al. (2011) Biochem Biophys Res Commun. 406(1):70-3; Qu et al. (2011) J Clin Gastroenterol. 45(4):355-60), gastric (Liu et al. (2010) Eur J Cancer. 47(5):784-91) and brain (Skog et al. (2008) Nat Cell Biol. 10(12):1470-6) cancers. Furthermore, a number of recent studies of NSCLC specimens collectively have substantially supported the relevance of circulating miRNAs in NSCLC (Chen et al. (2008) Cell Res. 18(10):997-1006; Hu et al. (2010) J Clin Oncol. 28(10):1721-6; Chen et al. (2011) Int J Cancer; Heegaard et al. (2011) Int. J. Cancer, Shen et al. (2011) Lab Invest. 91(4):579-87, Roth et al. (2011) Mol Oncol). Advancing on our earlier work, and supported by the important data reported in the NSCLC serum studies reported by others, here we present what we believe to be the largest global analysis of miRNAs (667 miRNAs) in serum specifically focusing on the most common type of NSCLC, adenocarcinoma.
[0007] The present inventors have surprisingly found a group of miRNAs that can be used in the diagnosis of lung adenocarcinoma.
OBJECT OF THE INVENTION
[0008] A first object of the invention is to provide novel biomarkers for the detection of lung adenocarcinoma. The ideal biomarker should be one that can be sampled minimally invasively, and sensitively enough to detect early presence of tumors in almost all patients and absent or minimal in healthy tumor free individuals.
SUMMARY OF THE INVENTION
[0009] According to the present invention there is provided a diagnostic kit to detect lung adenocarcinoma, or to stratify patients according to expected prognosis comprising at least one oligonucleotide probe capable of binding to at least a portion of a circulating miRNA selected from the group comprising miR-556, -550, -939, -616*, -146b-3p and -30c-1*.
[0010] The diagnostic kit may comprise at least one oligonucleotide probe capable of binding to at least a portion of a circulating miRNA selected from the group comprising miR-556, -550, -939, -616*, -146b-3p, -30c-1*, -339-5p and -656.
[0011] The kit may be adapted for performance of an assay selected from a real-time PCR assay, a micro-array assay, a histochemical assay or an immunological assay. For LRG assays cytochrome C may be used as a capturing ligand for building an ELISA. All such assays are well known to those of skill in the art. Where the assay is a histochemical assay, the antibody may be labelled with a suitable label. Suitable labels include coloured labels, fluorescent labels and radioactive labels.
[0012] The kit is capable of detecting lung adenocarcinoma, even in its earliest stage. This information is then used to guide further treatment regimens. Current methods of diagnosis and stratification of lung cancers are far from perfect, so the miRNA blood test of the invention has the potential to improve the current system and be more accurate and specific in determining the patient's treatment regimen
[0013] This novel diagnostic kit has potential for the following clinical applications:
[0014] The kit of the invention provides for the fast and accurate diagnosis of ADC. This is advantageous as it, allows the identification of the stage of ADC disease affecting a patient. As the necessary degree of treatment depends on the stage of the disease in the subject, the kit of the invention allows for a timely determination to be made by the clinician of the necessary treatment that will best address the needs of the patient. As ADC develops in stages, the faster the stage is determined, the quicker the patient may receive the necessary treatment, which will result in an overall better prognosis.
[0015] The miRNAs identified and incorporated into this kit may also serve as novel therapeutic targets for lung adenocarcinoma. The invention further provides a method of identifying a therapeutic agent capable of preventing or treating lung adenocarcinoma, comprising testing the ability of the potential therapeutic agent to alter the expression of at least one circulating miRNA selected from the group comprising miR-556, -550, -939, -616*, -146b-3p and -30c-1*. The invention may further comprise testing the ability of the potential therapeutic agent to alter the expression of at least one circulating miRNA selected from the group comprising miR-556, -550, -939, -616*, -146b-3p, -30c-1*, -339-5p and -656. By “alter”, it is meant that expression is increased or that expression is decreased.
[0016] In another aspect the invention provides use of a circulating miRNA selected from the group comprising miR-556, -550, -939, -616*, -146b-3p and -30c-1* to detect lung adenocarcinoma, or to stratify patients according to expected prognosis. In a further aspect, the use may comprise use selected from a group comprising miR-556, -550, -939, -616*, -146b-3p, -30c-1*, -339-5p and -656 to detect lung adenocarcinoma, or to stratify patients according to expected prognosis.
[0017] The detection may be carried out on a blood sample or a sample derived from blood.
[0018] The kit may be adapted for performance of an assay selected from a real-time PCR assay, a micro-array assay, a histochemical assay or an immunological assay. For LRG assays cytochrome C may be used as a capturing ligand for building an ELISA. All such assays are well known to those of skill in the art. Where the assay is a histochemical assay, the antibody may be labelled with a suitable label. Suitable labels include coloured labels, fluorescent labels and radioactive labels.
[0019] The invention also provides a method of detecting or screening for lung adenocarcinoma, comprising analysing a sample of blood taken from a patient to determine a level in the sample of one or more circulating miRNAs selected from the group comprising miR-556, -550, -939, -616*, -146b-3p and -30c-1*, the level of at least one of the miRNAs in the sample indicating the presence of lung adenocarcinoma. In an embodiment, when the level of the at least one miRNA in the sample falls above a predetermined threshold value for that miRNA, this indicates the presence of lung adenocarcinoma. Each miRNA in the group may have an independently predetermined threshold value. The threshold value for at least one of the miRNAs may be zero. The method may further comprise determining a level of a circulating miRNA in a sample selected from the group of miRNAs wherein the group further comprises miR-339-5p and miR-656. In an embodiment, when the level of the at least one miRNA selected from a subgroup comprising miR-339-5p and miR-656 falls below a predetermined threshold value, this indicates the presence of lung adenocarcinoma. The threshold value for at least one of the miRNAs selected from the group of eight miRNAs may be calculated based on an analysis of the level of at least one miRNA in one or more non-cancerous control samples.
[0020] The kits, assays and methods of the invention may comprise determining the level of at least 2 circulating miRNAs from the group, or at least 3 circulating miRNAs, or at least 4 circulating miRNAs, or at least 5 circulating miRNAs, or at least 6 circulating miRNAs, or at least 7 circulating miRNAs, or at least 8 circulating miRNAs from the group. In methods of the invention where the levels of at least 2 or more circulating miRNAs are determined and compared to a threshold, each miRNA may be compared to a separate, dedicated threshold. Alternatively, in methods of the invention where the levels of at least 2 or more circulating miRNAs are determined and compared to a threshold, the levels of the at least 2 circulating miRNAs may be expressed as a function and compared to a single compound threshold.
[0021] “Synthetic oligonucleotide” refers to molecules of nucleic acid polymers of 2 or more nucleotide bases that are not derived directly from genomic DNA or live organisms. The term synthetic oligonucleotide is intended to encompass DNA, RNA, and DNA/RNA hybrid molecules that have been manufactured chemically, or synthesized enzymatically in vitro.
[0022] An “oligonucleotide” is a nucleotide polymer having two or more nucleotide subunits covalently joined together. Oligonucleotides are generally about 10 to about 100 nucleotides. The sugar groups of the nucleotide subunits may be ribose, deoxyribose, or modified derivatives thereof such as OMe. The nucleotide subunits may be joined by linkages such as phosphodiester linkages, modified linkages or by non-nucleotide moieties that do not prevent hybridization of the oligonucleotide to its complementary target nucleotide sequence. Modified linkages include those in which a standard phosphodiester linkage is replaced with a different linkage, such as a phosphorothioate linkage, a methylphosphonate linkage, or a neutral peptide linkage. Nitrogenous base analogs also may be components of oligonucleotides in accordance with the invention.
[0023] A “target nucleic acid” is a nucleic acid comprising a target nucleic acid sequence. A “target nucleic acid sequence,” “target nucleotide sequence” or “target sequence” is a specific deoxyribonucleotide or ribonucleotide sequence that can be hybridized to a complementary oligonucleotide.
[0024] An “oligonucleotide probe” is an oligonucleotide having a nucleotide sequence sufficiently complementary to its target nucleic acid sequence to be able to form a detectable hybrid probe:target duplex under high stringency hybridization conditions. An oligonucleotide probe is an isolated chemical species and may include additional nucleotides outside of the targeted region as long as such nucleotides do not prevent hybridization under high stringency hybridization conditions. Non-complementary sequences, such as promoter sequences, restriction endonuclease recognition sites, or sequences that confer a desired secondary or tertiary structure such as a catalytic active site can be used to facilitate detection using the invented probes. An oligonucleotide probe optionally may be labelled with a detectable moiety such as a radioisotope, a fluorescent moiety, a chemiluminescent, a nanoparticle moiety, an enzyme or a ligand, which can be used to detect or confirm probe hybridization to its target sequence. Oligonucleotide probes are preferred to be in the size range of from about 10 to about 100 nucleotides in length, although it is possible for probes to be as much as and above about 500 nucleotides in length, or below 10 nucleotides in length.
[0025] A “hybrid” or a “duplex” is a complex formed between two single-stranded nucleic acid sequences by Watson-Crick base pairings or non-canonical base pairings between the complementary bases. “Hybridization” is the process by which two complementary strands of nucleic acid combine to form a double-stranded structure (“hybrid” or “duplex”).
[0026] “Complementarity” is a property conferred by the base sequence of a single strand of DNA or RNA which may form a hybrid or double-stranded DNA:DNA, RNA:RNA or DNA:RNA through hydrogen bonding between Watson-Crick base pairs on the respective strands. Adenine (A) ordinarily complements thymine (T) or uracil (U), while guanine (G) ordinarily complements cytosine (C).
[0027] The term “stringency” is used to describe the temperature, ionic strength and solvent composition existing during hybridization and the subsequent processing steps. Those skilled in the art will recognize that “stringency” conditions may be altered by varying those parameters either individually or together. Under high stringency conditions only highly complementary nucleic acid hybrids will form; hybrids without a sufficient degree of complementarity will not form. Accordingly, the stringency of the assay conditions determines the amount of complementarity needed between two nucleic acid strands forming a hybrid. Stringency conditions are chosen to maximize the difference in stability between the hybrid formed with the target and the non-target nucleic acid. This is well within the ability of one skilled in this art.
[0028] With “high stringency” conditions, nucleic acid base pairing will occur only between nucleic acid fragments that have a high frequency of complementary base sequences (for example, hybridization under “high stringency” conditions, may occur between homologs with about 85-100% identity, preferably about 70-100% identity). With medium stringency conditions, nucleic acid base pairing will occur between nucleic acids with an intermediate frequency of complementary base sequences (for example, hybridization under “medium stringency” conditions may occur between homologs with about 50-70% identity). Thus, conditions of “weak” or “low” stringency are often required with nucleic acids that are derived from organisms that are genetically diverse, as the frequency of complementary sequences is usually less.
[0029] ‘High stringency’ conditions are those equivalent to binding or hybridization at 42° C. in a solution consisting of 5×SSPE (43.8 g/l NaCl, 6.9 g/l NaH 2 PO 4 H 2 O and 1.85 g/l EDTA, ph adjusted to 7.4 with NaOH), 0.5% SDS, 5×Denhardt's reagent [50×Denhardt's contains per 500 ml: 5 g Ficoll (Type 400, Pharamcia), 5 g BSA (Fraction V; Sigma)] and 100 μg/ml denatured salmon sperm DNA followed by washing in a solution comprising 0.1×SSPE, 1.0% SDS at 42° C. when a probe of about 500 nucleotides in length is used. “Medium stringency’conditions are those equivalent to binding or hybridization at 42° C. in a solution consisting of 5×SSPE (43.8 g/l NaCl, 6.9 g/l NaH 2 PO 4 H 2 O and 1.85 g/l EDTA, pH adjusted to 7.4 with NaOH), 0.5% SDS, 5×Denhardt's reagent and 100 μg/ml denatured salmon sperm DNA followed by washing in a solution comprising 10.0×SSPE, 1.0% SDS at 42° C., when a probe of about 500 nucleotides in length is used.
[0030] ‘Low stringency’ conditions are those equivalent to binding or hybridization at 42° C. in a solution consisting of 5×SSPE (43.8 g/l NaCl, 6.9 g/l NaH 2 PO 4 H 2 O and 1.85 g/l EDTA, pH adjusted to 7.4 with NaOH), 0.1% SDS, 5×Denhardt's reagent and 100 μg/ml denatured salmon sperm DNA followed by washing in a solution comprising 5×SSPE, 0.1% SDS at 42° C. when a probe of about 500 nucleotides in length is used.
[0031] The examples above are for probes of about 500 nucleotides in length. However, it is well known in the art that the use of probes of smaller lengths, such as miRNAs, requires an increase in the stringency conditions, see protocol of Varallay et al, Nature Protocols, Vol. 3 No. 2 (2008). The way in which the stringency is increased is well known in the art and can achieved by altering the ‘washing’ step by way of decreasing the salt concentration via a decrease in the concentration of SSPE buffer and/or increasing the % of SDS and/or increasing the temperature.
[0032] In the context of nucleic acid in-vitro amplification based technologies, “stringency” is achieved by applying temperature conditions and ionic buffer conditions that are particular to that in-vitro amplification technology. For example, in the context of PCR and real-time PCR, “stringency” is achieved by applying specific temperatures and ionic buffer strength for hybridisation of the oligonucleotide primers and, with regards to real-time PCR hybridisation of the probe/s, to the target nucleic acid for in-vitro amplification of the target nucleic acid.
[0033] One skilled in the art will understand that substantially corresponding probes of the invention can vary from the referred-to sequence and still hybridize to the same target nucleic acid sequence. This variation from the nucleic acid may be stated in terms of a percentage of identical bases within the sequence or the percentage of perfectly complementary bases between the probe and its target sequence. Probes of the present invention substantially correspond to a nucleic acid sequence if these percentages are from about 100% to about 80% or from 0 base mismatches in about 10 nucleotide target sequence to about 2 bases mismatched in an about 10 nucleotide target sequence. In preferred embodiments, the percentage is from about 100% to about 85%. In more preferred embodiments, this percentage is from about 90% to about 100%; in other preferred embodiments, this percentage is from about 95% to about 100% e.g., 95, 96, 97, 98, 99, or 100%.
[0034] The terms “identical” or percent “identity,” in the context of two or more nucleic acids or polypeptide sequences, refer to two or more sequences or subsequences that are the same or have a specified percentage of amino acid residues or nucleotides that are the same (i.e., 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, or higher identity over a specified region, when compared and aligned for maximum correspondence over a comparison window or designated region) as measured using a BLAST or BLAST 2.0 sequence comparison algorithms with default parameters described below, or by manual alignment and visual inspection (see, e.g., NCBI web site at ncbi.nlm.nih.gov/BLAST/ or the like). Such sequences are then said to be “substantially identical.” This definition also refers to, or may be applied to, the compliment of a test sequence. The definition also includes sequences that have deletions and/or additions, as well as those that have substitutions. As described below, the preferred algorithms can account for gaps and the like. Preferably, identity exists over a region that is at least about 25 amino acids or nucleotides in length, or more preferably over a region that is 50-100 amino acids or nucleotides in length.
[0035] For sequence comparison, typically one sequence acts as a reference sequence, to which test sequences are compared. When using a sequence comparison algorithm, test and reference sequences are entered into a computer, subsequence coordinates are designated, if necessary, and sequence algorithm program parameters are designated. Preferably, default program parameters can be used, or alternative parameters can be designated. The sequence comparison algorithm then calculates the percent sequence identities for the test sequences relative to the reference sequence, based on the program parameters.
[0036] A “comparison window,” as used herein, includes reference to a segment of any one of the number of contiguous positions selected from the group consisting of from 20 to 600, usually about 50 to about 200, more usually about 100 to about 150 in which a sequence may be compared to a reference sequence of the same number of contiguous positions after the two sequences are optimally aligned. Methods of alignment of sequences for comparison are well-known in the art. Optimal alignment of sequences for comparison can be conducted, e.g., by the local homology algorithm of Smith & Waterman (1981) Adv. Appl. Math. 2:482, by the homology alignment algorithm of Needleman & Wunsch (1970) J. Mol. Biol. 48:443, by the search for similarity method of Pearson & Lipman (1988) Proc. Nat'l. Acad. Sci. USA 85:2444, by computerized implementations of these algorithms (GAP, BESTFIT, FASTA, and TFASTA in the Wisconsin Genetics Software Package, Genetics Computer Group, 575 Science Dr., Madison, Wis.), or by manual alignment and visual inspection (see, e.g., Current Protocols in Molecular Biology (Ausubel et al., eds. 1987-2005, Wiley Interscience)).
[0037] A preferred example of algorithm that is suitable for determining percent sequence identity and sequence similarity are the BLAST and BLAST 2.0 algorithms, which are described in Altschul et al (1977) Nuc. Acids Res. 25:3389-3402 and Altschul et al. (1990) J. Mol. Biol. 215:403-410, respectively. BLAST and BLAST 2.0 are used, with the parameters described herein, to determine percent sequence identity for the nucleic acids and proteins of the invention. Software for performing BLAST analyses is publicly available through the National Center for Biotechnology Information. This algorithm involves first identifying high scoring sequence pairs (HSPs) by identifying short words of length W in the query sequence, which either match or satisfy some positive-valued threshold score T when aligned with a word of the same length in a database sequence. T is referred to as the neighborhood word score threshold (Altschul et al., supra). These initial neighborhood word hits act as seeds for initiating searches to find longer HSPs containing them. The word hits are extended in both directions along each sequence for as far as the cumulative alignment score can be increased. Cumulative scores are calculated using, for nucleotide sequences, the parameters M (reward score for a pair of matching residues; always >0) and N (penalty score for mismatching residues; always <0). For amino acid sequences, a scoring matrix is used to calculate the cumulative score. Extension of the word hits in each direction are halted when: the cumulative alignment score falls off by the quantity X from its maximum achieved value; the cumulative score goes to zero or below, due to the accumulation of one or more negative-scoring residue alignments; or the end of either sequence is reached. The BLAST algorithm parameters W, T, and X determine the sensitivity and speed of the alignment. The BLASTN program (for nucleotide sequences) uses as defaults a wordlength (W) of 11, an expectation (E) of 10, M=5, N=−4 and a comparison of both strands. For amino acid sequences, the BLASTP program uses as defaults a wordlength of 3, and expectation (E) of 10, and the BLOSUM62 scoring matrix (see Henikoff & Henikoff (1989) Proc. Natl. Acad. Sci. USA 89:10915) alignments (B) of 50, expectation (E) of 10, M=5, N=−4, and a comparison of both strands.
[0038] “Nucleic acid” refers to deoxyribonucleotides or ribonucleotides and polymers thereof in either single- or double-stranded form, and complements thereof. The term encompasses nucleic acids containing known nucleotide analogs or modified backbone residues or linkages, which are synthetic, naturally occurring, and non-naturally occurring, which have similar binding properties as the reference nucleic acid, and which are metabolized in a manner similar to the reference nucleotides. Examples of such analogs include, without limitation, phosphorothioates, phosphoramidates, methyl phosphonates, chiral-methyl phosphonates, 2-O-methyl ribonucleotides, peptide-nucleic acids (PNAs).
[0039] By “sufficiently complementary” or “substantially complementary” is meant nucleic acids having a sufficient amount of contiguous complementary nucleotides to form, under high stringency hybridization conditions, a hybrid that is stable for detection.
[0040] By “nucleic acid hybrid” or “oligonucleotide:target duplex” is meant a structure that is a double-stranded, hydrogen-bonded structure, preferably about 10 to about 100 nucleotides in length, more preferably 14 to 50 nucleotides in length, although this will depend to an extent on the overall length of the oligonucleotide probe. The structure is sufficiently stable to be detected by means such as chemiluminescent or fluorescent light detection, autoradiography, electrochemical analysis or gel electrophoresis. Such hybrids include RNA:RNA, RNA:DNA, or DNA:DNA duplex molecules.
[0041] “RNA and DNA equivalents” refer to RNA and DNA molecules having the same complementary base pair hybridization properties. RNA and DNA equivalents have different sugar groups (i.e., ribose versus deoxyribose), and may differ by the presence of uracil in RNA and thymine in DNA. The difference between RNA and DNA equivalents do not contribute to differences in substantially corresponding nucleic acid sequences because the equivalents have the same degree of complementarity to a particular sequence.
[0042] By “preferentially hybridize” is meant that under high stringency hybridization conditions oligonucleotide probes can hybridize their target nucleic acids to form stable probe:target hybrids (thereby indicating the presence of the target nucleic acids) without forming stable probe:non-target hybrids (that would indicate the presence of non-target nucleic acids from other organisms). Thus, the probe hybridizes to target nucleic acid to a sufficiently greater extent than to non-target nucleic acid to enable one skilled in the art to accurately detect the presence of (for example Candida) and distinguish these species from other organisms. Preferential hybridization can be measured using techniques known in the art and described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] FIG. 1 . miR-556, -550, -939, -616*, -146b-3p and -30c-1* were detected at substantially higher amounts in serum from ADC patients (n=40) compared to their individually (A) or mean value (B) for their paired age- and gender-matched controls (n=40). miR-339-5p and miR-656 were detected at substantially lower levels in serum from ADC patients (n=40), as shown after comparing their individual (C) or mean value (D) for their paired age- and gender-matched controls (n=40). Graphs represent fold increase in ADC (mean+/−SE)
[0044] FIG. 2 . Considering ADC tumour Stage, miR-556, -550, -939, -616*, -146b-3p and -30c-1* were detected at substantially higher amounts in serum from Stage 1 ADC patients (n=10) compared to their individually paired age- and gender-matched controls. The circulating amounts of each of these miRNAs increased significantly again in Stage 2 compared to Stage 1, before decreasing again in Stage 3 disease and then increasing again, to some extent, in Stage 4. Conversely, miR-339-5p levels were decreasing from Stage 1 to Stage 2 and then to Stage 3 with a lesser effect from Stage 3 to Stage 4; although this was not significant. A similar trend was observed for miR-656 except that the reduced levels in Stages 1 and 2 disease did not differ significantly from each other. Graphs represent fold increase in ADC compared to their individually paired age- and gender-matched controls (mean+/−SE).
[0045] FIG. 3 . Considering ADC tumour Stage, miR-556, -550, -939, -616*, -146b-3p and -30c-1* were detected at substantially higher amounts whereas, miR-339-5p and miR-656 was down-regulated in serum from all Stages of ADC patients compared to the mean detection level in the paired age- and gender-matched controls; although a direct association was not found with disease stage. Graphs represent fold increase in ADC compared to their individually paired age- and gender-matched controls (mean+/−SE).
[0046] FIG. 4 . Co-analysis of miR-556, -550, -939, -616*, -146b-3p and -30c-1* shows significantly increased levels in ADC sera overall compared to their collective levels in paired age- and gender-matched controls. Increased levels of these 6 miRNAs were found in Stage 2 sera compared to that in Stage 1, but fell again in Stage 3 before rising in Stage 4 (A). Co-analysis of miR-339-5p and miR-656 showed reduced levels in ADC sera overall compared to their combined levels in paired age- and gender-matched controls (B). Graphs represent fold increase in ADC compared to the mean levels in control sera (mean+/−SE).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0047] The aim here was to apply global profiling approaches to explore miRNAs in serum from patients and with ADC of the lung, investigating if these miRNAs may have potential as diagnostic biomarkers. This study involved RNA isolation from 80 sera specimens including those from patients with ADC (equal numbers of Stages 1, 2, 3 and 4) and age- and gender-matched controls (n=40 each). 667 miRNAs were co-analysed in these specimens using TaqMan low density arrays. Individual miRNAs were selected for qPCR validation. Successful isolation of RNA was achieved from all sera specimens. The quantities of RNA in ADC and control sera did not differ significantly (p=0.470). Overall, approximately 390 and 370 miRNAs, respectively, were detected in ADC and control sera. A group of six miRNAs, miR-30c-11*, miR-616*, miR-146b-3p, miR-566, miR-550 and miR-939, was found to be present at substantially higher levels in ADC compared to control sera. Conversely, two further miRNAs. miR-339-5p and miR-656 were detected at substantially lower levels in the serum from ADC patients compared to control sera. Furthermore, co-analysis of these miRNAs showed a correlation between miRNA expression and progression from Stages 1 to Stage 2 disease; although the numbers of specimens included was too limited to derive a meaningful statistical relevance on. Differences in miRNA profile identified here suggest that circulating miRNAs may have potential as diagnostic biomarkers for ADC. Of particular interest, we believe that this panel of six miRNAs has never previously been associated with serum or with ADC.
Material and Methods
Patient Characteristics
[0048] The study involved the analysis of 667 miRNAs in 80 serum specimens. Forty-two of the specimens were procured from consenting patients who were diagnosed with adenocarcinoma (ADC) of the lung. Serum specimens from 40 age-, gender- and BMI-matched healthy volunteers were analysed as controls.
RNA Extraction
[0049] RNA was isolated from 250 μl of each 0.45 μm-filtered serum specimen by extracting with TriReagent (Sigma; Poole, England) using a modification of the procedure that we previously reported (O'Driscoll et al. (2008) Cancer Genomics Proteomics. 5(2):94-104). RNA was subsequently assessed at 230 nm, 260 nm and 280 nm using a Nanodrop ND-1000 (Labtech International, Ringmer East Sussex).
[0000] Global Analysis of miRNAs
[0050] Global profiling of miR expression was performed using the TaqMan Array Human Microarray Panel, representing 667 miRNAs on 2 array acrd/specimen analysed i.e. TaqMan Low Density Array (TLDA) panel A (377 miRNAs) and panel B (290 miRNAs) (Applied Biosystems, CA, USA). cDNA was prepared from three μl RNA (25 ng/μl) according to the ABI microRNA TLDA Reverse Transcription Reaction protocol. The cDNA product (2.5 μl per specimen) was pre-amplified according to the ABI TLDA pre-amplification protocol. The ABI Taqman microRNA low density arrays (TLDA, Applied Biosystems) were selected as the platform for microRNA profiling. The amplified product was then quantified using an Applied Biosystems 7900 HT Real-Time PCR system. For initial screening, pooled specimens (equal quantities) of RNA for each cancer Stage versus pooled specimens of each set of matched controls were evaluated. Subsequent to the success of this step, individual specimens were analysed.
[0000] Real-Time Quantification of micro-RNAs
[0051] Validation of miRNAs by single and co-analysis was performed using qRT-PCR analysis (Applied Biosystems TaqMan® Micro-RNA Assay). This assay includes a reverse transcription (RT) step using the TaqMan microRNA reverse transcription kit (Applied Biosystems, CA, USA), reverse-transcribed with a MultiScribe reverse transcriptase. Briefly, the RT reaction consisted of 1.5 μL 10×RT Buffer, 0.15 μL dNTPs 100 mM, 0.19 μL RNase Inhibitor 20 U/μL, 1.0 MultiScribe reverse transcriptase, 3 μL of primer and 5 ng total RNA in a final volume of 15 μL. The reaction was then incubated in using a 7900 HT Real-Time PCR system for 30 min at 16° C., 30 min at 42° C., 5 min at 85° C., and then held at 4° C. The RT products were subsequently amplified with sequence-specific primers using the Applied Biosystems 7900HT Real-Time PCR system. The 20 μL PCR mix contains 1.33 μL RT product, 1 μL TaqMan® Universal PCR Master Mix (20×), 1 μL TaqMan® probe. The reactions were incubated in a 96-well plate at 95° C. for 10 min followed by 40 cycles of 95° C. for 15 mins and at 60° C. for 1 min.
Data Analysis
[0052] The ABI TaqMan SDS v2.3 software was utilized to obtain raw C T values. As each TLDA was performed for a given specimen (n=80) based on fixed, constant quantities of RNA in each case, to avoid introducing any bias at this stage, the raw C T data (SDS file format) were exported from the Plate Centric View. P-values (T-test; significance=<0.05) and fold change was calculated using the following 2-ΔC T described by Livak and Schmittgen, 2001). For analysis of TLDA data, values for each specimen were normalised to the mean of the C T values. Fold changes in ADC serum versus control serum were thus determined by the ΔC T method as described previously i.e. cycle threshold (C T ) ADC-(C T ) control (Livak and Schmittgen (2001) Methods 25:402-408; Chen et al. (2008) Cell Res. 18(10):997-1006; Hu et al. (2010) J Clin Oncol. 28(10):1721-6; Hennessey et al. (2012)). Excel and SPSS 16.1 statistics packages were used. To assess sensitivity and specificity, receiver operating characteristic (ROC) curves were created using GraphPad.
Results
Patient Characteristics
[0053] This study involved analysis of 80 serum specimens, including 40 sera from patients (22 male and 18 female) with ADC and from 40 age-, gender- and BMI-matched healthy volunteers. Regarding cigarette smoking history for the patient cohort, 29% never smoked, 16% previously smoked, and 55% were smokers at the time of diagnosis. Forty-eight percent of the controls never smoked, 30% previously smoked and 22% are current smokers. There was no significant (p=0.470) difference between the ages of the individual included in each group i.e. ADC patients had a median and mean age of 65 yrs. For controls, the median and mean age was 64 years. Table 1 summarises the gender balance and age following sub-division of the matched specimens based on ADC Stage at which the patients presented.
[0000] TABLE 1 Adenocarcinoma patients and healthy controls Controls ADC miRNA (Yrs; mean +/− SD) (Yrs; mean +/− SD) P value Stage 1 59.9 +/− 2.0 62.1 +/− 2.0 0.450 (6 male; 4 female) Stage 2 67.6 +/− 40 68.9 +/− 3.5 0.810 (6 male; 4 female) Stage 3 58.2 +/− 2.4 60.2 +/− 3.2 0.630 (5 male; 5 female) Stage 4 70.9 +/− 2.0 70.0 +/− 2.7 0.790 (5 male; 5 female)
RNA Yield and miRNA Presence
[0054] Total RNA quantification from each serum specimen showed the yields to be similar from the patient and control cohort. Specifically for each 250 μl of patients serum, an average of 1.88+/−0.33 μg RNA was retrieved, with control sera producing a mean of 1.83+/−0.2 μg RNA (p=0.98).
[0055] The results from this study of 667 miRNAs evaluated by low density arrays showed that the numbers of miRNAs present in ADC and control sera do not differ substantially. Assuming C T values of <35 as indicative of miRNA presence, 230+/−51 miRNAs were detected in serum from ADC patients and 240+/−21 were detected in control sera (p=0.729). Applying less stringent C T values of <40 as present, 326+/−68 miRNAs were detected in patients sera and 336+/−36 in control sera (p=0.759).
[0000] Assessing for miRNAs Reported to Generally be Present in Serum or Plasma
[0056] A number of miRNAs have been reported as typically present in serum/plasma including miR-16, miR-103, miR-93, miR-192 and miR-451. As expected, we found these miRNAs to be present in all specimens analysed, with no significant differences in detection level between the 40 sera specimens from ADC patients and the 40 normal sera (see Table 2).
[0000] TABLE 2 Assessment of 5 miRNAs commonly detected in serum or plasma miRNA Control (Mean C T ) ADC (Mean C T ) P value miR-16 21.5 +/− 1.5 22.2 +/− 2.9 0.748 miR-103 28.7 +/− 1.6 30.1 +/− 2.2 0.351 miR-93 26.5 +/− 1.1 27.7 +/− 3.1 0.604 miR-192 29.5 +/− 0.9 29.9 +/− 2.5 0.772 miR-451 25.0 +/− 1.8 26.4 +/− 4.2 0.640
miRNAs Identified as Associated with ADC Using Taqman Low Density Arrays
[0057] TaqMan low density arrays showed 3 miRNAs to be undetectable (assuming no amplification by 40 C T to indicated absence) in all 40 control sera specimens, and present in ADC sera at all stages of disease. These are miR-556, miR-550 and miR-939. A number of other miRNAs, while present at low levels in some control sera, were found to be present at substantially higher levels in ADC sera compared to control. Specifically, the mean fold increases for these miRNAs in ADC serum specimens compared to control sera were as follows: miR-517c, 12.3 fold (range: 2.3-18.8 fold); miR-770-5p, 17.3 fold (range: 2.1-40.3); miR-605, 26.7 fold (range 2.1-42.0 fold); miR-212, 9 fold (range: 4.1-23.0 fold); miR-601, 6.8 fold (range: 3.3-14.6 fold). When all data was normalised to mean C T , prior to comparison of ADC C T to control C T values, the mean fold increases for these miRNAs in ADC serum specimens compared to control sera were as follows: miR-517c (21.6 fold; range: 2.1-63.9 fold); miR-770-5p (15.8 fold; range: 2.0-36.6); miR-605 (50.4 fold; range 1.2-143.3 fold); miR-212 (10.7 fold; range: 2.3-21.6 fold); miR-601 (7.8 fold; range: 3.1-13.2 fold). Conversely, two miRNAs were found to be at substantial higher levels across the 40 normal sera specimens compared to ADC sera i.e. miR-656 and miR-339 were detected at, on average, 20.1-fold (range: 2.6-37.4 fold) and 22.7-fold (range: 3.3-62.7 fold) higher levels in control compared to ADC serum specimens. When this data was normalised to mean C T , prior to comparison of ADC C T to control C T values, the mean fold increases were as follows: miR-656 (22.8-fold; range: 2.8-44.5 fold) and miR-339-5p (21.4-fold; range: 4.8-69.1 fold).
[0000] qPCR Validation of Results Arising from TLDA Analysis
[0058] Array technology enabled co-analysis of many (667) miRNAs. However, in order to establish if the results from such analysis would consistently be found using a more routine technique that could potentially be translated to hospital laboratories for analysis, 6 initial miRNAs and two subsequent miRNAs were selected for individual analysis in all 80 specimens using standard quantitative polymerase chain reaction (qPCR) analysis. This more limited group of miRNA was selected as RNA quantities available were limited. However, these would prove in principle if validation would be achieved. The fact that little, if any, information is published on these miRNAs means that their selection also adds to the advancement of our understanding of miRNAs. Specifically, these miRNAs included miR-556, miR-550 and miR-939 (found by TLDAs to be absent from control sera (n=40) and present in ADC sera (n=40)). The other 3 miRNAs selected for qPCR analysis were miR-616*, miR-146b-3p and miR-30c-1* which were identified as potential biomarkers for ADC in a more limited pilot study of Stage 1 ADC only (n=10) and age- and gender-matched control (n=10) sera in accordance with the section entitled “Supplementary Material” below. The fact that this trend was also found through the TLDA analysis here i.e. miR-616*, miR-146b-3p and miR-30c-1* were present (≦35 C T ) in the Stage 1, but were absent from matched control sera supported their further investigation. The other two miRNAs selected for assessment by qPCR were miR-339-5p and miR-656, that were identified as at substantially lower levels in ADC sera compared to control specimens.
[0059] miR-566:
[0060] Using quantitative PCR analysis, miR-566 was detected in all specimens with the exception of one ADC specimen. Directly comparing each ADC and matched control showed miR-556 to be 70+/−29.4 fold increased in ADC sera, in all but 5 matched pairs ( FIG. 1(A) ). As individual matched normal specimens would not necessarily always be available for comparison, we also analysed levels in each ADC specimen compared to the overall mean levels in the 40 controls; showing a 19.1+/−4.4 fold increase in 95% of cases (see FIG. 1(B) ). Considering the 4 Stages of ADC, levels of circulating serum miR-556 in ADC specimens (compared to their individual matched control pairs) were found to increase in Stage 2 disease versus to Stage 1. However, levels in Stage 3 decreased substantially compared to Stage 2 before increasing again in Stage 4 disease (see FIG. 2 ). This trend was also observed when miR-556 in individual ADC sera were compared to the mean level in control specimens (see FIG. 3 ).
[0061] miR-550:
[0062] miR-550 was detected in 100% of ADC sera. In 15% of comparison pairs (6/40) miR-550 went from undetectable in normal serum to present in ADC. While some level of miR-550 was detectable in 34 of the normal sera, the amounts were substantially greater in ADC compared to control sera in the majority (75%) of cases; with an average fold increase of miR-550 in ADC sera of 24.6+/−8.8 ( FIG. 1(A) ). when compared to its matched control or 8.7+/−2.8 when compared to the mean of the controls ( FIG. 1(B) ). For miR-550, the AUC value from ROC analysis was 0.72, showing a significant (p=0.0006) difference between ADC patients and healthy controls. When considering age- and gender-matched pair comparisons, serum levels of miR-550 increased in Stage 2 disease compared to Stage 1, with levels in Stage 3 decreasing substantially compared to Stages 1 and 2, before increasing again in Stage 4 disease ( FIG. 2 ). Comparison of each ADC with the mean of control values indicated a marginal increase from Stage 1 to Stage 2 to Stage 3, with an apparently more substantial increase at Stage 4 ( FIG. 3 ). However, it should be noted that this increase is strongly influenced by one Stage 4 ADC serum specimen that had exceptionally high levels of miR-550. Eliminating this specimen bring the average fold increase in Stage 4 to a similar level to that in Stage 1-3 inclusively.
[0063] miR-939: miR-939 was detected in 100% of serum specimens and was found to be at substantially higher level (i.e. 254.2+/−143.4 fold) in 85% of cases where ADC specimens were compared directly to their age- and gender-matched control sera ( FIG. 1(A) ). Comparison of each ADC specimen to the mean level of miR-939 in control sera showed an average increase in ADC of 45.6+/−15.2 fold ( FIG. 1 (B)). Of note, the same levels of miR-939 were detected in one ADC specimen when compared to its matched control levels, while 3 (Stage 3) sera specimens had slightly lower levels of miR-939 compared to control, reflecting a mean difference of (1.7+/−0.5 C T ). Considering the 4 disease Stages, both matched-pair comparisons and comparisons of individual ADC specimen levels with the mean control level showed levels of circulating serum miR-939 increased in Stage 2, with levels in Stage 3 decreasing substantially compared to Stages 1 and 2, before increasing again in Stage 4 disease (see FIGS. 2 & 3 ).
[0064] miR-616*:
[0065] miR-616* was detected in 98% of ADC serum specimens. In 30% of matched specimens, miR-616* went from undetectable in controls to being present in ADC. While miR-616* was within detectable levels in 27 of control sera, in the majority (82.5%) of matched specimens, the amounts were substantially higher level (i.e. 20+/−5.2 fold) in ADC compared to individual paired control sera ( FIG. 1(A) ) The miR-616* AUC value from ROC analysis was 0.71, demonstrating a significant (p=0.001) difference between ADC patients and healthy controls. The increased levels of miR-616* in ADC compared to mean of controls was found to be 4.5+/−0.7 fold ( FIG. 1(B) ). Levels of miR-616* detectable in ADC serum did not consistently correlate with disease Stage (see FIGS. 2 & 3 ).
[0066] miR-146b-3p:
[0067] miR-146b-3p was detected in 95% of ADC serum specimens. In 51.5% of matched specimens compared it went from undetectable in controls to being present in ADC. In 5% of cases this miRNA was absent from both the ADC and its matched control specimen. Where miR-146b-3p was detected in both ADC and control sera, the general trend was substantially higher levels (i.e. 44+/−12.3 fold) in ADC compared to age- and gender-matched control sera ( FIG. 1(A) ). For miR-146b-3p, the AUC value from ROC analysis was 0.82; demonstrating a significant (p<0.0001) difference between ADC patients and healthy controls. This was reflected as 4.9+/−0.9 fold when comparing individuals ADC specimens that showed increased levels of miR-146b-3p to the average levels in the controls ( FIG. 1(B) ). Considering the 4 Stages of ADC, as for miR-556, levels of circulating miR-146b-3p increased in Stage 2 disease compared to Stage 1. However, levels in Stage 3 & 4 decreased compared to Stage 2 (see FIGS. 2 & 3 ).
[0068] miR-30c-1*:
[0069] miR-30c-11* was detected, by qPCR, in 70% of ADC serum specimens and in 28% of control sera. In 53% of cases, miR-30c-1* went from undetectable in controls to being present in ADC. When miR-30c-1* were detected in control serum, in general the amounts present were substantially higher (i.e. 19.5+/−3.9 fold) in early stage ADC compared to their respective matched controls. Of note, in a limited number of matched pairs (15%; 6/40) lower levels of miR-30c-1* were found in ADC compared to matched control sera. Overall, however, the AUC value from miR-30c-1* ROC analysis was 0.74 demonstrating a significant (p=0.00018) difference between ADC patients and healthy controls. Comparing increased levels of miR-30c-1* in each ADC sera specimen, a mean increase of 4.3+/−0.8 was found, compared to the average in controls. Again a minority (12.5%) of ADC specimens showed lower levels (2.1+/−0.5) of this miRNA compared to matched controls in early disease. Considering the 4 disease Stages, as for a number of other miRNAs evaluated, miR-30c-1* levels increase in Stage 2 disease compared to Stage 1, with levels in Stage 3 decreasing compared to Stage 2, before increasing again in Stage 4 disease (see FIGS. 2 & 3 ). Importantly, while miR-30c-1* was detectable in only 70% of ADC specimens overall, its absence was restricted to the earlier stages of the diseases and, importantly, miR-30c-1* was detected in 100% of Stage 4 specimens.
[0070] miR-339-5p:
[0071] qPCR analysis confirmed that the levels of miR-339-5p were substantially lower in serum from ADC patients compared to that from healthy controls ( FIG. 1(C) ). Considering the individual stages of disease, miR-339-5p was substantially lower in 40% and 70% of the Stage 1 and Stage 2, respectively, and in 100% of both Stage 3 and Stage 4 ADC serum specimens. The AUC value from miR-339-5p ROC analysis was determined to be 0.6.
[0072] miR-656:
[0073] qPCR analysis also validated our TLDA analysis of miR-656 i.e. miR-656 level was down in ADC serum specimens compared to their age- and gender-matched control sera ( FIG. 1(D) ). This was found to be the situation in 40% of Stage 1 specimens, 60% of Stage 2 specimens, and 70% of both Stages 3 and 4. The AUC value from miR-656 ROC analysis was 0.6.
[0000] Co-Analysis of Panel of miRNAs in all Specimens
[0074] As all 6 of the initial miRNAs identified as potential panel members were not over-expressed in 100% of ADC specimens, we co-assessed their expression. A minimum of 2 miRNAs and up to the maximum of all 6 miRNAs were over-expressed in any given ADC specimen. This emphasises the relevance of assessing all 6 miRNA. Considering all 6 miRNAs, the AUC value from ROC co-analysis was 0.7, indicating a significant (p<0.0001) difference between ADC patients and healthy controls. As indicated in FIG. 4 , co-analysis of the miRNAs show a 13.8+/2.9 fold increase levels in ADC compared to control sera. Considering each stage of disease individually, this was reflected in their increased levels in Stage 2 compared to Stage 1, with reduced levels in Stage 3 sera before increasing again in Stage 4. In the relation to the combination of the two subsequent miRNAs (miR-339-5p and miR-656) reduced in ADC sera, the AUC value from ROC co-analysis was 0.6, indicating a significant (p=0.02) difference between ADC patients and healthy controls. As shown in FIG. 4B , co-analysis of these two miRNAs show 110.7+77.7 fold decrease in levels in ADC compared to control sera. Considering each stage of disease individually, this was reflected in their decreased levels from Stage 1 to Stage 2 to Stage 3, with no substantial difference noted between Stage 3 and Stage 4.
Discussion
[0075] ADC of the lung is currently the single biggest killer in cancer. Studies by us and others strongly support a potential role for RNAs as circulating minimally-invasive biomarkers. In fact, a number of recently published and emerging studies suggest that miRNAs exist in sera that are associated, in general, with non-small cell lung cancer. Advancing on this, here we report what we believe to be the first large study (677 miRNAs) of circulating miRNAs specifically in ADC. Our study compared the miRNA profile of ADC with to age- and gender-matched control sera. The main novel findings of this study include the observation that there are >300 miRNAs detectable in serum; while many (270-290) miRNAs are present in serum from healthy controls as well as ADC patients, a number of miRNAs are differentially detected (based on absent versus presence or differential levels of detection) under these circumstances. Here we identified a group of 6 miRNAs that exist at substantially higher levels in the ADC compared to control sera. We consistently found increased amounts of these miRNAs to be present in serum from patients with Stage 2 disease compared to Stage 1, with levels reduced in Stage 3 before rising again in Stage 4. In addition, we identified a group of 2 miRNAs that exist at lower levels in ADC compared to control sera.
[0076] In relation to numbers of circulating miRNAs and considering relevant studies performed by others, Chen et al. (2008) Cell Res. 18(10):997-1006 reported on an important study including analysis of serum from 7 young Chinese subjects where over 100 and 91 miRNAs, respectively, were detected in male and female subjects. Assessing cohorts of 30 NSCLC patients based on disease survival, Hu et al. (2010) J Clin Oncol. 28(10):1721-6 detected 109 miRNAs and 101 miRNAs in the serum from patients with longer- and shorter-survival times, respectively. In the study reported here which including serum from 44 males and 36 females, we did not find any association between miRNA numbers and gender. This is in agreement with a recent study by Heegaard et al. (2011) Int. J. Cancer, where no association was found between gender and serum/plasma miRNA profiles. However, compared to the study by Chen et al. (2008) Cell Res. 18(10):997-1006, we detected many more sera miRNAs overall i.e. approximately 390 and 370 miRNAs in ADC and control sera, respectively. The greater number of miRNAs detected here may be due to a combination of factors, including advancement on technology for miRNAs identification and evaluation—and so the numbers of miRNAs known to exist and detectable—as well as the somewhat larger cohorts of cases possible for us to evaluate. Of note, Heegaard et al. (2011) Int. J. Cancer reported considerable difference in miRNA levels (amounts 14 miRNAs significantly reduced in serum from African American compared to European Americans) so it is conceivable that, as with many genetic and phenotypic traits associated with cancer, race may some way contribute to circulating miRNA profiles; emphasis the importance of increasing the numbers of international collaborative studies in this field. Overall, we believe that our work complements studies by Chen et al. (2008) Cell Res. 18(10):997-1006 and J Clin Oncol. 28(10): 1721-6 and collectively adds to our understanding of the numbers and scope of miRNAs in the circulation.
[0077] In relation to disease biomarkers, assessing NSCLC overall as a single disease (Chen et al. (2011; IJC in press), evaluated 91 miRNAs and identified 10 of these as potential biomarkers for NSCLC. Importantly their study did not include analysis of the 6 miRNAs (miR-30c-1*, miR-616*, miR-146b-3p, miR-566, miR-550 and miR-939) which we detail in this study of ADC. Of the 10 miRNAs reported as differentially expressed, Chen et al. (2011), miR-199a-5p was found to be substantially (15.64 fold) increased in NSCLC compared to control sera. In keeping with this, we found miR-199a-5p to be present in ADC sera but absent from control sera. The remaining 9 miRNAs reported by Chen et al. (2011) were not substantially different in our ADC and control sera. Differences in these two observations are likely to be contributed to by the fact that our study was specifically of ADC, while no specific associations with NSCLC subtype were investigated by Chen et al. (2011).
[0078] In their study of 30 serum miRNAs, in NSCLC compared to controls, Heegaard et al. (2011) Int. J. Cancer observed reduced quantities of 7 miRNAs including miR-221, let-7a, -155, 17-5p, -27a, -106a and -146b. Interestingly our microarray analysis showed a similar trend for miR-221, let-7a, 17-5p, -27a and -106a.
[0079] For miR-155, we observed increased levels in Stage 1 disease, but reduced levels for Stages 2-4 inclusively (and so we did not consider this to be one of the most relevant miRNAs from our study). The discrepancy with miR-155 between the study by Heegaard et al. (2011) Int. J. Cancer and the work presented here may, again, be attributed to the disease being analysed (NSCLC collectively versus ADC) and the stage of disease i.e. Heegaard et al. (2011) Int. J. Cancer included Stages 1 and 2 of NSCLC, while we considered all 4 Stages of ADC). Of note, in a study of serum from 35 lung cancer patients (including 18 small cell lung cancers and 9 NSCLC— but the subtypes were not defined), Roth et al. (2011) reported levels of miR-155 to be significantly higher in lung cancer compared to benign disease.
[0080] Our data on miR-146b conflicted with that found by Heegaard et al. (2011) Int. J. Cancer i.e. miR-146b levels were substantially increased in our ADC but reduced in the NSCLC analysed by Heegaard et al. (2011) Int. J. Cancer.
[0081] Included here, are some points regarding the increased amounts of “our 6 miRNAs” in Stage 2 versus Stage 1. Our data suggests a potential association with early events of ADC development and possibly associated inflammatory events. Further studies with larger sample populations will provide additional evidence as to this observation in relation to tumour stages.
CONCLUSION
[0082] Many observations are in agreement with more general studies of NSCLC serum or, indeed, cancer tissue, performed by others. However, through global analysis of 667 miRNAs in ADC alone we have been able to identify a group of 6 miRNAs, increased levels of which are associated with the presence of ADC. While independent validation in much larger cohorts are now warranted, we believe that that this study adds novel information to this field of circulating miRNAs and the quest to identify biomarkers for diagnosis and, ultimately, more personalized management of cancer patients.
SUPPLEMENTARY MATERIAL
[0083] The preliminary data referred to was based on once-off exploratory assays (i.e. n=1 assays, rather than our typical n=3).
[0084] For this pilot study, serum specimens from patients with Stage 1 ADC and age-matched controls (n=10 each) were purchased from a biobank (Asterand; http://www.asterand.com). RNA was isolated these 250 μl serum specimen after passing through a 0.45 μm-filter. RNA was extracted with TriReagent (Sigma; Poole, England) and was quantified as we previously described (O'Driscoll et al. (2008) Cancer Genomics Proteomics. 5(2):94-104). cDNA was synthesised using TaqMan microRNA reverse transcription kit (Applied Biosystems) and Multiplex RT Human Primer Pool Sets (8 primer pools/sample, each pool containing 48 different TaqMan reverse transcription primers). 100 ng total RNA was used for each of 8 RT reactions i.e. 800 ng/sample. Resulting cDNA was then diluted by a factor of 62.5, 50 μL of diluted cDNA was mixed with 50 μL of TaqMan universal PCR master mix (Applied Biosystems), and then 100 μL was added to the appropriate ports (8 ports/TaqMan low density array (TLDA) card, corresponding to 8 sets of cDNA/sample from 8 primer pools). TLDA cards were run on ABI 7900HT Real Time PCR system (Applied Biosystems). cDNA was applied to first generation arrays representing 48 human miRNAs. Following application of T-test, differentially expressed targets were identified as miRNAs with a fold change≧2 and p-value<0.05. The Results were as follows: Based on the criteria above, miR-146b-3p, miR-30c-11* and miR-616* were found to be 4.2 fold; 2.6 fold; and 6.9 fold higher levels in the Stage 1 ADC sera compared to the levels in the age- and gender matched controls.
[0085] The words “comprises/comprising” and the words “having/including” when used herein with reference to the present invention are used to specify the presence of stated features, integers, steps or components but does not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.
[0086] It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination.
|
A diagnostic kit to detect lung adenocarcinoma, or to stratify patients according to expected prognosis comprising at least one oligonucleotide probe capable of binding to at least a portion of a circulating miRNA selected from the group comprising miR-556, -550, -939, -616*, -146b-3p, -30c-1*, -339-5p and -656.
| 2
|
The invention concerns an anchoring bolt with a connection portion, a smooth rod section and an insertion portion, by which it is possible to produce conical undercutting in a cylindrical pre-bore which is filled with a mortar capsule, when the anchoring bolt is drilled into the bore.
BACKGROUND AND PRIOR ART
An anchoring bolt of that kind is described in DE-OS No. 29 41 769. The conical undercutting is produced in the case of the known anchoring bolt by the cooperation of rod profiling and the presence of abrasive grains in the mortar capsule. The anchoring bolt executes a staggering motion in which the insertion end, with its profiling, is moved in a more or less defined path. The abrasive grains of the mortar capsule, in the case of the known anchoring bolt, are pulled along intermittently with a component of motion in the circumferential direction during the drilling-in movement and, as a result of their being alongside the insertion portion, they are forced along the walls of the cylindrical pre-bore. The exact shape of the undercutting results as a matter of chance and it is not excluded that a cross-section through the undercutting is oval instead of round.
If the known anchoring bolt should be used for anchoring in a so-called parting zone, a defined undercutting is desirable. In particular it is advantageous of the undercut has circular symmetry, since it cannot be foreseen in which direction the cracks that may possibly appear will run.
SUMMARY OF THE INVENTION
Starting from the above-described state of the art, the invention has the object of providing an anchoring bolt of the kind mentioned in the introduction by which it is possible to provide a defined and reproducible widening without the introduction of abrasive grains.
This object is accomplished according to the invention by having the anchoring bolt provided, in the region of the insertion portion, with a slot, running axially from the insertion end, into which there projects the narrowed-down end stem of an axially shiftable spreading wedge. In the setting operation the wedge first breaks the resin mortar capsule located in the bore hole and then finally reaches the bottom of the bore. Under hammer-driling movement and continuous axial pressure, the insertion end is then pushed over the wedge standing up in the bore. The insertion portion of the anchoring bolt is hereby pressed against the bore walls and widened. The wedge is driven into the slot until its stem abuts the closed slot end. When this point is reached, the anchor rod has reached its greatest possible spreading and the intended undercut is produced.
The removal of the bore material is performed either by profiling formed on the insertion portion of the rod or by inserts provided in the insertion portion which are disposed radially protruding beyond its circumference.
It is useful for the wedge to have an extension in the form of a stem with parallel running surfaces, so that the wedge can be clamped in the slot and the user receives the anchor bolt and the wedge as a set. It is advantageous for the slot to extend through the profiling all the way into the smooth shaft section and for the width of the wedge to be somewhat smaller than the outer diameter of the profiling. The optimum size of the wedge angle for the wedge depends upon the hardness of the fastening ground, the material quality of the anchoring bolt and the length of the wedge. A favorable wedge angle for a fastening ground of concrete lies in the region from 2° to 6°. Good crushing of the mortar capsule and mixing up of the synthetic resin mortar is obtained when the wedge has an obtuse point at its outward end and the anchoring bolt is provided at its end surface with mixing teeth.
In one example of embodiment of the invention the inserts are constituted as round hard metal pegs, which are soldered, cemented or pressed into radially extending socket bores. In order to prevent pulling the insertion portion of the anchoring bolt, once it becomes fixed in the bore, away from the wedge, it is advantageous for the socket bores to extend radially all the way through to the slot and for the hard metal pegs to be guided and radially shiftable therein. After the greatest possible spreading has been reached, the hard metal pegs slip into cavities which are provided at the forward end of the wedge surfaces of the wedge. By the instrusion of the inwardly lying ends of the hard metal pegs the withdrawing of the anchoring bolt from the wedge is effectively prevented. The cavities can have the configuration of shoulders or of grooves running perpendicularly to the wedge surfaces.
The use of the anchoring bolt according to the invention also has the advantage of dispensing with the provision of additional materials in the mortar capsule that is to be used, since the excavated material is usable as additional material.
It is of particular advantage that the anchoring bolt is at the same time a fastening means and a widening tool for obtaining undercutting in the deepest part of a cylindrical bore hole, since in consequence the anchor bolt does not have to be removed from the bore after completing the undercut.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiment examples of the subject matter of the invention are illustrated in the drawings, in which:
FIG. 1 shows a first embodiment example of the anchoring bolt of the invention in the region of the mouth of a bore, in a side view;
FIG. 2 shows the anchoring bolt according to FIG. 1 in inserted condition, in a side view partly in section;
FIG. 3 shows a further embodiment example of the anchoring bolt according to the invention in the region of the mouth of a bore before the crushing of the mortar capsule, in a side view, the mortar capsule partly in section;
FIG. 4 shows the insertion portion of the anchoring bolt according to FIG. 3, in an enlarged side view;
FIG. 5 shows the anchoring bolt according to FIG. 3 in an intermediate stage of insertion in a bore, in a side view partly in section;
FIG. 6 shows the anchoring bolt according to FIG. 3 in inserted condition, in a side view, partly in section;
FIG. 7 shows the insertion portion of another embodiment example of the anchoring bolt according to the invention, in partial section and partly in a side view, with an intermediate stage being shown at the left, and a final stage at the right, of the performance of the undercut, and
FIG. 8 shows a further embodiment example of the anchoring bolt according to the invention in a representation corresponding to FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The anchoring bolt designated as a whole by 1 consists essentially of a connection portion 2, a smooth shaft section 3 and an insertion portion 4. The connection portion 2 has external threading 5 that goes over into an intermediate connection 6. At the end of the threading 5 opposite the intermediate connection 6 there is provided a tappet element 7 extending upwards axially above the connection part 2. The tappet is constituted as a hexagonal stud in the nature of a screw head and is provided with a transition 8 that has an inclination preventing shearing effects.
At the insertion end of the anchoring bolt 1 the insertion portion 4 is provided with profiling 9 that is visible in FIG. 1 and forms a shoulder 28 where it terminates at the smooth shaft end. This profiling 9 can be constituted in sawtooth, trapezoidal or pointed shape. The outer diameter of the profiling 9 corresponds to the nominal thread diameter of the external threading 5, so that the anchoring bolt can have an insertion type mounting.
As is readily recognizable in FIG. 1, the anchoring bolt 1 has a slot 10 that extends from the front end of the anchoring bolt 1, proceeding axially and centrally through the insertion portion 4 to the smooth shaft section 3. The slot 10 is constituted as a cavity that extends diametrally somewhat to each side as it penetrates through the insertion portion 4. The profiling 9 extends at least over 2/3 of the length of the slot 10.
The end surface 11 of the insertion portion 4 extends essentially at right angles to the longitudinal axis of the anchoring bolt 1, and is equipped with mixing teeth 12. A spreading wedge 13 projects with its extension stem 14 past the mixing teeth 12 into the slot 10. The stem 14 has a thickness that is equal to the slot width. The stem 14 has two surfaces 15 and 16 which run parallel to each other and lie against the lateral edges of the slot 10.
There is shown in FIG. 1 how the wedge 13 can be clamped in the slot 10 so that the user can receive the anchor bolt 1 and the spreading wedge 13 as a complementary set. The clamping can be obtained by precise fitting of the thickness of the stem 14 to the clearance of the slot 10 or instead by pressing the wedge 13 with its wedge surfaces 17 and 18 a little into the slot 10.
The wedge surfaces 17 and 18 of the wedge 13 form a wedge angle that, for example, for a fastening ground of concrete, amounts to 2° to 6°. The wedge surfaces 17 and 18 terminate, at the end opposite to the stem 14, in a wide-angle point 19 that primarily has the task of shattering the glass container of a synthetic resin mortar capsule 20 and providing a good mixing up of the mortar mass. Furthermore, a reduction of friction forces is obtained by the obtuse point 19 when the wedge 13 is seated on the bottom of the bore 21 represented in FIG. 1. The width of the wedge 13 is somewhat less than the outer diameter of the profiling 9.
The anchor rod 1 is made of hardenable steel and may be hardened completey through or have a hard surface and a tough elastic core. Starting materials that come into consideration for the wedge 13 are preferably case-hardened or through-hardened steel, but also hard metal or ceramics.
The overall length of the wedge 13 corresponds to the length of the slot 10. For reducing the friction forces between the stem 14 of the wedge 13 and the walls of the slot 10, the wedge 13 or the slot 10 can also be coated with a lubricant.
Whereas FIG. 1 shows the beginning of the insertion procedure for the anchoring bolt 1 in a bore 21, FIG. 2 shows the anchoring bolt after setting in place. It is plainly recognizable in FIG. 2 that the anchoring bolt 1 serves at the same time as fastening means and as widening tool for obtaining an undercut 22 in the deepest part of the cylindrical bore 21.
In preparation for a setting operation the cylindrical bore 21 is first drilled in a fastening ground 23. Thereafter a synthetic resin mortar capsule 20 is pushed into the bore 21. Finally the anchoring bolt, together with the wedge 13 clamped in the slot 10, is introduced into the bore 21 with percussion-drilling movement and continuous axial pressure, while the mortar capsule 20 is shattered and its contents mixed up. As soon as the blunt point of the broad bottom of the wedge 13 has reached the bore bottom 24, the insertion portion 4 of the anchoring bolt 1 is pushed over the wedge 13 standing up in the bore. The profiling 9 of the anchoring bolt 1 is thereby pressed against the walls of the bore 21 and the bore is widened corresponding to the amount of the material removed. The spreading wedge 13 is driven so far into the slot 10 that the stem 14 lies against the closed end of the slot 10. When this state is reached, the anchoring rod 1 has reached its largest possible spreading, has produced the intended undercut 22 and has formed an interlocked connection with the ground. The bonding, i.e. the mortar mass 29, is supported by the shoulder 28 which provides a small initial slip.
As is further recognizable in FIG. 2, an insertion type assembly is possible. The object 25 to be fastened is pressed against the surface of the fastening ground 23 with the help of a nut 26 and a washer 27.
The profiling 9 of the insertion portion 4 can, as mentioned, be constituted by sawtooth, trapezoidal or pointed shape or could also in the case of another illustrative example not shown in the drawings be entirely omitted if as described below hard metal pegs 30, ceramic rods or other suitable inserts are used, in which case, if an insertion assembly is desired, the outer diameter of the smooth insertion portion is smaller than the nominal thread diameter of the external threading 5.
In the embodiment example shown in FIGS. 3 to 6 and especially in FIG. 4 the insertion portion 4 at its outer end has two radial blind bores 31 extending at right angles to the slot 10 in which hard metal pegs 30 are set. The profile of the hard metal pegs 30 is preferably round but can have any desired contour. As the material for the pegs 30 hard metal, ceramic or hardened steel is used. The fastening of the hard metal pegs 30 into the blind bores 31 is performed by soldering, cementing or press-fitting. The diameter of the hard metal pegs 30 is made suitable to the outer diameter of the anchor bolt 1, with the hard metal pegs 30 protruding radially beyond the circumference of the insertion portion 4 or of the profiling 9.
In the case of smooth and cylindrically-shaped insertion ends the hard metal pegs 30 alone perform the material removal for producing an undercut 22. If no hard metal pegs are present, the profiling 9 takes over this assignment as above explained. If, as shown in the embodiment example according to FIGS. 3 to 8, both the profiling 9 and also the hard metal pegs 30 are provided, the profiling 9 provides support for the mixing together of the mortar mass 29.
While FIG. 3. shows the beginning of the setting of the anchoring bolt 1 in a bore 21, FIG. 5 shows the anchoring bolt 1 during the setting operation and FIG. 6 the anchoring bolt 1 after termination of the setting operation. As is evident from FIGS. 5 and 6, the anchoring bolt 1 of the second embodiment example is at the same time fastening means and widening tool for obtaining an undercut 22 in the deepest part of the cylindrical bore 21.
The setting operation corresponds essentially to the setting operation described above for the anchoring bolt 1 according to FIG. 1. In order to prevent a premature spreading of the insertion portion 4 in the shattering of the mortar capsule 20, shoulders 35 are formed on the stem 14 of the wedge 13 in the embodiment example according to FIGS. 3 and 4. As soon as the point of the wedge 13 has reached the bottom 24 of the bore, the insertion portion 4 is pushed fully over the wedge 13 standing up in the bore 21. At this time, according to the construction of the insertion portion 4, the profiling 9 and/or the hard metal pegs 30 of the anchoring bolt 1 are pressed against the wall of the bore 21 and produce a widening corresponding to the magnitude of the material removal. In the course of the provision of the undercut 22 the wedge 13 is driven so far into the slot 10 that the stem 14 abuts against the closed end of the slot 10, as shown in FIG. 6. Upon reaching this state the anchoring bolt 1 has reached its greatest possible spreading, by which intended undercut 22 is produced and a shape-locked connection is made.
An insertion type assembly is performed also in the case of the embodiment example shown in FIG. 6. The object 25 to be fastened, as in the case of the first embodiment example, is pressed against the surface of the fastening ground 23 with the assistance of a nut 26 and a washer 27.
FIGS. 7 and 8 show two further embodiment examples of the anchoring bolt 1, in which instead of the blind bores 31 (FIG. 4) socket bore passages 32 are provided at the front end of the insertion portion 4. The hard metal pegs 30, in contrast to the embodiment example shown in FIGS. 3 to 6, are prolonged and can slide in the passage-type socket bores 32. During the widening operation they lie against the wedge surfaces 17 and 18 of the wedge 13 and after the greatest possible spreading is reached they drop back respectively into cavities provided for the purpose in the region of the obtuse point 19 of the wedge 13.
In the embodiment example shown in FIG. 7 the cavities are constituted in the form of shoulders 33. In the embodiment example according to FIG. 8, instead of the shoulders, grooves 34 are provided that extend perpendicularly to the longitudinal axis of the wedge surfaces 17 and 18 of the wedge 13 and have a width that is sufficient for catching the inwardly located end of the hard metal pegs 30.
By these precautions it is prevented that the insertion portion 4 of the anchor bolt 1 already anchored in the bore could be pulled away from the wedge 13. In the case of an axial pull in the wedge direction of the wedge 13 a carrying along of the wedge 13 is assured by means of the hard metal pegs 30 caught in the shoulders 33 or the grooves 34, so that it is not possible to pull the widened insertion portion 4 away from the wedge 13 and to press it together by the bore that becomes narrower in the direction of pull.
The preferred field of application of the anchoring bolt 1 is anchoring in a so-called partition zone. The direction in which cracks run in a fastening ground is not calculable and there is accordingly the danger that such cracks will run transversely through a fastening bore and increase the diameter of the latter. In the case of the anchoring bolt 1 according to the invention, as the result of the undercutting or grasping around in the deepest part of the bore, there is still sufficient residual holding force present to prevent the anchoring bolt 1 from falling out of the bore 21 in spite of a possible loosening, when a crack runs directly through the bore 21.
|
In order to produce conical undercutting of the bore when the anchoring bolt is driven into a previously bored hole with a percussion drill, the insertion end of the bolt has a slot into which the thin end of a wedge is inserted. Hard metal pegs set in radial bores near the insertion end of the bolt at diametrically opposite places on the periphery of the bolt protrude slightly and, as the bolt is driven into place, the wedge spreads its insertion end and causes the hard metal pegs to undercut the walls of the bore more and more as the bolt is set in place. A conical undercutting of the bar thus results.
| 4
|
FIELD OF THE INVENTION
The invention relates to plastic blends, which may be called polymer alloys, made from natural sources, namely starch, which exhibit environmentally desirable biodegradation properties.
TECHNOLOGY REVIEW
The New York Times reported on Sunday, Oct. 21, 1990 at page F9 that plastic products have become a symbol of the nation's litter and solid waste disposal problems. Further, since plastics are almost universally derived from petroleum products, they present a drain on what could become a scarce and increasingly costly resource.
As a result, there is a need to develop plastics made from natural sources, such as starch and sugars, rather than oil. Plastics made from these materials could ease the pressure on oil supplies if oil prices increase. Plastics derived from natural sources also have the desirable property of degrading into benign components relatively quickly and completely after use.
It is possible to make biodegradable plastics from sugars and organic acids using bacteria. One procedure is similar to the fermentation process that produces ethyl alcohol, except that the bacteria used, Alcaligenes eutrophus, converts feed materials into a plastic material known as polyhydroxybutyrate-valerate, or PHBV. The bacteria accumulates the PHVB as a store of energy in the same way that animals and humans accumulate fat. When the bacteria have accumulated up to 80% of their dry body weight as PHVB, the cells are burst open with steam and the plastic is collected. The product is reported to have been made by Imperial Chemical Industries, Ltd. in Great Britain at a cost of $15 a pound, compared to less than a $1 a pound for common plastics.
The Warner-Lambert Company is reported to be building the plant in Rockford, Ill. to produce as much as 100 million pounds a year of a plastic material made from starch derived from corn or potatoes. The Warner-Lambert process does not involve any bacteria. Instead, the starch is melted under high pressure in the presence of water to produce "destructurized" starch. The starch-water material is loaded into injection molding machines where it is melted in a screw conveyor and injected into a mold where it hardens. Details of the Warner-Lambert process may be found in their published European patent application 327,505, published Aug. 9, 1989. As described therein, water is present in amounts from 10 to 20% by weight compared to the weight of the starch (see page 3, lines 47 to 49). The starch-water material is melted under high pressure in an injection molding machine over a period of approximately 12 minutes including approximately 10 minutes of heating and approximately 2 minutes in the molten state to produce destructurized starch (see page 2, lines 16-21 and page 5, lines 16-18).
U.S. Pat. Nos. 4,133,784; 4,337,181; and 4,454,268, assigned to the U.S. Department of Agriculture, disclose flexible, starch-based films prepared from gelatinized starch and ethylene acrylic acid (EAA). Gelatinization is effected, e.g., by heating the starch in an aqueous solution at temperatures above about 60° C. until the starch granules are sufficiently swollen and disrupted that they form a smooth, viscous dispersion in the water. See U.S. Pat. No. 4,133,784 at column 2, lines 55-61; U.S. Pat. No. 4,337,181 at column 3, lines 34-41; and U.S. Pat. No. 4,454,268 at column 2, lines 48-56.
Starch alone has been used to produce films, but such films are brittle and highly moisture sensitive (R. L. Whistler, et al., Starch Chemistry and Technology, 2nd Ed., pages 269-274 (Academic Press 1984)).
There exists a need to develop additional plastics made from natural sources, namely starch. In particular, it is desirable to provide new polymer alloys, which are mixtures of unmodified starch and at least one synthetic polymer. Such polymer alloys will desirably have better mechanical properties than starch, while exhibiting desirable biodegradation properties.
SUMMARY OF THE INVENTION
It has surprisingly been discovered that dry starch, which has been neither destructurized nor gelatinized, is useful to prepare biodegradable plastic blends, which may be called polymer alloys, including this starch and a copolymer of an olefin and a comonomer selected from the group consisting of C 1-6 alkylacrylates, C 1-6 alkylmethacrylates, and vinyl acetate, and optionally also containing a poly(mono)olefin or a poly(mixed) olefin. As used herein a poly(mono)olefin refers to a polyolefin of one olefin monomer, and a poly(mixed)olefin refers to a polyolefin of two or more olefin monomers. The polymer alloys of the present invention exhibit good mechanical properties and, in addition, exhibit desirable degradation properties.
DETAILED DESCRIPTION OF THE INVENTION
The starch-thermoplastic resin polymer alloys of the present invention are prepared by mixing a carrier resin and starch as described below. The term "starch" describes starch obtained from cereal grains or root crops, including but not limited to corn, rice, sorghum, tapioca, wheat, and potatoes. The starch so used may contain any ratio of amylose, the linear component of starch, to amylopectin, the branched component; pure amylose or pure amylopectin may also be used. Derivatized or chemically modified starches are also encompassed by this description.
The masterbatches of the invention are prepared using dry, or "Pearl" starch. The term masterbatch as used herein refers to a mixture of starch and a carrier resin. The masterbatch may be blended with a third resin. The use of a masterbatch allows for the optional addition of another resin in a controlled fashion. Starch content of the masterbatch preferably ranges from about 50% to about 80% by weight compared to total dry solids; it is understood starch contents of the masterbatch below 50% can be prepared as well. Starch contents of at least about 10% are useful, that is, polymer alloys produced from these masterbatches exhibit improved biodegradation properties, compared to polymers not containing starch. The moisture content of the dry starch used to prepare the masterbatch in the practice of the invention is usually between about 10% and about 15%. Moisture contents below about 15% are preferred.
The carrier resin used to prepare the masterbatches described herein may be any of the family of copolymers made from an olefin, e.g., ethylene, propylene, or the like, copolymerized with at least one comonomer comprising a C 1 -C 6 alkyl acrylate, e.g., methyl acrylate, ethyl acrylate, hexyl acrylate and the like; a C 1 -C 6 alkyl methacrylate, e.g., methyl methacrylate, ethyl methacrylate, hexyl, methacrylate, and the like; or vinyl acetate. Especially preferred are the well known copolymers of ethylene with an alkyl ester of acrylic acid. These are disclosed in U.S. Pat. No. 2,953,551. Generally, the acrylate or methacrylate portion of the copolymer can range from about 3 to about 30 weight percent. The olefin portion of the copolymer can range from about 70 to about 97 weight percent. Suitable olefinacrylate copolymers, as defined above, can be prepared by methods well known to those skilled in the art or can be obtained commercially. Preferred materials are copolymers of ethylene and one of the following monomers: methyl acrylate, ethyl acrylate, butyl acrylate, and vinyl acetate. Comonomer contents of these preferred materials can range from about 3 to about 25 percent, weight basis. The most preferred copolymer for use in the present invention is an ethyleneethyl acrylate copolymer in which the weight ratio of the ethylene fraction to the ethyl acrylate fraction is about 4.5 to 1. For example, Union Carbide's DPDA 9169 ethylene ethyl acrylate is suitable for use in the present invention.
Without wishing to be bound by any theory, it is believed the more polar comonomer adheres, or "anchors" itself, to the hydrophobic starch particle surface via hydrogen bonding and dipole interactions. This interaction presents a hydrophobic medium to the nonpolar polyolefin matrix. It is also believed the polymeric nature of the copolymer enhances the mechanical properties of the resulting composite due to entanglement formation with the matrix. These copolymers are available in a wide range of molecular weights and molecular weight distributions (as measured by the Melt Index method, ASTM D1238).
Three copolymers are used to illustrate but not to limit this invention: poly(ethylene-co-methyl acrylate) (EMA); poly(ethylene-co-ethyl acrylate) (EEA); and poly(ethylene-co-vinyl acetate) (EVA). The copolymers comprised from about 16% to about 50% of the total solids of the resulting masterbatches. Melt index values range from 1.5 to 20.
Starch/copolymer masterbatches can be prepared with a variety of plastics processing equipment. The key steps in the mixing process are the removal of water and other volatiles, and sufficient mixing action to achieve dispersion of the starch in the copolymer resin. For example, mixing in a batch mixer such as a Banbury-brand mixer usually takes between about 3 and about 5 minutes for a 300 lb. (136 kg) charge. The resin mixtures are then extruded and chopped to form pellets and thereafter molded in accordance with conventional methods. Vented twin screw extruders are particularly well suited for these tasks. Vented single screw extruders can be utilized, as well as batch mixers such as a Banbury-brand mixer. Failure to remove the moisture before the extrudate exits the die results in foamy pellets which yield unacceptable products. Processing temperatures can range from just above the melting point of the copolymer, typically 80° to 90° C., to the thermal stability of the starch, approximately 230° C.
The ratio of the starch to the carrier resin in the blends of the present invention is sufficient to improve the biodegradation properties of the carrier resin, and/or to reduce the petrochemical content of the blend. Such an amount is generally within the range of about 10 and about 80 weight percent, compared to the weight of the blend. Preferably the quantity of starch to carrier resin is between about 50 and about 80 weight percent, and most preferably it is between about 60 and about 80 weight percent.
Within the described components, and within the broad composition ranges specified above, many resin mixtures may PG,10 be prepared in accordance with the present invention which exhibit improved biodegradability and/or reduced dependence on oil-derived petrochemicals. The present invention provides resin mixtures which exhibit good molding and film-forming characteristics, and are useful in preparing a wide variety of molded and film products.
Other additives known to those skilled in the art may also be incorporated into the masterbatch during the compounding step. These include performance agents, such as slip agents and mold releases, lubricants, and plasticizers. Colorants may be incorporated. Pro-oxidants such as unsaturated organic compounds and transition metal compounds may be added to enhance the oxidation of the resin matrix to which the masterbatch is added during conversion to product.
The resulting starch masterbatches may then be "let down" or blended with polyolefins such as polyethylene or polypropylene during conversion processes such as injection molding or film blowing. Such blending techniques are well known to those skilled in the art. All types of polyolefins such as polyethylene (LDPE, LLDPE, and HDPE) may be in the practice of the invention. Starch content of the finished products range from about 6% to about 30% in films, and up to about 60% in injection molding. Unless otherwise stated herein, all percentages are by weight compared to the total dry solids. The moisture content of the masterbatch must be kept below approximately 0.5% during conversion to eliminate voids and bubbles caused by the escape of steam. Common inorganic desiccants such as silica gels (physical adsorption) or calcium oxide (chemical combination) may be used to control the moisture during this step.
It is obvious to those skilled in the art that other conversion processes, including but not limited to blow molding, thermoforming, and laminating, can also be used to convert the starch masterbatch into a biodegradable finished product.
In order that those skilled in this art may better understand the invention the following examples are presented. While these examples illustrate specific embodiments of this invention, the invention is not limited to these embodiments and includes all embodiments which would be apparent to those skilled in the art. Unless otherwise stated, all percentages in the example are by weight.
EXAMPLE 1
Into a vented, 40 mm Berstorff twin screw extruder were fed air dry starch (Cargill Pearl) at 13% moisture content, and EEA (Union Carbide DPDA 9169) at a ratio which yielded a final product with 60% starch based on total solids. The extrudate was a dense, off-white pellet with little odor and a volatiles content of 0.4%. Screw speeds were 175 rpm, and the temperature profile ranged from 185° C. in the first zone to 200° C. at the die. The strands were air cooled and pelletized.
EXAMPLE 2
Air dry starch (Grain Processing Corp. "Pearl B200") and EEA (Union Carbide DPDA 9169) were fed into a Berstorff 90 mm vented twin screw extruder at a rate which yielded a product with 50% starch based on total solids. Screw speeds were 250 rpm, and the temperature profile ranged from 115° C. at the first zone to 175° C. at the die. The strands were quenched in water and pelletized. The product was a dense, off white material.
EXAMPLE 3
Air dry corn starch (Cargill Pearl), EEA (Union Carbide DPDA 9169), and butadiene-styrene copolymer (BDS) (Firestone Stereon 841A) were fed into a vented Werner & Pfleiderer 57mm twin screw extruder at a rate which yielded a product consisting of 63% starch, 16% EEA, and 22% BDS, based on total solids. Screw speeds were 275 rpm, and temperatures ranged from 120° C. to 180° C. The extrudate was air cooled on a chilled belt and pelletized. The pellets were dense and off-white in color.
EXAMPLE 4
Into the same extruder used in Example 2 were fed air dry corn starch (Grain Processing Corp. "Pearl B200"), EEA (Union Carbide DPDA 9169), and polyethylene (Union Carbide GRSN 7042) at rates which yielded a product consisting of 50% starch, 40% EEA, and 10% PE, based on total solids. Extrusion temperatures were 125° C. to 180° C. and screw speeds were 175 rpm. The extrudate was quenched in a water trough, pelletized, and dried. The resulting pellets were dense and white in appearance.
EXAMPLE 5
57.0 grams of air dry corn starch, 11.5 grams of EVA (DuPont Elvax 350), and 1.5 grams of mold release (Henkel Emerest 2715) were mixed in a Brabender laboratory bowl mixer with a capacity of approximately 55 cc. The mixing speed was 60 rpm and the temperature was 350° F. After mixing for five minutes, the resulting compound was removed and chopped into small pieces while hot. The cooled material was a hard, bony substance with an off white color. Its content, based on total solids, was 79% starch, 18.5% EVA, and 2.5% mold release.
EXAMPLE 6
In the same mixer used in Example 5 were fed 57 grams air dry corn starch, 11.5 grams EMA (Chevron 2205), and 1.5 grams mold release. The mixing temperature, speed, and time, were the same as in Example 5. The resulting material was hard and bony, with an off white color. Its composition was 79% starch, 18.5% EMA, and 2.5% mold release.
EXAMPLE 7
In the mixer used in Examples 5 and 6 were fed 57 grams of air dry corn starch, 11.5 grams of EEA (Union Carbide DPDA 6169), and 1.5 grams of mold release. Mixing conditions were identical to Example 5 and 6. The resulting compound was hard and bony with an off an off white color. Its composition was 79% starch, 18.5% EEA, and 2.5% mold-release.
EXAMPLE 8
Blown Films Using Example 1
The compound prepared by the method of Example 1 was mixed low density polyethylene and carbon black color with linear concentrate at levels to yield 7.5%, 10.0%, and 12.5% starch in the final product. The film was blown on a Gloucester extruder with a 12 inch die and welded into bags. Temperatures ranged from 350° F. to 375° F. The resulting flexible films were 0.0010 to 0.0012 inches thick. Their strengths, as measured by the Dart Drop Impact Test (ASTM D1709), were 123 grams, 86 grams, and 90 grams. Comparable PE values are 200 grams.
EXAMPLE 9
Injection Molding Using Example 1
The compound prepared in Example 1 was mixed with low density polyethylene (LDPE) (Quantum Chemical Co. NA 270) to yield starch contents of 20%, 30%, 40%, 50%, and 60% in the final product. The 60% starch product was pure masterbatch, with no LDPE added. These formulations were molded on an Arburg 25 Ton injection molding machine into tensile bars for testing according to ASTM D638. Processing temperatures ranged from 275° F. to 325° F. The resulting bars were off white in color and quite flexible. Tensile properties are given in Table 1.
EXAMPLE 10
Injection molding Using Examples 5, 6, and 7
The compounds prepared in Examples 5, 6, and 7 were mixed with LDPE (Quantum Chemical NA202) and injection molded on the same machine used in Example 9. Starch content of the final products was 40%, based on total solids. Molding temperatures ranged from 280° F. to 325° F. Tensile properties of these compounds are given in Table 2.
EXAMPLE 11
Injection Molding Using Example 2
The material prepared in Example 2 was blended with polypropylene (PP) and black color concentrate to give a product with 30% starch. This mixture was molded into flower pots on a Cincinnati Milacron 300 ton injection molding machine, at temperature from 390° F. to 425° F.
TABLE 1______________________________________ Tensile Elongation to% Starch Strength (psi) Break (%)______________________________________ 0 1,091 38620 792 14630 667 8040 592 8150 506 4860 384 25______________________________________
TABLE 2______________________________________ Tensile Elongation toResin % Starch Strength (psi) Break (%)______________________________________EVA 40 654 60EMA 40 662 81EEA 40 680 40LDPE Control 0 1100 205______________________________________
EXAMPLE 12
Biodegradability of Starch Containing Compounds Samples prepared according to Examples 1 and 9 were placed in glass beakers containing water from Lake Decatur, Decatur, Ill. After several days, mold growth was evident on all the samples of the invention. No mold growth was observed on PE controls.
It is understood that various other modifications will be apparent to and can readily be made by those skilled in the art without departing from the scope and spirit of this invention. Accordingly, it is not intended that the scope of the claims appended hereto be limited to the description as set forth herein, but rather that the claims be construed as encompassing all the features of patentable novelty which reside in the present invention, including all features which would be treated as equivalents thereof by those skilled in the art to which this invention pertains.
|
A biodegradable plastic composition prepared by mixing:
(a) dry unmodified starch, e.g. Pearl starch,
(b) a copolymer of an olefin and a comonomer selected from the group of C 1-6 alkylacrylates, C 1-6 alkylmethacrylates, and vinyl acetate, and optionally also including,
(c) a poly(mono)olefin or a poly(mixed)olefin, and articles manufactured by injection molding or blowing films of this composition.
| 2
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a radio-frequency power amplifier (RF power amplifier hereinafter), and more particularly, to a RF power amplifier with high output efficiency and a wide range of gain control.
2. Description of the Related Art
In general, RF power amplifiers are used in wireless communication systems to amplify and transmit signals. High efficiency and output power are the necessary requirements of RF power amplifiers. Furthermore, in order to be appropriate for various communicating distances at different occasions, the RF power amplifier must be able to provide a wide range of gain control such that the output power can be adaptively controlled according to the communicating distance, thereby reducing unnecessary output power consumption.
At present, the various methods for controlling RF power amplifiers applied in monolithic microwave integrated circuits (MMIC) include: (1) a power-synthesizing method, (2) a power-attenuating method, (3) the unbalanced bias cascode (UBIC) method, (4) a drain voltage controlling method, and (5) a gate voltage controlling method. The drawbacks of the above five methods are described as follows.
(1) With the power-synthesizing method, a plurality of power synthesizers (or power amplifiers) is combined to achieve output power control. However, giving the relatively high cost of the synthesizers, the number of the synthesizers always is restricted to reduce the cost, thereby reducing the possible options for the output power level. In addition, the control circuits are very complicated.
(2) With the power-attenuating method, power attenuators are disposed in the RF output circuits to directly attenuate the output power, thereby achieving output power control. However, it is very difficult to design attenuators with a wide range of power-attenuating capacity, low power consumption, and lower cost for MMIC applications.
(3) With the UBIC method, a common-source FET (field-effect transistor) and a common-gate FET are cascoded (connected in series) to serve as an amplifying stage, and a plurality of amplifying stages are cascoded to work as a power amplifier. By varying the gate voltages at the gate of the common-gate FETs, the drain currents of the common-source FETs are varied in response, thereby achieving output power control. However, the control circuits applied in the UBIC method are complicated and costly. In addition, the amplifiers are vulnerable to oscillation and instability, because impedance matching between amplifying stages is very difficult.
(4) With the drain-voltage control method, a source-control transistor is added to the source input of the RF power transistor, and the drain current of the RF power transistor can be adjusted by varying the gate voltage of the RF power transistor, thereby achieving output power control. However, the fabrication cost is very high.
(5) The gate-voltage control method will be described as follows, with reference to FIG. 1.
In the case of the gate-voltage control method, the RF power amplifier comprises an input-stage amplifier, an intermediate-stage (or driving-stage) amplifier, and a power-stage amplifier. The above three amplifiers are serially connected. The above three stage amplifiers consist of RF power transistors Q1, Q2, Q3 with bias circuits respectively. The bias sources Vg1, Vg2, Vg3 are used to bias the gates of the power transistors Q1, Q2, and Q3 to adjust the operating point of the power transistors Q1, Q2, and Q3 respectively. General speaking, the input-stage amplifier functions in class A or Class AB mode by adjusting the operating point of the RF power transistor Q1. The input-stage amplifier is used to first amplify the input signal RF in . The power-stage amplifier always functions in Class AB mode by adjusting the operating point of the RF power transistor Q3. By varying the gate biases of the transistors Q1, Q2, and Q3, the amplification ratios of the three amplifier stages can be adjusted, and therefore the RF power amplifier can amplify the input signal RF in to the expected power level.
The gate-voltage control method is simple, but there are still some drawbacks. Because the gate voltage Vgs of the RF power transistor only has a narrow voltage control range, a wide range of gain control and precise output power control are very difficult to achieve. Furthermore, the power-stage amplifier functions in class AB mode, and thus it is always in the turned-on state. Consequently, a great deal of power is dissipated by the power-stage amplifier. Furthermore, because the power-stage amplifier is always in the turned-on state, the noise generated between every amplifier stage is amplified and output.
SUMMARY OF THE INVENTION
In view of the above problems, the present invention provides a RF power amplifier with high efficiency and a wide gain control range. According to the present invention, the power transistor of the power-stage amplifier in the RF power amplifier is well biased, such that the power-stage amplifier can function in class C mode. Further, by varying the gate voltage of the power transistor in the driving-stage amplifier, the driving-stage amplifier can output a control signal with a wide range of variation. Through using the control signal, the Class C power-stage amplifier can be driven directly, such that the RF power amplifier can achieve high efficiency, a wide gain control range, high stability, a highly linear fine-increment level of control, and low power dissipation.
In order to achieve the above objects, a RF power amplifier with high efficiency and a wide range of gain control is disclosed. The RF power amplifier according to the present invention comprises the devices described as follows.
(1) A first-stage amplifier comprises a first power transistor, a first bias circuit, and a first bias source. The drain and source of the first power transistor are coupled to a voltage source node and a ground reference node respectively. The first bias source with a fixed voltage level is fed to the gate of the first power transistor via said first bias circuit, thereby allowing said first-stage amplifier to function as a class A or a class AB amplifier. An input signal coupled to the gate of said first power transistor is amplified and then output at the drain of said first power transistor.
(2) A second-stage amplifier comprises a second power transistor, a second bias circuit, and a second bias source. The drain and source of the second power transistor are coupled to the voltage source node and the ground reference node respectively. The second bias source is fed to the gate of the second power transistor via the second bias circuit. Therefore, the turn-on drain current of the second power transistor can be adjusted by varying the voltage of the second bias source to achieve output power control. Further, the output signal of the first-stage amplifier coupled to the gate of the second-stage power transistor is amplified by the second-stage amplifier and then output at the drain of the second power transistor.
(3) A third-stage amplifier comprises a third power transistor, a third bias circuit, and a third bias source. The drain and source of the third power transistor are coupled to a voltage source node and a ground reference node respectively. The third bias source with a fixed voltage level is fed to the gate of the third power transistor via the third bias circuit, thereby allowing the third-stage amplifier to function as a class C amplifier. Further, the output signal of the second-stage amplifier coupled to the gate of the third-stage power transistor is amplified by said third-stage amplifier and then output at the drain of the third power transistor.
Furthermore, the second-stage amplifier further comprises a level control circuit which is coupled to the gate of the second power transistor, such that the turn-on drain current of said second power transistor can be finely adjusted.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features and advantages of the present invention will become apparent by way of the following detailed description of the preferred but non-limiting embodiments. Description is made with reference to the accompanying drawings.
FIG. 1 schematically depicts a circuit diagram of a conventional RF power amplifier using the gate-voltage control method.
FIG. 2 schematically depicts a circuit diagram of a preferred embodiment of a RF power amplifier according to the present invention.
FIG. 3A depicts the relationship of output power P out (dBm) and the efficiency E(%) of the RF power amplifier with respect to variation of the second bias source Vg2, at 900 MHz.
FIG. 3B depicts the relationship of the total dissipated current I d (mA) with respect to variation of the second bias source Vg2, at 900 MHz.
FIG. 4A depicts the relationship of the output power P out (dBm) and the efficiency E(%) of the RF power amplifier with respect to variation of the second bias source Vg2, at 915 MHz.
FIG. 4B depicts the relation of the total dissipated current I d (mA) with respect to variation of the second bias source Vg2, at 915 MHz.
FIG. 5A depicts the relations of the output power P out (dBm) and the efficiency E(%) of the RF power amplifier with respect to variation of the second bias source Vg2, at 930 MHz.
FIG. 5B depicts the relation of the total dissipated current I d (mA) with respect to variation of the second bias source Vg2, at 930 MHz.
DETAILED DESCRIPTION OF THE INVENTION
Preferred Embodiment
FIG. 2 schematically depicts a circuit diagram of a preferred embodiment of a RF power amplifier according to the present invention. The RF power amplifier according to the present invention consists of a first-stage amplifier I, a second-stage amplifier II, and a third-stage amplifier III, which will be detailed described hereinafter, with reference to FIG. 2.
(1) The first-stage amplifier I comprises a first power transistor Q1, a first bias circuit B1, and a first bias source Vg1. The first power transistor Q1 can be a field-effect transistor (JFET or MOSFET), and in this embodiment, an n-channel JFET is applied. Through a conducting path, the drain and source of the first power transistor are coupled to a voltage source node V DD and a ground reference node respectively. The first bias source Vg1 with a fixed voltage level is fed to the gate of the first power transistor Q1 via the first bias circuit B1. In this embodiment, the voltage level of the bias source Vg1 is about -0.55 V. The gate of the operating point of the JFET Q1 is biased by Vg1 (-0.55 V), such that the first-stage amplifier functions as a class A or a class AB amplifier. An input signal RF in coupled to the gate of said first power transistor (JFET) Q1 is amplified and then output at the drain of said first power transistor (JFET) Q1.
(2) The second-stage amplifier II comprises a second power transistor Q2, a second bias circuit B2, and a second bias source Vg2. The second power transistor Q2 also can be a field-effect transistor (JFET or MOSFET), and in this embodiment, an n-channel JFET is applied, for example. For the same way, through a conducting path, the drain and source of the second power transistor Q2 are coupled to the voltage source node V DD and a ground reference node respectively. The second bias source Vg2 is fed to the gate of the second power transistor Q2 via the second bias circuit B2. Therefore, the turn-on drain current of the second power transistor Q2 can be adjusted by varying the voltage level of the second bias source Vg2 to change the amplification ratio of the second-stage amplifier, thus achieving output power control. Further, the output signal of the first-stage amplifier I coupled to the gate of the second-stage power transistor Q2 is amplified by the second-stage amplifier II and then output at the drain of the second power transistor Q2.
In the second-stage amplifier II, a level control circuit (LVC hereinafter) is further comprised. The LVC receives an input voltage of between 3V and 0V, and emits output voltage of between 0V˜-2V coupled to the second bias source Vg2. By using the LVC to finely vary the voltage at gate of the second power transistor Q2, the turn-on drain current of the second power transistor can also be finely adjusted, thus achieving a fine increment of adjustment over the output power.
(3) The third-stage amplifier III comprises a third power transistor Q3, a third bias circuit B3, and a third bias source Vg3. The third power transistor Q3 can also be a field-effect transistor (JFET or MOSFET), and in this embodiment, an n-channel JFET is applied. Through a conducting path, the drain and source of the third power transistor are coupled to the voltage source node V DD and the ground reference node respectively. The third bias source Vg3 with a fixed voltage level is fed to the gate of the third power transistor Q3 via the third bias circuit B3. In this embodiment, the voltage level of the bias source Vg3 is about -1.8V. The gate of the operating point of the JFET Q1 is biased by Vg3 (-1.8 V), such that the third-stage amplifier III functions as a class C amplifier. Therefore, when the third-stage amplifier III is only biased by the third source Vg3 (DC source), it is in the "OFF" state. When the third-stage amplifier III receives the output signals from the second-stage amplifier II, the third-stage amplifier III will be activated and amplifies and outputs a RF signal at the drain of the third power transistor Q3. Consequently, the power dissipated by the third-stage amplifier can be reduced, and the output noise can be reduced.
If the power of the input signal RF in is set at -3 dBm, the first and third bias source Vg1 and Vg3 are set at -0.55V and -1.8V respectively, and the voltage source V DD is 3.3V, the experiment results of the embodiment are obtained. FIG. 3A, FIG. 4A, and FIG. 5A depict the relationship of output power P out (dBm) and the efficiency E(%) of the RF power amplifier with respect to the variations of the second bias source Vg2, at 900 MHz, 915 MHz, and 930 MHz respectively. FIG. 3B, FIG. 4B, and FIG. 5B depict the relation of the total dissipated current I d (mA) with respect to the variations of the second bias source Vg2, at 900 MHz, 915 MHz, and 930 MHz respectively.
As depicted in FIG. 3A, FIG. 4A, and FIG. 5A, the output power of the RF power amplifier can be widely varied from +25 dBm to -25 dBm. The output power P out (dBm) in response to the second bias source Vg2 has high linearity and efficiency E(%). Consequently, in the RF power amplifier according to the present invention, the second-stage (driving-stage) amplifier can output a signal with wide range variation and high power by varying the bias source Vg2. The third-stage (power-stage) amplifier, which works in class C mode, is directly driven by the output signal from the second-stage. Therefore, high efficiency, a wide range of gain control, and fine increment of power-control with high linearity can be achieved.
As depicted in FIG. 3B, FIG. 4B, and FIG. 5B, when the output power is 0 dBm (that is 1 mW), for example, the total dissipated current is less than 25 mA. Furthermore, the third-stage (power-stage) amplifier works as a class C amplifier, which is always in the "OFF" state when no input signal is received. Compared with the conventional power stage (in class AB mode), the third-stage amplifier is not always in a conducting state and will not dissipate power in standby mode, thus noise will not be amplified when there is no RF signal input.
Furthermore, the bias sources Vg1 and Vg3 are of fixed level and the bias source Vg2 is variable to control the power output. In the prior art, the bias sources are all variable, such that variation of the bias sources influence the impedance match between the amplifier stages, and therefore the RF power amplifier may oscillate and become unstable. To avoid the problems of the prior art, the circuit design must be more complicated and costly.
According to the present invention, however, only the second bias source Vg2 is variable, so impedance matching and circuit design are easier, and the RF power amplifier is more stable and less costly.
While the invention has been described in terms of what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention need not be limited to the disclosed embodiments. On the contrary, it is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims, the scope of which should be accorded the broadest interpretation so as to encompass all such modifications and similar structures.
|
A RF power amplifier with the advantages of high output efficiency and a wide range of gain control is disclosed. By appropriately biasing the power transistor of the power-stage amplifier in the RF power amplifier, the power-stage amplifier functions as a class C amplifier. By varying the bias source of the driving-stage amplifier and keeping the bias sources of the input-stage and power-stage amplifiers at a fixed level, the driving-stage can output a driving signal with a wide range of variable gain. Consequently, the driving signal can be used to drive the power-stage amplifier to obtain highly efficient output and of a wide range of output power gain control.
| 7
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a U.S. national stage of International Application No. PCT/JP2011/065146, filed on Jul. 1, 2011. Priority under 35 U.S.C. §119(a) and 35 U.S.C. §365(b) is claimed from Japanese Application No. 2010-152606, filed Jul. 5, 2010, the disclosure of which is also incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention relates to a medium feeding direction switching mechanism by which a feeding direction of a carried information recording medium is switched and relates to a medium issuing and collecting device which is provided with the medium feeding direction switching mechanism.
BACKGROUND
[0003] Conventionally, a card issuing device in which a card accommodated in a card stacker is issued has been known (see, for example, Patent Literature 1). The card issuing device described in Patent Literature 1 includes a first feed roller and a second feed roller for carrying a card. The first feed roller and the second feed roller are disposed with a predetermined distance in a feeding direction of a card. Further, the card issuing device includes a first counter roller which is oppositely disposed to the first feed roller and a second counter roller which is oppositely disposed to the second feed roller. The first counter roller and the second counter roller are rotatably supported by fixed shafts which are fixed to a plate. Further, a motor is connected with the plate through a gear train and the plate is capable of turning over a predetermined angle with a rotation center of the second feed roller as a turning center.
[0004] In the card issuing device described in Patent Literature 1, when the first and the second feed rollers are rotated in a forward direction in a state that the first feed roller and the first counter roller abut each other and the second feed roller and the second counter roller abut each other, a card is issued from a card stacker. Further, the card issuing device is provided with a function for collecting a card and, when a card is to be collected, the plate is turned in a state that a card is sandwiched between the first feed roller and the first counter roller and between the second feed roller and the second counter roller. When the plate is turned, the second counter roller is moved along the surface of the second feed roller and the first counter roller is separated from the first feed roller. Further, in this state, when the first and the second feed rollers are rotated in a reverse direction, a card sandwiched between the second feed roller and the second counter roller is collected to a lower side portion of the card issuing device. As described above, in the card issuing device described in Patent Literature 1, a feeding direction of a carried card is switched by turning the plate.
[0005] [PTL 1] Japanese Patent No. 4186033
[0006] However, in the card issuing device described in Patent Literature 1, a feeding direction of a carried card is switched by turning the plate and thus a gear train and a motor for turning the plate are required. In other words, in the card issuing device described in Patent Literature 1, a structure for switching a feeding direction of a carried card is complicated.
SUMMARY
[0007] In view of the problem described above, at least an embodiment of the present invention provides a medium feeding direction switching mechanism which is capable of switching a feeding direction of a carried information recording medium with a simple structure. Further, at least an embodiment of the present invention provides a medium issuing and collecting device which is provided with the medium feeding direction switching mechanism.
[0008] In order to solve the above problem, at least an embodiment of the present invention provides a medium feeding direction switching mechanism for switching a feeding direction of a carried information recording medium including a feed roller which is structured to abut with an information recording medium for carrying the information recording medium, a pinch roller which is oppositely disposed to the feed roller for sandwiching and carrying the information recording medium together with the feed roller, an urging member which urges the pinch roller toward the feed roller, a bearing which rotatably supports a rotation shaft rotating together with the pinch roller or a support shaft which rotatably supports the pinch roller, a first holding member which holds the urging member, and a second holding member which holds the support shaft or the bearing so that the pinch roller is capable of turning with a rotation center of the feed roller as a turning center between a first facing position where the pinch roller and the feed roller are facing each other in a predetermined first direction and a second facing position where the pinch roller and the feed roller are each other in a predetermined second direction that is inclined with respect to the first direction. One end of the urging member is engaged with the support shaft or the bearing and the other end of the urging member is engaged with the first holding member and, when the feed roller is rotated in a forward direction, the pinch roller located at the second facing position is moved to the first facing position and, when the feed roller is rotated in a reverse direction, the pinch roller located at the first facing position is moved to the second facing position.
[0009] The medium feeding direction switching mechanism in accordance with at least an embodiment of the present invention includes the feed roller, the pinch roller, and the urging member which urges the pinch roller toward the feed roller. Further, in at least an embodiment of the present invention, the pinch roller is capable of turning between the first facing position and the second facing position with the rotation center of the feed roller as a turning center. In addition, in at least an embodiment of the present invention, when the feed roller is rotated in the forward direction, the pinch roller located at the second facing position is moved to the first facing position and, when the feed roller is rotated in the reverse direction, the pinch roller located at the first facing position is moved to the second facing position.
[0010] In other words, in at least an embodiment of the present invention, when the feed roller is rotated in the reverse direction, the pinch roller located at the first facing position is moved to the second facing position by appropriately setting the friction coefficients of the feed roller, the pinch roller and the information recording medium, the urging force of the urging member and the like. Further, in at least an embodiment of the present invention, when the feed roller is rotated in the forward direction, the pinch roller located at the second facing position is moved to the first facing position by appropriately setting the friction coefficients of the feed roller, the pinch roller and the information recording medium, the urging force of the urging member and the like. Further, in at least an embodiment of the present invention, the second direction is inclined with respect to the first direction and thus, when the pinch roller is moved between the first facing position and the second facing position, a feeding direction of the information recording medium carried by the feed roller and the pinch roller is switched. Therefore, in the medium feeding direction switching mechanism according to at least an embodiment of the present invention, a feeding direction of the carried information recording medium can be switched with a simple structure with the use of the urging member.
[0011] In at least an embodiment of the present invention, it is preferable that a third facing position where the pinch roller and the feed roller are each other so that a rotation center of the feed roller, one end of the urging member and the other end of the urging member are disposed in a substantially straight line is located between the first facing position and the second facing position. According to this structure, the pinch roller can be held at the first facing position and the second facing position by the urging force of the urging member and the pinch roller is stably held at the first facing position and the second facing position. According to this structure, in a case that the friction coefficients of the feed roller, the pinch roller and the information recording medium, the urging force of the urging member and the like are appropriately set, when the feed roller is rotated in the reverse direction, the pinch roller is moved from the first facing position to the third facing position by a frictional force between the feed roller and the information recording medium, a frictional force between the pinch roller and the information recording medium and the like, or by a frictional force between the feed roller and the pinch roller and the like and, when the pinch roller has passed the third facing position, the pinch roller is moved to the second facing position mainly by the urging force of the urging member. Further, in a case that the friction coefficients of the feed roller, the pinch roller and the information recording medium, the urging force of the urging member and the like are appropriately set, when the feed roller is rotated in the forward direction, the pinch roller is moved from the second facing position to the third facing position by a frictional force between the feed roller and the information recording medium, a frictional force between the pinch roller and the information recording medium and the like, or by a frictional force between the feed roller and the pinch roller and the like and, when the pinch roller has passed the third facing position, the pinch roller is moved to the first facing position mainly by the urging force of the urging member.
[0012] In at least an embodiment of the present invention, it is preferable that the third facing position is located at a substantially middle position between the first facing position and the second facing position. According to this structure, in comparison with a case that the third facing position is displaced to the first facing position side or to the second facing position side, the friction coefficients of the feed roller, the pinch roller and the information recording medium, the urging force of the urging member and the like for moving the pinch roller from the first facing position to the third facing position, and the friction coefficients of the feed roller, the pinch roller and the information recording medium, the urging force of the urging member and the like for moving the pinch roller from the second facing position to the third facing position are easily set. Therefore, the pinch roller is easily moved between the first facing position and the second facing position.
[0013] In at least an embodiment of the present invention, for example, the second holding member is formed with a guide part for guiding the support shaft or the bearing so that the pinch roller is capable of turning with the rotation center of the feed roller as the turning center between the first facing position and the second facing position, and the first holding member is fixed to the second holding member or the first holding member is integrally formed with the second holding member. Further, in this case, it is preferable that the guide part is formed on both end sides of the support shaft or the rotation shaft. According to this structure, the support shaft or the bearing is appropriately guided between the first facing position and the second facing position by the guide part.
[0014] In at least an embodiment of the present invention, it is preferable that the medium feeding direction switching mechanism includes a sorting member which is capable of abutting with an end part in a feeding direction of the information recording medium sandwiched between the feed roller and the pinch roller when the feed roller is rotated in a reverse direction and the sorting member guides the information recording medium so that the pinch roller is moved to the second facing position. According to this structure, the pinch roller is easily moved from the first facing position to the second facing position by utilizing the sorting member.
[0015] In at least an embodiment of the present invention, the sorting member is, for example, capable of turning between a position at which the sorting member closes a first feeding path that is a feeding path for the information recording medium when the feed roller is rotated in the forward direction and a position at which the sorting member opens the first feeding path, and the sorting member is urged in a direction for closing the first feeding path and, when the feed roller is rotated in the forward direction, the information recording medium abuts the sorting member and the sorting member opens the first feeding path.
[0016] In at least an embodiment of the present invention, it is preferable that the medium feeding direction switching mechanism includes a feeding guide which structures a medium feeding passage where the information recording medium is carried. The feeding guide is formed with an escape part for preventing the information recording medium from abutting with the feeding guide when the pinch roller is moved between the first facing position and the second facing position in a state that the information recording medium is sandwiched between the feed roller and the pinch roller. According to this structure, even when the pinch roller is moved between the first facing position and the second facing position in a state that an information recording medium is sandwiched between the feed roller and the pinch roller, the pinch roller is easily moved between the first facing position and the second facing position.
[0017] The medium feeding direction switching mechanism in accordance with at least an embodiment of the present invention may be utilized in a medium issuing and collecting device which includes a medium accommodating part in which an information recording medium for being sent out toward the medium feeding direction switching mechanism is accommodated and a medium collecting part in which the information recording medium is to be collected. In the medium issuing and collecting device, when the feed roller is rotated in a forward direction, the information recording medium which is sent out from the medium accommodating part is issued and, when the feed roller is rotated in a reverse direction, the information recording medium is collected in the medium collecting part. In this case, the medium issuing and collecting device is, for example, provided with a recording and reproducing part in which recording of information is performed to the information recording medium that is sent out from the medium accommodating part and reproduction of information recorded in the information recording medium is performed. The feed roller is rotated in the forward direction or the reverse direction based on a reproduction result in the recording and reproducing part. In the medium issuing and collecting device, since a structure of the medium feeding direction switching mechanism is simplified, a structure of the medium issuing and collecting device is simplified. Therefore, the size of the medium issuing and collecting device can be reduced.
[0018] As described above, in the medium feeding direction switching mechanism in accordance with at least an embodiment of the present invention, a feeding direction of a carried information recording medium is switched with a simple structure. Further, in the medium issuing and collecting device in accordance with at least an embodiment of the present invention, since a structure of the medium feeding direction switching mechanism is simplified, a structure of the device is simplified and the size of the device is reduced.
BRIEF DESCRIPTION OF DRAWINGS
[0019] Embodiments will now be described, by way of example only, with reference to the accompanying drawings which are meant to be exemplary, not limiting, and wherein like elements are numbered alike in several Figures, in which:
[0020] FIG. 1 is a perspective view showing a medium issuing and collecting device in accordance with an embodiment of the present invention.
[0021] FIG. 2 is an explanatory side view showing a schematic structure of a part of the medium issuing and collecting device shown in FIG. 1 .
[0022] FIG. 3 is an explanatory perspective view showing a structure of a medium feeding direction switching mechanism shown in FIG. 2 .
[0023] FIG. 4 is an enlarged view showing an “E” part in FIG. 1 .
[0024] FIG. 5 is an enlarged view showing an “F” part in FIG. 2 .
[0025] FIG. 6 is an enlarged view showing a “G” part in FIG. 5 .
[0026] FIG. 7 is an explanatory view showing an urging member in accordance with another embodiment of the present invention.
[0027] FIG. 8 is an explanatory view showing an urging member in accordance with another embodiment of the present invention.
DESCRIPTION OF EMBODIMENTS
[0028] Embodiments of the present invention will be described below with reference to the accompanying drawings.
Schematic Structure of Medium Issuing and Collecting Device
[0029] FIG. 1 is a perspective view showing a medium issuing and collecting device 1 in accordance with an embodiment of the present invention. FIG. 2 is an explanatory side view showing a schematic structure of a part of the medium issuing and collecting device 1 shown in FIG. 1 .
[0030] The medium issuing and collecting device 1 in this embodiment is provided with a card issuing function for issuing a card 2 , which is an information recording medium, and a card collecting function for collecting a card 2 . In this embodiment, an issued card 2 is ejected to an “X1” direction side in FIGS. 1 and 2 . In the following descriptions, the “X1” direction side in FIG. 1 is set to be a “front” side in the medium issuing and collecting device 1 and an “X2” direction side which is an opposite side to the “X1” direction side is set to be a “rear” side in the medium issuing and collecting device 1 .
[0031] As shown in FIGS. 1 and 2 , the medium issuing and collecting device 1 includes a recording and reproducing part 3 which performs recording of information to a card 2 and reproduction of recorded information from a card 2 , a card sending-out part 4 which sends out a card 2 toward the recording and reproducing part 3 , a card collecting part 5 as a medium collecting part which collects a card 2 , and a feeding direction switching mechanism 6 as a medium feeding direction switching mechanism in which a feeding direction of a card 2 when the card 2 is to be issued and a feeding direction of a card 2 when the card 2 is to be collected are switched.
[0032] The recording and reproducing part 3 , the card collecting part 5 and the feeding direction switching mechanism 6 are disposed on the front side of the medium issuing and collecting device 1 and the card sending-out part 4 is disposed on the rear side of the medium issuing and collecting device 1 . A card feeding passage 7 as a medium feeding passage where a card 2 is carried is formed in an inside of a front side portion of the medium issuing and collecting device 1 .
[0033] The card 2 is, for example, a rectangular card made of vinyl chloride whose thickness is about 0.7-0.8 mm. The card 2 in this embodiment is a non-contact type IC card and the card 2 is incorporated with an antenna for communication. A magnetic stripe may be formed on the surface of the card 2 or an IC chip may be fixed to the card 2 . Further, the card 2 may be a PET (polyethylene terephthalate) card whose thickness is about 0.18-0.36 mm or a paper card having a predetermined thickness.
[0034] The recording and reproducing part 3 includes an antenna 9 for communication and a control circuit board 10 . The antenna 9 and the control circuit board 10 are fixed to the frame 11 which structures a front side portion of the medium issuing and collecting device 1 . The card collecting part 5 is a collecting container for collecting a card 2 and a part on the lower end side of the frame 11 is structured as the card collecting part 5 . A space is formed in an inside of the card collecting part 5 and collected cards 2 are stacked and accommodated in this space. The card feeding passage 7 is formed in the inside of the frame 11 . The frame 11 in this embodiment is a feeding guide which structures the card feeding passage 7 .
[0035] The card sending-out part 4 includes a card accommodating part 12 as a medium accommodating part in which a plurality of cards 2 before issued is stacked and accommodated in an upper and lower direction, a sending-out roller 13 for sending out a card accommodated at the lowest position among a plurality of the cards 2 accommodated in the card accommodating part 12 to a front face side of the card sending-out part 4 , a sending-out roller 14 for further sending out the card 2 which is sent out by the sending-out roller 13 to the front side of the medium issuing and collecting device 1 , a pad roller 15 which is oppositely disposed to the sending-out roller 14 and is urged toward the sending-out roller 14 , and card separating rollers 16 and 17 for preventing two cards 2 from being sent out in a stacked state from the card accommodating part 12 .
[0036] The card accommodating part 12 is formed in a rectangular box-like shape whose a part of a side face and upper face are opened. A gate through which a card 2 accommodated in the card accommodating part 12 is passed toward the front side is formed between a bottom face part 12 a of the card accommodating part 12 and a lower end of its front side wall part 12 b. The sending-out roller 13 is an eccentric roller and an upper end side of the sending-out roller 13 is disposed in an inside of a through hole which is formed in the bottom face part 12 a. The sending-out roller 13 is connected with a motor not shown. The sending-out roller 14 is connected with a motor not shown. The pad roller 15 is disposed so as to face an upper end of the sending-out roller 14 .
[0037] The card separating rollers 16 and 17 are disposed between the sending-out roller 14 and the pad roller 15 and the card accommodating part 12 . Further, the card separating rollers 16 and 17 are disposed so as to be each other in the upper and lower direction. In this embodiment, the card separating roller 16 is disposed on a lower side and the card separating roller 17 is disposed on an upper side. When a card 2 is to be sent out from the card accommodating part 12 , the card separating roller 16 is rotated in a direction for feeding the card 2 to the front side (in other words, in a clockwise direction in FIG. 2 ) and the card separating roller 17 is rotated in a direction for feeding the card 2 to the rear side (in other words, in the clockwise direction in FIG. 2 ). As described above, the card separating rollers 16 and 17 which are oppositely disposed to each other in the upper and lower direction are rotated in the same direction as each other and thus, when two cards 2 are sent out in a stacked state from the card accommodating part 12 , a card 2 on an upper side is returned to the inside of the card accommodating part 12 .
Structure of Medium Feeding Direction Switching Mechanism
[0038] FIG. 3 is an explanatory perspective view showing a structure of the medium feeding direction switching mechanism 6 shown in FIG. 2 . FIG. 4 is an enlarged view showing an “E” part in FIG. 1 . FIG. 5 is an enlarged view showing an “F” part in FIG. 2 . FIG. 6 is an enlarged view showing a “G” part in FIG. 5 .
[0039] The feeding direction switching mechanism 6 includes a feed roller 20 that abuts a card 2 for carrying the card 2 , a pinch roller 21 which is oppositely disposed to the feed roller 20 , two torsion coil springs 22 as an urging member for urging the pinch roller 21 toward the feed roller 20 , and a flapper 23 as a sorting member by which a card 2 is guided to the card accommodating part 12 when the feed roller 20 is rotated in a direction so that the card 2 is carried to the rear side.
[0040] The feed roller 20 is disposed on the front side with respect to the recording and reproducing part 3 in the front and rear direction. As shown in FIG. 3 , a rotation shaft 24 to which the feed roller 20 is fixed is fixed with one gear structuring a gear train 25 and the feed roller 20 is connected with a motor 26 through the gear train 25 . A distance between the feed roller 20 and the sending-out roller 14 in the front and rear direction is set to be shorter than a length in the front and rear direction of a card 2 in the medium issuing and collecting device 1 .
[0041] The pinch roller 21 is urged toward the feed roller 20 from a roughly upper side by an urging force of the torsion coil spring 22 and a card 2 is sandwiched between the feed roller 20 and the pinch roller 21 and is carried by the feed roller 20 and the pinch roller 21 . Further, the pinch roller 21 is rotatably supported by a support shaft 27 .
[0042] Both end sides of the support shaft 27 are held by the frame 11 . The frame 11 is formed with a guide groove 11 a as a guide part into which the support shaft 27 is inserted as shown in FIG. 4 . The guide groove 11 a is formed at two positions and each of both end sides of the support shaft 27 is inserted into the guide groove 11 a. The frame 11 in this embodiment is a second holding member which holds the support shaft 27 .
[0043] A position of the pinch roller 21 is set to be a first facing position “P 1 ” where the pinch roller 21 and the feed roller 20 are each other in the upper and lower direction as shown by the solid line in FIGS. 5 and 6 . Further, a position of the pinch roller 21 is set to be a second facing position “P 2 ” where the pinch roller 21 and the feed roller 20 are each other in an inclined state by an angle “θ” in a counterclockwise direction in FIGS. 5 and 6 with respect to the upper and lower direction (in other words, in a direction which is inclined by an angle “θ” to the rear side) as shown by the two-dot chain line in FIGS. 5 and 6 . In this case, the guide groove 11 a performs a function for guiding the support shaft 27 so that the pinch roller 21 is capable of being turned between the first facing position “P 1 ” and the second facing position “P 2 ” with the rotation center “C 1 ” of the feed roller 20 as a turning center. The guide groove 11 a is formed in a roughly rectangular shape or a roughly circular arc shape whose center is the rotation center “C 1 ” of the feed roller 20 . The angle “θ” is an acute angle. Further, the angle “θ” is a relatively small angle and, for example, in a range from about 15° to about 20°.
[0044] One end of the torsion coil spring 22 (specifically, a tip end of one arm of the torsion coil spring 22 ) is formed as an engagement part 22 a which is formed in a ring shape. Further, the other end of the torsion coil spring 22 (specifically, a tip end of the other arm of the torsion coil spring 22 ) is formed as an engagement part 22 b which is formed in a ring shape. In this embodiment, each of the both end sides of the support shaft 27 is inserted into the engagement part 22 a and each of the engagement parts 22 a is engaged with each of the both end sides of the support shaft 27 . In other words, in this embodiment, the torsion coil spring 22 is disposed on each of the both end sides of the support shaft 27 . A fixed shaft 28 which is fixed to the frame 11 is inserted into the engagement part 22 b and the engagement part 22 b is engaged with the fixed shaft 28 . The engagement part 22 a is relatively turnable with respect to the support shaft 27 and the engagement part 22 b is relatively turnable with respect to the fixed shaft 28 . The fixed shaft 28 in this embodiment is a first holding member which holds the torsion coil spring 22 . The fixed shaft 28 may be integrally formed with the frame 11 .
[0045] The fixed shaft 28 is disposed on an upper side with respect to the pinch roller 21 . Further, as shown in FIG. 6 , the fixed shaft 28 is fixed to the frame 11 so that the center “C 2 ” of the support shaft 27 when the pinch roller 21 is located at a substantially middle position between the first facing position “P 1 ” and the second facing position “P 2 ” is disposed on the straight line “L” which is formed by connecting the rotation center “C 1 ” of the feed roller 20 with the center “C 3 ” of the fixed shaft 28 . In other words, a third facing position where the pinch roller 21 and the feed roller 20 are each other is set between the first facing position “P 1 ” and the second facing position “P 2 ” so that the rotation center “C 1 ” of the feed roller 20 , the engagement part 22 a of the torsion coil spring 22 , and its engagement part 22 b are disposed on a substantially straight line. The engagement part 22 b of the torsion coil spring 22 is disposed on the straight line “L” which is inclined by an angle “θ/2” with respect to the upper and lower direction in the counterclockwise direction in FIG. 6 . When the pinch roller 21 is located at the third facing position, the urging force of the torsion coil spring 22 becomes the maximum.
[0046] The flapper 23 is disposed on the front side with respect to the sending-out roller 14 . The flapper 23 is turnably supported by a fixed shaft 29 which is fixed to the frame 11 . Further, the flapper 23 is formed with a closing part 23 a for closing a feeding path “R 1 ” for a card 2 , which is carried to the front side from the card sending-out part 4 , so as to protrude from the fixed shaft 29 in a roughly oblique upper direction. In this embodiment, the flapper 23 is supported by the fixed shaft 29 so that the flapper 23 is turnable between a closing position at which the closing part 23 a closes the feeding path “R 1 ” as shown by the solid line in FIG. 5 and an opened position at which the closing part 23 a opens the feeding path “R 1 ” as shown by the two-dot chain line in FIG. 5 . Further, the flapper 23 is urged in a direction in which the closing part 23 a closes the feeding path “R 1 ” (in other words, in a counterclockwise direction in FIG. 5 ) by an urging member not shown or by its own weight. The feeding path “R 1 ” in this embodiment is a first feeding path.
[0047] In this embodiment, when a card 2 is to be sent out from the card sending-out part 4 , the feed roller 20 is rotated in a clockwise direction in FIG. 5 . Further, when the card 2 is sent out from the card sending-out part 4 , the card 2 abuts an upper face side of the closing part 23 a and, as shown by the two-dot chain line in FIG. 5 , the closing part 23 a is turned to the position where the feeding path “R 1 ” is opened. In other words, when the feed roller 20 is rotated in the clockwise direction in FIG. 5 , the card 2 abuts the upper face side of the closing part 23 a to set the flapper 23 to open the feeding path “R 1 ”.
[0048] Further, in this embodiment, friction coefficients of the feed roller 20 and the pinch roller 21 , an urging force of the torsion coil spring 22 , the angle “θ” and the like are set so that, when the feed roller 20 is rotated in the clockwise direction in FIG. 5 in a state that the pinch roller 21 located at the second facing position “P 2 ” abuts the feed roller 20 , the pinch roller 21 is moved to the first facing position “P 1 ” along an outer peripheral face of the feed roller 20 and, in addition, so that a force by which the pinch roller 21 located at the second facing position “P 2 ” passes through the third facing position, a frictional force between the pinch roller 21 and the support shaft 27 , and a frictional force between the feed roller 20 and the pinch roller 21 become larger in this order.
[0049] In a case that the pinch roller 21 located at the second facing position “P 2 ” is to be moved to the first facing position “P 1 ”, the pinch roller 21 is moved from the second facing position “P 2 ” to the third facing position by the frictional force between the feed roller 20 and the pinch roller 21 and the like and, when the pinch roller 21 has passed the third facing position, the pinch roller 21 is moved to the first facing position “P 1 ” mainly by the urging force of the torsion coil spring 22 . In other words, the pinch roller 21 is moved from the second facing position “P 2 ” to the first facing position “P 1 ” by utilizing a so-called toggle motion in which the third facing position is its toggle point. Further, the pinch roller 21 is hardly rotated with the support shaft 27 as a center during the pinch roller 21 is moved from the second facing position “P 2 ” to the first facing position “P 1 ” and, after moved to the first facing position “P 1 ”, the pinch roller 21 is rotated with the support shaft 27 as a center. Further, when the pinch roller 21 is located at the first facing position “P 1 ”, the pinch roller 21 is held at the first facing position “P 1 ” by the urging force of the torsion coil spring 22 , and the pinch roller 21 and the feed roller 20 are each other in a direction substantially perpendicular to the front and rear direction which is a feeding direction of a card 2 when the card 2 is to be issued (in other words, in the upper and lower direction).
[0050] Further, in this embodiment, the friction coefficients of the feed roller 20 and the pinch roller 21 , the urging force of the torsion coil spring 22 , the angle “θ” and the like are set so that, when the feed roller 20 is rotated in a counterclockwise direction in FIG. 5 in a state that a card 2 whose rear end of the card 2 is disposed on the front side with respect to the closing part 23 a is sandwiched between the pinch roller 21 located at the first facing position “P 1 ” and the feed roller 20 , the pinch roller 21 is moved to the second facing position “P 2 ” along the outer peripheral face of the feed roller 20 and, so that a force by which the pinch roller 21 located at the first facing position “P 1 ” passes through the third facing position, the frictional force between the pinch roller 21 and the support shaft 27 , and the frictional force between the feed roller 20 and the pinch roller 21 become larger in this order.
[0051] When the pinch roller 21 located at the first facing position “P 1 ” is to be moved to the second facing position “P 2 ”, the pinch roller 21 is moved from the first facing position “P 1 ” to the third facing position by a frictional force between the feed roller 20 and the card 2 and by a frictional force between the pinch roller 21 and the card 2 and, when the pinch roller 21 has passed the third facing position, the pinch roller 21 is moved to the second facing position “P 2 ” mainly by the urging force of the torsion coil spring 22 . In other words, the pinch roller 21 is moved from the first facing position “P 1 ” to the second facing position “P 2 ” by utilizing a so-called toggle motion in which the third facing position is its toggle point. Further, the pinch roller 21 is hardly rotated with the support shaft 27 as a center during the pinch roller 21 is moved from the first facing position “P 1 ” to the second facing position “P 2 ” and, after moved to the second facing position “P 2 ”, the pinch roller 21 is rotated with the support shaft 27 as a center. Further, when the pinch roller 21 is located at the second facing position “P 2 ”, the pinch roller 21 is held at the second facing position “P 2 ” by the urging force of the torsion coil spring 22 , and the pinch roller 21 and the feed roller 20 are each other in a direction substantially perpendicular to the feeding direction of a card 2 when the card 2 is to be collected to the card collecting part 5 .
[0052] Further, when the feed roller 20 is rotated in the counterclockwise direction in FIG. 5 in a state that a card 2 is sandwiched between the pinch roller 21 and the feed roller 20 , a rear end of the card 2 abuts a lower side face of the closing part 23 a which closes the feeding path “R 1 ”. When the rear end of the card 2 abuts the lower side face of the closing part 23 a, a moment in the counterclockwise direction in FIG. 5 is occurred on the front end side of the card 2 by an elastic force of the card 2 with the abutting part of the closing part 23 a with the card 2 as a supporting point. Movement to the second facing position “P 2 ” of the pinch roller 21 sandwiching the card 2 together with the feed roller 20 is assisted by this moment occurred on the front end side of the card 2 . In other words, the flapper 23 in this embodiment performs a function for guiding a card 2 so that the pinch roller 21 is moved to the second facing position “P 2 ”. Further, in this embodiment, the flapper 23 is disposed so that, when the pinch roller 21 is moved to the second facing position “P 2 ”, the rear end side of the card 2 does not abut the lower side face of the closing part 23 a.
[0053] As described above, in this embodiment, when the pinch roller 21 is turned and moved to the first facing position “P 1 ” or the second facing position “P 2 ” with the rotation center “C 1 ” of the feed roller 20 as a center, the feeding direction of a card 2 is switched to an oblique direction which is inclined with respect to the front and rear direction or to the front and rear direction.
[0054] In accordance with an embodiment of the present invention, the friction coefficients of the feed roller 20 and the pinch roller 21 , the urging force of the torsion coil spring 22 , the angle “θ” and the like may be set so that, after the rear end of a card 2 abuts a lower side face of the closing part 23 a, the pinch roller 21 is capable of passing through the third facing position by utilizing a moment occurred on the front end side of the card 2 in the counterclockwise direction in FIG. 5 . In other words, the friction coefficients of the feed roller 20 and the pinch roller 21 , the urging force of the torsion coil spring 22 , the angle “θ” and the like may be set so that, when the feed roller 20 is rotated in the counterclockwise direction in FIG. 5 , although the pinch roller 21 cannot pass through the third facing position only by the frictional force between the feed roller 20 and the card 2 and the frictional force between the pinch roller 21 and the card 2 , the pinch roller 21 is capable of passing through the third facing position when the moment is occurred on the front end side of the card 2 .
[0055] As shown in FIG. 5 , a recessed part 11 b which is recessed toward an upper side is formed on an upper face of the card feeding passage 7 on a front side with respect to the feed roller 20 and the pinch roller 21 . In other words, the frame 11 is formed with the recessed part 11 b. The recessed part 11 b is an escape part for preventing a card 2 from abutting with the frame 11 when the feed roller 20 is rotated in the counterclockwise direction in FIG. 5 in a state that the card 2 is sandwiched between the feed roller 20 and the pinch roller 21 and the pinch roller 21 is moved from the first facing position “P 1 ” to the second facing position “P 2 ”.
Schematic Operation of Medium Issuing and Collecting Device
[0056] A schematic operation for issuing and collecting a card 2 in the medium issuing and collecting device 1 structured as described above will be described below. In the following descriptions, rotation of the feed roller 20 in the clockwise direction in FIG. 5 is referred to as a forward rotation and rotation of the feed roller 20 in the counterclockwise direction in FIG. 5 is referred to as a reverse rotation.
[0057] In the medium issuing and collecting device 1 , when a card 2 accommodated in the card accommodating part 12 is to be issued, first, a card 2 is sent out from the card sending-out part 4 toward the recording and reproducing part 3 and the feeding direction switching mechanism 6 by the sending-out rollers 13 and 14 and the pad roller 15 . The card 2 having been sent out is temporarily stopped on a lower side of the recording and reproducing part 3 . In this case, a front end side of the card 2 is sandwiched between the feed roller 20 and the pinch roller 21 and a rear end side of the card 2 is sandwiched between the sending-out roller 14 and the pad roller 15 .
[0058] In this state, communication is performed between an antenna incorporated into the card 2 and the antenna 9 and predetermined information is recorded in the card 2 . Further, in order to confirm whether appropriate information is recorded in the card 2 or not, communication is performed between the antenna incorporated into the card 2 and the antenna 9 and the information recorded in the card 2 is reproduced. As a result of reproduction of the information, when the recorded information in the card 2 is confirmed to be the information to be recorded, the feed roller 20 is rotated in the forward direction to issue the card 2 .
[0059] On the other hand, when the recorded information in the card 2 cannot be reproduced or, when the recorded information in the card 2 and the information to be recorded are not coincided with each other, the card 2 is collected. Specifically, the feed roller 20 is rotated in the forward direction until the rear end of the card 2 is disposed on the front side with respect to the closing part 23 a and then, the feed roller 20 is rotated in the reverse direction. When the feed roller 20 is rotated in the reverse direction, the pinch roller 21 located at the first facing position “P 1 ” is moved to the second facing position “P 2 ”. In this case, the movement of the pinch roller 21 to the second facing position “P 2 ” is assisted by abutting the rear end of the card 2 with the lower side face of the closing part 23 a.
[0060] Further, when the pinch roller 21 is moved to the second facing position “P 2 ”, the card 2 is carried until the front end of the card 2 is passed through between the feed roller 20 and the pinch roller 21 and, when the front end of the card 2 is passed through between the feed roller 20 and the pinch roller 21 , the card 2 is collected in the card collecting part 5 . When the card 2 is collected in the card collecting part 5 , next card 2 is sent out from the card sending-out part 4 . When the feed roller 20 is rotated in the forward direction for sending out the next card 2 , the pinch roller 21 located at the first facing position “P 1 ” is moved to the second facing position “P 2 ”.
[0061] As described above, in this embodiment, the feed roller 20 is rotated in the forward direction or the reverse direction based on a reproduced result in the recording and reproducing part 3 . In accordance with an embodiment of the present invention, when a user forgets to take the issued card 2 , the feed roller 20 is rotated in the reverse direction and the card 2 is collected in the card collecting part 5 .
Principal Effects in this Embodiment
[0062] As described above, in this embodiment, when the feed roller 20 is rotated in the forward direction, the pinch roller 21 located at the second facing position “P 2 ” is moved to the first facing position “P 1 ” and is held at the first facing position “P 1 ” by the urging force of the torsion coil spring 22 . Further, when the feed roller 20 is rotated in the reverse direction, the pinch roller 21 located at the first facing position “P 1 ” is moved to the second facing position “P 2 ” and is held at the second facing position “P 2 ” by the urging force of the torsion coil spring 22 . Further, in this embodiment, when the pinch roller 21 is moved to the first facing position “P 1 ” or the second facing position “P 2 ”, the feeding direction of a card 2 which is carried by the feed roller 20 and the pinch roller 21 is switched. Therefore, in this embodiment, the feeding direction of a carried card 2 is switched with a simple structure with the use of the torsion coil spring 22 . Further, in this embodiment, the structure of the feeding direction switching mechanism 6 is simplified and thus the structure of the medium issuing and collecting device 1 can be simplified. Therefore, the size of the medium issuing and collecting device 1 can be reduced.
[0063] In this embodiment, the third facing position which is the toggle point is located at a substantially middle position between the first facing position “P 1 ” and the second facing position “P 2 ”. Therefore, in comparison with a case that the third facing position is displaced to the first facing position “P 1 ” side or to the second facing position “P 2 ” side, the friction coefficients of the feed roller 20 and the pinch roller 21 , the urging force of the torsion coil spring 22 and the like are easily set for moving the pinch roller 21 from the first facing position “P 1 ” to the third facing position, and the friction coefficients of the feed roller 20 and the pinch roller 21 , the urging force of the torsion coil spring 22 and the like are easily set for moving the pinch roller 21 from the second facing position “P 2 ” to the third facing position. Therefore, in this embodiment, the pinch roller 21 is easily moved between the first facing position “P 1 ” and the second facing position “P 2 ”.
[0064] In this embodiment, the flapper 23 performs a function for guiding a card 2 so that the pinch roller 21 is moved to the second facing position “P 2 ”. Therefore, the pinch roller 21 is easily moved from the first facing position “P 1 ” to the second facing position “P 2 ” by utilizing the flapper 23 . Further, in this embodiment, the recessed part 11 b is formed in the frame 11 so as to prevent a card 2 from abutting with the frame 11 when the feed roller 20 is rotated in the reverse direction in a state that a card 2 is sandwiched between the feed roller 20 and the pinch roller 21 and the pinch roller 21 is moved from the first facing position “P 1 ” to the second facing position “P 2 ”. Therefore, the pinch roller 21 is easily moved from the first facing position “P 1 ” to the second facing position “P 2 ”.
[0065] In this embodiment, the pinch roller 21 is turned with the rotation center “C 1 ” of the feed roller 20 as a turning center and, when the pinch roller 21 is moved from the first facing position “P 1 ” to the second facing position “P 2 ”, the feeding direction of a card 2 is switched. Further, the flapper 23 is disposed so that, when the pinch roller 21 is moved to the second facing position “P 2 ”, the rear end side of the card 2 does not abut the lower side face of the closing part 23 a. Therefore, when the feeding direction of a card 2 is to be switched and, after the feeding direction of the card 2 is switched, the card 2 sandwiched between the pinch roller 21 and the feed roller 20 is hardly resiliently bent. Accordingly, in this embodiment, damage of an antenna incorporated into a card 2 which is occurred due to a bending stress of the card 2 can be prevented.
[0066] In this embodiment, the guide groove 11 a is formed on both end sides of the support shaft 27 . Further, the torsion coil spring 22 is disposed at each of the both end sides of the support shaft 27 . Therefore, the support shaft 27 can be moved in a well balanced manner between the first facing position “P 1 ” and the second facing position “P 2 ” by the guide grooves 11 a and the torsion coil springs 22 which are disposed on the both end sides of the support shaft 27 and thus the support shaft 27 is easily moved.
Other Embodiments
[0067] Although the present invention has been shown and described with reference to a specific embodiment, various changes and modifications will be apparent to those skilled in the art from the teachings herein.
[0068] In the embodiment described above, the urging member which urges the pinch roller 21 toward the feed roller 20 is a torsion coil spring 22 . However, the present invention is not limited to this embodiment. For example, the urging member which urges the pinch roller 21 toward the feed roller 20 may be a tension coil spring 32 as shown in FIG. 7 . In this case, one end of the tension coil spring 32 is relatively turnably attached to the support shaft 27 and the other end of the tension coil spring 32 is relatively turnably attached to a fixed shaft 33 which is a first holding member that is fixed to the frame 11 on a lower side with respect to the feed roller 20 . Further, the fixed shaft 33 is fixed to the frame 11 so that the center “C 2 ” of the support shaft 27 when the pinch roller 21 is located at a substantially middle position between the first facing position “P 1 ” and the second facing position “P 2 ” is disposed on the straight line “L 1 ” which is formed by connecting the rotation center “C 1 ” of the feed roller 20 with the center “C 13 ” of the fixed shaft 33 .
[0069] Further, the urging member which urges the pinch roller 21 toward the feed roller 20 may be a compression coil spring 42 as shown in FIG. 8 . In this case, one end of the compression coil spring 42 abuts the support shaft 27 and the other end of the compression coil spring 42 is relatively turnably attached to the fixed shaft 43 which is a first holding member fixed to the frame 11 on an upper side with respect to the pinch roller 21 . Further, the fixed shaft 43 is fixed to the frame 11 so that the center “C 2 ” of the support shaft 27 when the pinch roller 21 is located at a substantially middle position between the first facing position “P 1 ” and the second facing position “P 2 ” is disposed on the straight line “L 2 ” which is formed by connecting the rotation center “C 1 ” of the feed roller 20 with the center “C 23 ” of the fixed shaft 43 . When the urging member is a compression coil spring 42 , a guide part is required for preventing buckling of the compression coil spring 42 .
[0070] Further, the urging member which urges the pinch roller 21 toward the feed roller 20 may be another type of spring member or may be an elastic member such as rubber.
[0071] In the embodiment described above, the support shaft 27 which supports the pinch roller 21 is held by the frame 11 . However, the present invention is not limited to this embodiment. For example, the support shaft 27 may be held by a lever member which is capable of turning with the rotation center “C 1 ” of the feed roller 20 as a turning center. In this case, for example, the support shaft 27 is fixed to one end side of the lever member and the other end side of the lever member is turnably held by the rotation shaft 24 . In this case, the pinch roller 21 is easily moved between the first facing position “P 1 ” and the second facing position “P 2 ” by utilizing a frictional force between the rotation shaft 24 and the lever member. Further, in this case, a side face of the lever member and a side face of the feed roller 20 may be contacted with each other in a pressed manner. According to this structure, the pinch roller 21 is further easily moved between the first facing position “P 1 ” and the second facing position “P 2 ” by utilizing the frictional force between the side face of the lever member and the side face of the feed roller 20 .
[0072] Further, in this case, similarly to the embodiment described above, a turning range of the lever member may be restricted by the support shaft 27 inserted into the guide groove 11 a and the guide groove 11 a so that the lever member is turned between the first facing position “P 1 ” and the second facing position “P 2 ”. Alternatively, a stopper member restricting a turning range of the lever member may be provided so that the lever member is turned between the first facing position “P 1 ” and the second facing position “P 2 ”. Further, in this case, the lever member is a second holding member which holds the support shaft 27 .
[0073] In the embodiment described above, the third facing position where the pinch roller 21 and the feed roller 20 are each other is located at a substantially middle position between the first facing position “P 1 ” and the second facing position “P 2 ” so that the rotation center “C 1 ” of the feed roller 20 , the engagement part 22 a and the engagement part 22 b of the torsion coil spring 22 are disposed in a substantially straight line. However, the present invention is not limited to this embodiment. For example, the third facing position may be displaced to the first facing position “P 1 ” side or may be displaced to the second facing position “P 2 ” side.
[0074] Further, the third facing position may be coincided with the first facing position “P 1 ” or may be coincided with the second facing position “P 2 ”. When the third facing position is coincided with the first facing position “P 1 ”, the pinch roller 21 is in an unstable state at the first facing position “P 1 ” and may be easily returned to the second facing position “P 2 ”. Further, in a case that the third facing position is coincided with the second facing position “P 2 ”, the pinch roller 21 is in an unstable state at the second facing position “P 2 ” and may be easily returned to the first facing position “P 1 ”. However, also in these cases, when the friction coefficients of the feed roller 20 and the pinch roller 21 , the urging force of the torsion coil spring 22 , the angle “θ” and the like are appropriately set, similarly to the embodiment described above, the feeding direction of a carried card 2 can be switched with a simple structure with the use of the torsion coil spring 22 .
[0075] In addition, the fixed shaft 28 may be fixed to the frame 11 so that the straight line “L” connecting the rotation center “C 1 ” of the feed roller 20 with the center “C 3 ” of the fixed shaft 28 is disposed on the clockwise direction side in FIG. 6 with respect to the line connecting the center “C 2 ” of the support shaft 27 with the rotation center “C 1 ” of the feed roller 20 when the pinch roller 21 is located at the first facing position “P 1 ”. In this case, the pinch roller 21 is urged to the second facing position “P 2 ” side by the urging force of the torsion coil spring 22 . Further, in this case, when the feed roller 20 is rotated in the forward direction, the pinch roller 21 located at the second facing position “P 2 ” is moved to the first facing position “P 1 ”. Alternatively, the fixed shaft 28 may be fixed to the frame 11 so that the straight line “L” connecting the rotation center “C 1 ” of the feed roller 20 with the center “C 3 ” of the fixed shaft 28 is disposed on the counterclockwise direction side in FIG. 6 with respect to the line connecting the center “C 2 ” of the support shaft 27 with the rotation center “C 1 ” of the feed roller 20 when the pinch roller 21 is located at the second facing position “P 2 ”. In this case, the pinch roller 21 is urged to the first facing position “P 1 ” side by the urging force of the torsion coil spring 22 . Further, in this case, when the feed roller 20 is rotated in the reverse direction, the pinch roller 21 located at the first facing position “P 1 ” is moved to the second facing position “P 2 ”. Also in these cases, when the friction coefficients of the feed roller 20 and the pinch roller 21 , the urging force of the torsion coil spring 22 , the angle “θ” and the like are appropriately set, similarly to the embodiment described above, the feeding direction of a carried card 2 can be switched with a simple structure with the use of the torsion coil spring 22 .
[0076] In the embodiment described above, the feeding direction switching mechanism 6 is provided with the flapper 23 . However, in a case that, when the feed roller 20 is rotated in the reverse direction, the pinch roller 21 is surely moved to the second facing position “P 2 ” so that a card 2 is surely collected in the card collecting part 5 , the feeding direction switching mechanism 6 may be provided with no flapper 23 .
[0077] In the embodiment described above, the pinch roller 21 is rotatably supported by the support shaft 27 . However, the present invention is not limited to this embodiment. For example, the pinch roller 21 may be fixed to a rotation shaft rotating together with the pinch roller 21 or the pinch roller 21 may be integrally formed with a rotation shaft rotating together with the pinch roller 21 . In this case, for example, a bearing which rotatably supports the rotation shaft is held by the frame 11 . Further, in this case, an end of the torsion coil spring 22 is engaged with the bearing and a guide part for guiding the bearing between the first facing position “P 1 ” and the second facing position “P 2 ” is formed in the frame 11 .
[0078] In the embodiment described above, the medium issuing and collecting device 1 collects a card 2 which is sent out from the card sending-out part 4 as needed. However, the present invention is not limited to this embodiment. For example, the medium issuing and collecting device 1 may collect a card 2 which is inserted from the outside as needed. Further, in the embodiment described above, the recording and reproducing part 3 is provided with the antenna 9 for communication. However, the recording and reproducing part 3 may be provided with a magnetic head and/or an IC contact instead of the antenna 9 or in addition to the antenna 9 .
[0079] In the embodiment described above, the medium issuing and collecting device 1 having an issuing function and a collecting function of a card 2 is described as an example of a structure of the feeding direction switching mechanism 6 in accordance with an embodiment of the present invention. However, the feeding direction switching mechanism 6 may be utilized in various devices in which switching of the feeding direction of a card 2 is required.
[0080] While the description above refers to particular embodiments of the present invention, it will be understood that many modifications may be made without departing from the spirit thereof. The accompanying claims are intended to cover such modifications as would fall within the true scope and spirit of the present invention.
[0081] The presently disclosed embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims, rather than the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
|
A medium transport direction switching mechanism may be provided of a simple configuration which is capable of switching the transport direction of a transported information recording medium. One end may be a biasing member for biasing a pinch roller toward a transport roller engages a support shaft which supports the pinch roller, whereas the other end of the biasing member engages a retaining member which retains the support shaft. In the medium transport direction switching mechanism, rotational behavior of the pinch roller centering upon a rotational center of the transport roller is possible between a first facing position and a second facing position, wherein the pinch roller moves to the first facing position when the transport roller rotates positively, and moves to the second facing position when the transport roller rotates negatively.
| 1
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is based on and claims the benefit of U.S. Provisional Application No. 60/703,120, filed Jul. 28, 2005, the entirety of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to implants and instruments for use in orthopaedic surgery. More particularly, this invention relates to a device and method for aligning, orienting and placing an implant into or onto supporting bone, or between adjacent bones without impaction.
[0004] 2. Description of the Related Art
[0005] The field of orthopaedic surgery includes joint arthroplasty, spinal disc replacement, spinal interbody fusion, vertebral compression fracture reduction and realignment osteotomies. Joint arthroplasty includes partial and total replacement of the bony support surfaces of articulating joints, to include knee, hip, shoulder, spinal facet, ankle, toe, finger, wrist and elbow. Spinal disc replacement includes partial and total replacement of the bony support surfaces of vertebral bodies, which are the endplates, and the annulus, the nucleus and combinations thereof. Within the specification reference is made to a spinal motion segment which is the combination of structures providing motion between adjacent vertebral bodies, that is two facet joints and a spinal disc. For the purposes of this specification, the term “Kinematic Restoration” will be used to broadly refer to joint arthroplasty, as defined above, and spinal disc replacement, as defined above, in human and in veterinarian applications.
[0006] In a healthy articulating joint, a smooth and resilient surface consisting of articular cartilage covers the bony structures to provide bone support surfaces. In a healthy spinal disc, vertebral body endplates provide bone support surfaces for the interposed annulus and nucleus. The annulus is attached to adjoining vertebral body endplates. Articulating joints and spinal discs generally consist of two or more relatively rigid bone structures that maintain a kinematic and dynamic relationship one to the other. Soft tissue structures spanning or interposed between the bone structures hold the bone structures together and aid in defining the motion or kinematics of one bone structure to the other.
[0007] The bone support surfaces, as described for articulating joints and for spinal discs, work in combination with the soft tissue structures spanning or interposed between them to form a mechanism that defines the envelop of motion of adjacent bone structures one to the other. Within a typical envelop of motion, the bone structures move in a predetermined pattern with respect to one another. When articulated to the limits of soft tissue constraint, the motion defines a total envelop of motion between the bony structures. Arthritis, degeneration, trauma and other pathologies lead to pain, deformity and compromised motion in articulating joints and in spinal discs.
[0008] Orthopaedic surgery includes Kinematic Restoration procedures as described above which relieve pain, correct deformity and restore motion in pathologic articulating joints and spinal discs. It is typical in such procedures to impact one or more implants into or onto the bone support surfaces or between adjacent bone support surfaces. One or more of the related bone support surfaces are prepared to receive one or more implants, such implants being placed and forcibly impacted therein, thereon or there between such bone support surfaces.
[0009] Spinal interbody fusion involves removal of a pathological nucleus, preparing the endplates to form bone support surfaces and includes placement of one or more implants, either of synthetic material, allograft bone, autograft bone or a combination thereof, between adjacent vertebral bodies to facilitate fusion between the vertebral bodies. Vertebral compression fracture reduction involves creating a cavity in the vertebral body to form bone support surfaces and includes placement of one or more implants, either of
[0010] Suitable synthetic materials for the implants described above include cobalt chromium alloys, titanium and titanium alloys, stainless steel, zirconia, alumina and other ceramic materials, polyethylene, urethanes, PEEK, carbon fiber filled PEEK, calcium based composites, Nitinol, and polymethylmethacrylate.
[0011] Orthopaedic implants for Kinematic Restoration can be secured to bone with cement or grouting material, by bone ingrowth or ongrowth, or by biologic materials. In the case of ingrowth or ongrowth, or biologic fixation, a close and stable fit between implant and supporting bone is required to promote positive bone remodeling. Such a fit has traditionally been attained by press-fitting the implant into, onto or between supporting bone. In the case of placing an implant into supporting bone for bone ingrowth or ongrowth, for example an acetabular cup in total hip replacement, the acetabulum is prepared and a corresponding cup size is selected to provide a line to line fit or a press-fit between the cup and the prepared acetabulum. Alternatively, if an implant is to be fitted over a supporting bone for bone ingrowth or ongrowth, for example the femoral component of a total knee replacement, the distal femur is prepared and a corresponding femoral component size is selected to provide a line to line fit or a press-fit between the femoral component and the prepared femur. The implant is held in position by an impaction device and impacted into place with a mallet. Such impaction is traumatic. Alternatively, if an implant is to be fitted between adjacent bones for bone ingrowth or ongrowth, for example a spinal disc replacement, the involved endplates are prepared and a corresponding disc replacement size is selected to provide proper height and tension of the interbody space. The implant may be held in position by an impaction device and impacted into place with a mallet. Such impaction is traumatic. Alternatively, the interbody space may be overly distracted to place the implant. Such over distraction is traumatic.
[0012] In surgical procedures relying on surgical navigation to aid the surgeon in restoring alignment and in aligning and positioning implants, such impaction may loosen and move navigational trackers introducing error in the surgical navigation of the procedure. In addition, subsequent impactions may alter alignment of the implant relative to supporting bone. Implant alignment is critical for long term function and durability of the implant.
[0013] Similarly, in spinal interbody fusion, vertebral compression fracture reduction and realignment osteotomy procedures a close and stable fit between implant and supporting bone is required to promote positive bone remodeling. Such a fit has traditionally been attained by press-fitting the implant between adjacent bones or into a supporting bone. The implant is held in position by an impaction device and impacted into place with a mallet. Such impaction is traumatic. Alternatively, the receiving site, either between adjacent bones for spinal interbody fusion, or within a bone for vertebral compression fracture reduction or realignment osteotomies, requires over distraction of the receiving site to place the implant. Such over distraction is traumatic.
[0014] There exists a need for a device and method to accurately align and orient an implant with the supporting bone. There also exists a need for a device and method to place an implant into, onto or between supporting bone without impaction or over distraction.
BRIEF SUMMARY OF THE INVENTION
[0015] The present invention provides a system and method for implant placement into or onto a supporting bone, or between adjacent bones, which involves less or minimally invasive surgical procedures. The present invention further provides a system and method to accurately align and orient an implant. Optionally, the present invention further provides an apparatus and method to displace adjacent bones while placing an implant onto or into one or more of the bones, or between the bones. The present invention provides an apparatus for placing an implant within a prepared bone cavity, over a prepared bone surface, or between prepared surfaces of adjacent bones wherein the implant is structured to press-fit into, onto or between the supporting bone or bones to provide initial implant stability, anatomical alignment and appropriate relative position of the supporting bone or bones. The implant having a final seated position relative to supporting bone or bones, when in such position the implant is placed properly in supporting bone or bones and the supporting bone restricts further advancement of the implant. As used herein, the following terms have the following definitions:
[0016] Orienting—For the purposes of the present invention orientating pertains to 1) orientating sub-components of an implant to one another, and 2) orientating implant components of a Kinematic Restoration to one another. In both cases orientating means to bring the parts into working relationship to one another so that the assembly of parts functions as intended.
[0017] Aligning—For the purposes of the present invention aligning pertains to 1) alignment of sub-components of an implant to supporting bone, such supporting bone being properly aligned, and 2) alignment of implant components of a Kinematic Restoration to supporting bone. In both cases aligning means to bring the parts into correct relative position with respect to the supporting bone so that the arthroplasty functions as intended.
[0018] Implant component and sub-component—For the purposes of the present invention an implant component refers to the parts that make up the arthroplasty, for example femoral, tibial and patellar components make up a total knee arthroplasty. Sub-component refers to the parts that make up the implant component. Each component may be unitary in construction, or may include a plurality of sub-components. Reference made to an “implant” refers to one or more of the components, or one or more of the sub-components, or a combination thereof.
[0019] Engagement force—For purposes of the present invention, the term “engagement force” as it relates to the sleeve to implant interface and to the sleeve to bone interface shall be defined as the force tending to slide a surface along another at which relative motion between the surfaces starts. Such engagement force may be provided by a number of mating surface structures to include frictional interference, ridges, grit blast, chemically etched, corrugated or patterned between the surfaces wherein the magnitude of the engagement force may be established by providing an appropriate coefficient of friction between the adjacent surfaces; engagement between adjoining surfaces, such engagement being mechanical interlock, releasable mechanical interlocks, pined interface, releasable pined interface, bonding of the interface, or other suitable means to restrain relative movement between two or more parts. Wherein the restraint has a threshold that when reached the parts move relative to one another, that threshold being the engagement force. The sleeve to implant interface and the sleeve to bone interface are under compression because the sleeve in the present invention is interposed between the implant and supporting bone and the implant is structured to provide a press-fit with supporting bone.
[0020] Joint Arthroplasty—For the purposes of this specification, the term “joint arthroplasty” includes partial and total replacement of the bony support surfaces of articulating joints, to include knee, hip, shoulder, spinal facet, ankle, toe, finger, wrist and elbow.
[0021] Spinal Disc Replacement—For the purposes of this specification, the term “spinal disc replacement” includes partial and total replacement of the bony support surfaces of vertebral bodies, which are the endplates, and the annulus, the nucleus and combinations thereof.
[0022] Spinal Motion Segment—For the purposes of this specification, the term “spinal motion segment” is the combination of structures providing motion between adjacent vertebral bodies, that is two facet joints and a spinal disc.
[0023] Kinematic Restoration—For the purposes of this specification, the term “kinematic restoration” will be used to broadly refer to joint arthroplasty, as defined herein, and spinal disc replacement, as defined above, in human and in veterinarian applications.
[0024] The present invention is comprised of an implant, a distracter, and a sleeve. The distracter is structured to provide a gradual insertion force to move the implant into, onto or between supporting bone or bones with the insertion force reacted by the supporting bone or bones. The sleeve is structured to interpose the implant and supporting bone and provide a differential engagement force between the sleeve-implant interface and the sleeve-bone interface to preferentially move the implant into, onto or between supporting bone structures. Optionally, the present invention may include an alignment guide. Alternatively, the present invention may include a surgical navigational tracker. The alignment guide is structured to orient and align the implant. Alternatively, the navigational tracker is structured to orient and align the implant. Optionally, the present invention may include a bone displacer structured to distract adjacent bones or adjacent bone support surfaces to facilitate placement of an implant.
[0025] The implant structured for use in Kinematic Restoration, spinal interbody fusion, vertebral compression fracture reduction or realignment osteotomy
[0026] The sleeve structured to:
interpose implant and bone or bones, to be of unitary construction, alternatively, to be a plurality of sleeves, to have a first surface structured to engage an implant (i.e. implant engagement), to have a second surface structured to engage a bone or bones (i.e. bone engagement).
[0032] The distracter structured to:
connect to an implant (i.e. implant connection), alternatively, connect to bone or bones (i.e. bone connection), connect to a sleeve or plurality of sleeves (i.e. sleeve connection), displace the implant relative to the sleeve, displace the sleeve relative to the bone or bones, displace the implant relative to the bone or bones.
[0039] In one embodiment of the present invention the distracter and sleeve are structured to place an implant between adjacent first and second bones, wherein:
the distracter is connected to the implant and to the sleeve, the sleeve has a first surface structured to engage the implant and a second surface structured to engage the first and second bones, the sleeve to bone engagement force being greater than the sleeve to implant engagement force, the distracter structured to displace the implant towards the implant's final seated position during which the sleeve to bone engagement force has not been exceeded and the relative position of the sleeve to the first and second bone does not significantly change, the implant is advanced to it's final seated position at which point the first and second bone restrict further advancement of the implant, continued displacement of the distracter then overcomes the sleeve to bone engagement force and the sleeve is moved away from the implant's final seated position and out of the implant to bone interface, the sleeve and distracter are then removed and the implant is in proper position.
[0047] In an alternative embodiment of the present invention the distracter and sleeve are structured to place an implant into a bone cavity, wherein:
the distracter is connected to the implant and to the sleeve, the sleeve has a first surface structured to engage the implant and a second surface structured to engage the bone cavity, the sleeve to bone engagement force being greater than the sleeve to implant engagement force, the distracter structured to displace the implant towards the implant's final seated position during which the sleeve to bone engagement force has not been exceeded and the relative position of the sleeve to bone cavity does not significantly change, the implant is advanced to it's final seated position at which point the bone restricts further advancement of the implant, continued displacement of the distracter then overcomes the sleeve to bone engagement force and the sleeve is moved away from the implant's final seated position and out of the implant to bone interface, the sleeve and distracter are then removed and the implant is in proper position.
[0055] In yet another embodiment of the present invention the distracter and sleeve are structured to place an implant onto a bone, wherein:
the distracter is connected to the bone and to the sleeve, the sleeve has a first surface structured to engage the implant and a second surface structured to engage the bone, the sleeve to bone engagement force being lower than the sleeve to implant engagement force, the distracter structured to displace the sleeve towards the implant's final seated position during which the sleeve to implant engagement force has not been exceeded and the relative position of the sleeve to implant does not significantly change, the implant is advanced to it's final seated position at which point the bone restricts further advancement of the implant, continued displacement of the distracter then overcomes the sleeve to implant engagement force and the sleeve is moved away from the implant's final seated position and out of the implant to bone interface, the sleeve and distracter are then removed and the implant is in proper position.
[0063] Optionally, each of the embodiments described above may include an alignment guide structured to:
attach to the inserter, alternatively, attach to the sleeve, alternatively, attach to the implant, alternatively, attach to one or more of the supporting bones, provide alignment rods aligned with anatomic features or implant features to provide a geometric reference between the implant and one or more of the supporting bones to align and orient the implant.
[0069] Optionally, each of the embodiments described above may include a surgical navigational tracker structured to:
attach to the inserter, alternatively, attach to the sleeve, alternatively, attach to the implant, alternatively, attach to one or more of the supporting bones, support reflective spheres typically used with optical surgical navigation system. Alternatively, to support electromagnetic targets typically used with electromagnetic surgical navigation systems. be navigated by the surgical navigation system to aid the surgeon in orienting and aligning the implant and to provide a geometric reference between the implant and one or more of the supporting bones to align and orient the implant.
[0076] Optionally, each of the embodiments described above may include a bone displacer structured to:
attach to the distracter, alternatively, be integral with the distracter, attach to one or more of the supporting bones, attach to the implant, distract adjacent bones away from one another, alternatively, distract the distracter away from one or more adjacent bones, alternatively, distract the implant away from one or more adjacent bones.
[0084] The distracter and the bone displacer are structured as hydraulic cylinders each having a piston and cylinder actuated by fluid or air pressure. Alternatively, the distracter or bone displacer may be mechanically actuated by screw mechanisms, scissors mechanisms, lever and fulcrum mechanisms, spring mechanisms, bladders, balloons, bellows, gear mechanisms, rack and pinion mechanisms, and other expandable devices or other elements that provide a force between two or more objects, or combinations thereof.
[0085] The structure of the connections between the distracter and sleeve, distracter and implant, and distracter and bone described above and the structure of the connections between the bone displacer and distracter, bone displacer and bone, and bone displacer and implant, include compressive contact surfaces, threaded interfaces and threaded fasteners, pinned interfaces, “T” slots; dovetail locks; cylindrical interlocks; button interlocks; spherical interlocks; trinkle locks; or a combination of these, or other connecting means used to connect two or more parts.
[0086] Suitable materials for the sleeve as described above and in the detailed description of the invention include cobalt-chromium alloy, stainless steel, titanium, titanium alloys, Nitinol, plastics, including but not limited to urethane, polyethylene and expanded polyethylene, nylon, woven fabric materials, and the like.
[0087] The invention will be further described with reference to the following detailed description taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0088] FIG. 1 is a perspective view of the surgical incision through which the present invention is structured to be used.
[0089] FIG. 2A is an illustration of a cup placed into a sleeve and placed into a prepared acetabulum in accordance with the present invention.
[0090] FIG. 2B is a cross sectional detailed view of FIG. 2A showing a cup placed into a cup sleeve and placed into a prepared acetabulum in accordance with the present invention.
[0091] FIG. 3 is a cross sectional view showing a cup placed into a cup sleeve and placed into a prepared acetabulum in accordance with the present invention.
[0092] FIG. 4 is a cross sectional view showing a cup placed into a cup sleeve and placed into a prepared acetabulum with a mechanical interlock released in accordance with the present invention.
[0093] FIG. 5 is a perspective view of a sleeve in accordance with the present invention.
[0094] FIG. 6 is a top perspective view of a cup inserter in accordance with the present invention.
[0095] FIG. 7 is bottom perspective view of the cup inserter in accordance with the present invention.
[0096] FIG. 8 is a perspective cross sectional view of the cup inserter of the present invention.
[0097] FIG. 9 is a cross sectional view of the cup inserter of the present invention.
[0098] FIG. 10A is a side view of a cup inserter aligned for placement of an acetabular cup in accordance with the present invention.
[0099] FIG. 10B is a side view of a femoral broach in accordance with the present invention.
[0100] FIG. 11 is a side view of a cup inserter inserting an acetabular cup in accordance with the present invention.
[0101] FIG. 12 is a side view of a cup inserter extracting a sleeve in accordance with the present invention.
[0102] FIG. 13 a is an exploded view of the cup inserter in accordance with the present invention.
[0103] FIG. 13 b is another exploded view of the cup inserter in accordance with the present invention.
[0104] FIG. 14 is a perspective view of a cup inserter and handle in accordance with the present invention.
[0105] FIG. 15 is a perspective view of a cup inserter, handle and alignment guide in accordance with the present invention.
[0106] FIG. 16 is a perspective view of a cup inserter, handle and surgical navigational tracker in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0107] As described above, the present invention is applicable to orthopaedic surgical procedures for Kinematic Restoration, spinal interbody fusion, vertebral compression fracture reduction and realignment osteotomy. In one embodiment of the present invention, the system is comprised of:
an implant—in this embodiment the implant is an acetabular cup, a distracter—in this embodiment the distracter is a cup inserter and specifically the stage II piston and cylinder, a sleeve—in this embodiment the sleeve is a cup sleeve, optionally, an alignment guide—in this embodiment the alignment guide is a cup alignment guide, optionally, a surgical navigational tracker—in this embodiment the surgical navigational tracker is a cup navigational tracker, optionally, a bone displacer—in this embodiment the bone displacer is the stage I piston and cylinder.
[0114] Referring to FIG. 1 , there is depicted a surgical incision 100 for a less invasive total hip arthroplasty. The muscles and soft tissues spanning the hip joint are exposed and either bluntly dissected along muscle fibers or separated along muscle boundaries. Optionally, select muscles may be taken down to increase surgical exposure and access to the hip joint. Anatomy of interest to this embodiment of the invention includes the pelvis 102 , the acetabulum 104 , the femur 108 , the joint capsule (not shown) and the muscles 105 and ligaments spanning the hip joint. The femoral head is resected at the base of the femoral neck 108 as shown in FIG. 1 to provide access to the medullary canal to prepare the canal to receive a femoral hip stem. In total hip arthroplasty, the articular surfaces of the proximal femur and the acetabulum are resurfaced. In general, after resecting the femoral head, the femur is prepared by reaming and broaching to prepare the femoral canal to receive a hip stem implant and femoral head implant there on. Alternatively, the femoral head may be sculpted to receive a resurfacing implant structured to fit over the prepared femoral head, this representing another embodiment of the present invention to place an implant onto a prepared bone surface. The acetabulum is generally prepared by reaming a hemispherical cavity to receive an acetabular cup.
[0115] Referring to FIG. 2A , the cup sleeve 16 interposes the cup 18 and the acetabulum 104 . The cup 18 size is selected to provide a press-fit within the prepared acetabulum 104 and the cup sleeve 16 size is selected to match the cup 18 size. Alternatively, a cup sleeve 16 may be structured to accommodate multiple cup sizes. The cup inserter, described in detail below, provides an insertion force IF to the cup 18 that is reacted by the cup sleeve 16 by a reaction force RF around the distal circumference of the cup sleeve. Now referring to FIG. 2B , the cup sleeve 16 to acetabulum 104 interface 136 is structured to provide a higher engagement force than the engagement force at the cup sleeve 16 and cup 18 interface 138 . The cup sleeve 16 surface at the sleeve-bone interface 136 is structured with circumferential ridges 17 to provide a mechanical interlock and an engagement force higher than that of the sleeve-implant interface 138 in which the sleeve surface is smooth. The ridges may be machined into the sleeve. Alternatively, the ridges may be chemically milled into the sleeve, or formed into the sleeve by a stamping process. Alternatively, the sleeve surface at the sleeve-bone interface 136 may be structured with a roughened texture as may be created by grit blasting, machining, chemical etching or formed into the sleeve by a stamping process.
[0116] Alternatively, the cup sleeve 16 surface at the sleeve-bone interface 136 may be structured to provide a releasable mechanical interlock. Referring to FIG. 3 , the cup sleeve 16 may be structured with a circumferential ridge 133 around the proximal edge that engages the acetabulum 104 . A sliding spacer 131 is interposed between the cup sleeve 16 and cup 18 to hold the ridge 133 in an extended position to engage the acetabulum 104 . The sliding spacer 131 is pulled distally by the surgeon grabbing the sliding spacer 131 with a forceps. As shown in FIG. 4 , when the sliding spacer 131 is pulled from underneath the circumferential ridge 133 , the ridge 133 pulls away from the acetabulum 104 releasing the cup sleeve 16 to slide from the cup 18 and acetabulum 104 interface. Alternatively, the ridge 133 may be intermittent to provide equally spaced tabs around the circumference of the proximal edge of the cup sleeve 16 to engage the acetabulum 104 .
[0117] Now referring to FIG. 5 , the body of the cup sleeve 16 is formed with a spherical closing 142 of the proximal edge 38 . The longitudinal serrations 36 equally spaced around the cup sleeve 16 provide relief in the cup sleeve 16 as the cup displaces proximally through the cup sleeve 16 . The serrations 36 are positioned relatively close to the proximal edge 38 to provide a lip 44 between each serration 36 and the proximal edge 38 , this lip 44 structured to provide constraint to hold the cup in the cup sleeve while the surgeon handles the cup inserter and cup to place the construct into the surgical site. The lip 44 then fracturing as the cup is advanced into the acetabulum to allow the cup to pass through the cup sleeve 16 as described in greater detail below. The perforations 26 evenly spaced around the distal aspect of the cup sleeve 16 are structured to provide a releasable pinned connection with the cup inserter as described in greater detail below. Alternatively, the perforations 26 may be structured to provide a pinned connection with the cup inserter.
[0118] The body of the cup sleeve 16 may be formed by deep drawing a metal into the shape of the cup sleeve 16 , then truncating the formed can to open the proximal end of the cup sleeve 16 and trimming the distal end 40 of the formed can. Alternatively, the cup sleeve 16 body may be machined. The longitudinal serrations 36 and perforations 26 can be die cut into the cup sleeve 16 . Alternatively, the longitudinal serrations 36 and perforations 26 may be laser cut or die stamped into the cup sleeve.
[0119] Referring now to FIGS. 6 and 7 which illustrate an assembly of the present invention, the cup 18 is held within the cup sleeve 16 . The cup sleeve 16 is structured to attach to the adapter ring 28 with releasable pinned interlocks that engage perforations 37 in the cup sleeve 16 . In one embodiment, the present invention includes a distracter and a bone displacer. Hydraulic pressure to activate the distracter is provide via a tube 82 which is ported to the stage II piston and cylinder described in detail below. Hydraulic pressure to activate the bone displacer is provided via a tube 80 which is ported to the stage I piston 140 and cylinder described in detail below. The cup inserter 10 is structured to attachably receive a handle to a boss 120 via two bayonet mounting tabs 122 . The manifold cap 46 is structured to be assembled and disassembled with the adapter ring 28 through a threaded connection described below. This threaded connection is locked from loosening during the surgical procedure by a mechanical interlock activated by a manifold lock 48 on the distal surface of the manifold cap 46 .
[0120] The operation of the cup inserter 10 is easiest to describe when referring to FIGS. 8 and 9 which are cross sectional views of the cup inserter 10 without a cup, but with a cup sleeve 16 illustrated. As described above, first hydraulic pressure supply is used to actuate a distracter structured within the cup inserter 10 and a second hydraulic pressure supply is used to actuate a bone displacer structured within the cup inserter 10 . The distracter is comprised of manifold 20 and stage II piston 24 structured to provide a piston and cylinder mechanism that when pressurized displaces the cup relative to the cup sleeve 16 . Hydraulic pressure is introduced via tube 82 described above and ported to the stage II cylinder 45 . An o-ring 41 provides a pressure seal for the stage II piston 24 and manifold 20 . The manifold 20 engages the adapter ring 28 through a mechanical interlock structured by tabs 60 on the inner diameter of the adapter ring 26 slidingly fitting into receiving pockets 61 in the outside diameter of the manifold 20 .
[0121] The manifold 20 attaches to the cup sleeve 16 via a releasable pinned interlock formed by a cantilever beam 29 and boss 25 in the adaptor ring 28 . Multiple cantilever beam 29 and boss 25 interlocks are equally spaced around the adaptor ring 28 and the number varies with the size of the adaptor ring as structured to attached to various sizes of the cup sleeve 16 . The cantilever beam 29 is deflected inward by applying force to the boss 25 thereby releasing the cup sleeve. The proximal edge of each boss 25 is beveled to allow the cup sleeve to slide over the boss 25 and depress the cantilever beam 29 during assembly of the cup sleeve 16 onto the adaptor ring 28 . Extending from the proximal surface of the stage II piston 20 is a treaded connector 56 structured to attach an adapter post 22 . Adapter posts 22 are provided for each cup size. The proximal end of the adapter post 22 is structured with a treaded connector 22 to attach to the cup. Alternatively, the proximal end of the adapter post 22 may be structured with a boss that slidably fits into a apical hole in the cup.
[0122] Once assembled, the cup inserter 10 is locked in an assembled position by the manifold lock 48 and boss 62 that slidably engages scallops 88 on the distal inner surface of the adapter ring 28 . Releasing the manifold lock 48 allows the manifold 20 to be unthreaded from the manifold cap 46 and disassembly of the cup inserter 10 .
[0123] The bone displacer is comprised of the stage I piston 26 and the cylinder within the manifold 20 . An o-ring 43 provide a pressure seal between the stage I piston 26 and the cylinder within the manifold 20 . The distal end of the stage I piston 26 is structured with a bore 140 to slidably receive the post of a femoral broach to support the cup inserter 10 when in use within the joint cavity. Alternatively, the cup inserter may be used independently without attachment to a broach or support by the femur.
[0124] Turning now to a description of the surgical procedure in which the cup inserter 10 is used to place a cup 18 . The acetabulum 104 and proximal femur have been surgically prepared as described above. The femoral broach that was used to prepare the proximal femur is left in place to support the cup inserter 10 . Starting with FIG. 10A , the cup inserter 10 and bone displacer are fully retracted. A cup 18 size is selected to provide a press-fit with the prepared acetabulum 104 and assembled with the cup inserter 10 and cup sleeve 16 . The cup handle is assembled to the cup inserter 10 onto boss 120 as described in detail below. Next, the cup inserter 10 is placed onto the broach post 110 , as can be seen in FIG. 10B , and the hip is reduced to place the cup 18 into the acetabulum 104 . Alternatively, the cup inserter 10 may be attached directly to the femur with screws, pins or other suitable mounting structure. Alternatively, the cup inserter 10 may be supported by the proximal femur without mechanical attachment thereto. Alternatively, the cup inserter 10 may be structured to place the cup without the cup inserter 10 attached to or supported by the femur.
[0125] It should be noted that due to the press-fit interference between the cup 18 and acetabulum 104 , the cup 18 is supported by the distal circumference of the acetabulum leaving a gap 134 apically between the cup 18 and acetabulum 104 . The stage I piston 26 is advanced by applying pressure with a syringe pump until the joint capsule is tensioned appropriately and the cup sleeve 16 engages the acetabulum 104 . The stage II piston 24 is advanced to provide an insertion force to the cup 18 . The insertion force is reacted through the sleeve 16 by a reaction force carried by the adaptor ring 28 attached to the cup sleeve 16 ; hence, the stage II piston 24 is structured to provide a distraction force between the cup 18 and the sleeve 16 . The sleeve 16 is held in place within the acetabulum by the higher engagement force at the sleeve-acetabulum interface, than that of the sleeve-cup interface as previously described. The cup 18 slides relative to the sleeve 116 until the gap apical 134 between the cup 18 and acetabulum 104 is closed. At which point the distraction force provided by the stage II piston 24 pulls the sleeve 16 from the acetabulum 104 by overcoming the frictional force at the sleeve-acetabulum interface as previously described.
[0126] Referring now to FIG. 11 , as the stage II piston deploys to seat the cup 18 , the stage I piston is adjusted to maintain distraction of the joint capsule and displace the femur. Now referring to FIG. 12 , after the cup 18 is fully seated in the acetabulum 104 , the stage II piston 24 continues to pull the sleeve 16 from the cup-acetabulum interface until the sleeve 16 is fully removed. At this point the manifold 20 is free from the stage II piston 24 and the sleeve 16 , adaptor ring 28 , manifold 20 and manifold cap 46 assembly are removed from the hip joint cavity by orienting the femur away from the acetabulum and removing these components from the broach post 110 . The stage II piston 24 and adaptor post 22 are then removed from the cup 18 .
[0127] Given the numerous parts making up the cup inserter 10 , it is beneficial to briefly list the parts as shown in exploded views. Referring to FIGS. 13 a and 13 b , the cup sleeve 16 , the cup 18 , the adapter post 22 , the stage II piston 24 , the manifold 20 with o-ring 41 assembled, the stage I piston with o-ring 43 assembled, the adapter ring 28 , the manifold gasket 30 , the manifold cap 46 , the manifold lock 48 and the manifold retainer 64 . It is also beneficial to briefly describe the fluid pathways for the distracter, driven by stage II, and the bone displacer, driven by stage I, configurations within the cup inserter 10 . Starting with the pressure supply, a first and a second syringe pump (not shown) are used to provide hydraulic pressure to drive stage I and stage II pistons. Each syringe pump is filled with sterile saline solution. The first syringe pump is connected to stage I via tube 80 and the second syringe pump is connected to stage II via tube 82 . The fluid pathway for stage I is tube 80 -manifold cap 46 port 90 -gasket 30 port 76 -manifold 20 port 84 -leading to manifold 20 internal cylinder 35 . The fluid pathway for stage II is tube 82 -manifold cap 46 port 92 -gasket 30 port 78 -manifold 20 port 86 -leading to manifold 20 external cylinder 27 .
[0128] Referring to FIG. 14 , in another embodiment in accordance with the present invention, the cup inserter 10 is attached to a handle 126 such that a surgeon places cup inserter 10 and cup 18 directly into the acetabulum and holds sleeve 16 in contact with supporting bone. The handle 126 structured to slidably receive the manifold cap attachment boss 120 with opposing bayonet bosses 122 to engage receiving bayonet openings 124 . The lock nut 130 is structured to secure the bayonet bosses 122 within the receiving bayonet openings 124 , and the clinch nut 132 structured to lock the lock nut 130 in place. Alternatively, the cup inserter 10 may be structured to attach to or be supported by the femur directly or indirectly as described above. The stage II piston 24 is extended to push cup 18 along sleeve 16 and into the acetabulum. The frictional force between sleeve 16 and supporting bone holds sleeve 16 in position relative to the supporting bone until inserter cup 10 is seated in supporting bone. After seating, cup inserter 10 is in proper position and additional pulling force to sleeve 16 slides sleeve 16 from the cup-bone interface. This is continued until sleeve 16 is free of the interface at which time cup inserter 10 and sleeve 16 are removed from the joint cavity and the surgical procedure is completed.
[0129] Optionally, the cup inserter 10 and handle 126 may be structured for attachment of an alignment guide. Referring to FIG. 15 , an alignment guide 150 with an alignment rod 162 structured to indicate cup inclination and alignment rod 160 structured to indicate cup anteversion relative to the axis of the torso may be used to check alignment of the cup 18 by attaching the alignment guide 150 to handle 126 , such attachment structured as a channel 164 in the upper base 156 and lower base 154 of the alignment guide 150 that slidably fits over the handle 126 via channel 164 and clamps to the handle 126 thumb screw 152 to stabilize the alignment guide 150 in proper alignment relative to the cup inserter 10 and handle 126 . Alternatively, the alignment guide may be attached to the handle 126 by threaded fasteners passed through clearance receiving holes in the upper base 156 and threaded into threaded receiving holes in the handle 126 .
[0130] Optionally, the cup inserter 10 and handle 126 may be structured for attachment of a surgical navigational tracker for use with a surgical navigational system. Referring to FIG. 16 , a surgical navigational tracker 166 with three reflective spheres 170 supported on a frame 168 and an upper base 156 and lower base 154 of the alignment guide 150 that slidably fits over the handle 126 via channel 164 and clamps to the handle 126 thumb screw 152 to stabilize the alignment guide 150 in proper alignment relative to the cup inserter 10 and handle 126 . Alternatively, the surgical navigational tracker 166 may be attached to the alignment guide 150 to handle 126 by threaded fasteners passed through clearance receiving holes in the upper base 156 and threaded into threaded receiving holes in the handle 126 . Cup 18 alignment is checked with the a surgical navigational tracker 166 attached to the cup inserter 10 and handle 126 . The surgical navigational system will measure cup 18 inclination and anteversion and provide a report to the surgeon. Alternatively, the alignment guide 150 and the surgical navigational tracker 166 may be structured for attachment to the cup inserter 10 and handle 126 with “T” slots; dovetail locks; cylindrical interlocks; button interlocks; spherical interlocks; or a combination of these, or other connecting means used to connect two or more parts.
[0131] While this disclosure covers placing a cup into the acetabulum, the present invention is applicable to orthopaedic surgical procedures for Kinematic Restoration, spinal interbody fusion, vertebral compression fracture reduction and realignment osteotomy.
[0132] It is contemplated that features disclosed in this application can be mixed and matched to suit particular circumstances. Various other modifications and changes will be apparent to those of ordinary skill in the art without departing from the spirit and scope of the present invention. Accordingly, reference should be made to the claims to determine the scope of the present invention.
|
A system and method for placing an implant into or onto supporting bone, or between adjacent bones, without impaction is disclosed. The system includes an implant, a distracter, and a sleeve. Optionally, the invention includes an alignment guide, a surgical navigational tracker, and a bone displacer. The sleeve is structured to interpose the implant and supporting bone and provide a differential engagement force between the sleeve-implant interface and the sleeve-bone interface to preferentially move the implant into, onto or between supporting bone structures.
| 0
|
CROSS REFERENCE TO RELATED APPLICATION
This is a continuation-in-part of U.S. application Ser. No. 943,730, filed Sep. 11, 1992, now abandoned.
BACKGROUND OF THE INVENTION
The present invention refers to an electric heating element, more particularly a heating element to be used, e.g. for seat heaters in vehicles, in heating pads, heating blankets, heatable garments etc.
Such resilient and mostly also ductile heating elements are already known. They are generally formed of a flat envelope of synthetic textile material containing an electric resistance wire which is mostly inserted in a zigzag or meander shape but which may also have the form of a thin, flat ribbon.
Although they are resilient, these known heating elements have the drawback that they are poorly adapted to uneven or even bent supports. They are not extendable. If they are placed around the bend of the support, there is a risk that the resistance wire will be broken. In most cases, they are too thick to form a non-thickening layer, e.g. in car seats, and their manufacture is relatively expensive. Moreover, their electric heating power cannot be varied individually.
SUMMARY OF THE INVENTION
It is an object of the present invention to overcome the drawbacks of the known planar heating elements and to provide a new heating element for universal application which is simple in manufacture, and to provide a method for its manufacture.
This object is attained by an electric heating element which is formed of a textile knit fabric comprising at least two conductive, mutually separated current supply wires and resistance wires running from one of the current supply wires to the other. The current supply wires may be incorporated, according to the intarsia technique, in at least one course of respective superposed and mutually interlaced stitches. The resistance wires are incorporated in horizontal stitch courses at a mutual distance of at least one non-conductive stitch course. A solid, contact making stitch interlace is provided between the current supply and resistance wires.
Furthermore, a method for the manufacture of the novel heating element is provided, wherein the textile knit fabric is produced and one of resistance wires or current supply wires are additionally incorporated in the direction of the stitch courses, and the other of current supply wires or resistance wires, respectively, are incorporated in the direction of the stitch loops, and wherein the wires and/or the obtained textile knit fabric is coated or impregnated in a corrosion resistant or moisture resistant manner at least at the points of intersection of the current supply and resistance wires.
Thus the invention is based upon the idea of incorporating the heat producing wires of an electric resistance heating device into a resilient and extendable as well as drapable knit fabric.
The manufacture of knit fabrics by knitting is known and will not be described here again. The incorporation of the current supply wires and of the resistance wires may be carried out in particular on flat knitting machines in the most diverse ways.
The basic structure of the heating element of the invention is such that at least two resistance wires are arranged substantially in parallel to each other and are in electric contact with at least two current supply wires, while it is understood that the current supply wires must not be in contact among themselves, whereas a mutual contact of some resistance wires is not detrimental.
In the manufacture of the knit fabric, the wires may be inserted as weft yarns or warp yarns or both. Furthermore, incorporation as a replacement of the stitch yarn or as an addition to the stitch yarn may be considered. One of the wires may be incorporated by the intarsia technique if the connection perpendicularly to the knitting direction, i.e. of superposed stitches is concerned. The wire may also be a slightly twisted component of a stitch yarn.
Any construction of the knit fabric of the heating element may be chosen, e.g. right/right construction, jersey stitch, left/left construction, double stitch, etc. Also, transferred stitches may be used in order to obtain a reinforcement; this is particularly interesting for the current supply wires.
The known knitting techniques allow production of any shape of the heating surface. Even an almost semicircular arrangement of the current supply wires is possible. By graduations of the mutual distances of the current supply wires and/or by a varied density of the resistance wires or by the choice of different wire sizes, respectively, the most varied heating powers are possible over the surface of the fabric.
The necessary contact safety between the current supply wires and the resistance wires is positively ensured by the solid stitch interlacing of the planar textile structure, as has been shown in tests. In this context, the heating element of the invention is advantageously protected from corrosion and moisture, namely at least at the points of intersection, i.e. at the connections of the current supply wires and the resistance wires, where there is an additional risk of local element formation. For this purpose, the wires can be provided with a corrosion resistant, but electrically conductive, coating formed e.g. of a polymer which is made conductive by means of graphite, EC soot or germanium, or of an amide-imide polymer which is conductive itself. It is preferred, however, to impregnate the finished heating element at least in the area of the mentioned points of intersection in a corrosion resistant and moisture resistant manner, e.g. with a dispersion of silicon resins or polytetrafluorethylene which is subsequently dried. In some cases it is even better to use a silicon prepolymer, to dry and subsequently cross-link the applied solution or dispersion by thermal and/or catalytic means. Protective substances of this kind are known to one skilled in the art.
According to the desired purpose, the material for the wires may be chosen at will. Copper wires, which may be silvered as the case may be, may be considered for the current supply wires, and the known nickel-chrome alloy wires for the resistance wires.
The heating element of the invention may be manufactured in the form of a planar structure, but also three-dimensionally, e.g. as a preshaped car seat cover. It is further suitable for a fitting insertion in garments such as motorcycle garments, and it may be directly manufactured in the desired shape.
Besides the "net-like" knit fabrics described above, all other known weaves are applicable in connection with a heating conductor or with current supply wires, also in combination with a warp and/or weft reinforcement, and are capable of being produced without any problems. As also mentioned above, a planar (two-dimensional) or a three-dimensional structure may be concerned. Such three-dimensional structures and their manufacture are described in U.S. patent application Ser. No. 08/089,112 filed on Jul. 8, 1993 which claims the priority of Swiss Patent Application No. 2149/92 of Jul. 8, 1992 to the applicant. Specifically, the shape of the three-dimensional textiles is achieved by adding and/or removing loops and/or subsequent extensions.
The heating conductors may consist of a resistance wire or of other conductive materials and may be coated or sheathed as well. Neither do the heating conductors have to follow a "wave-shaped" course (see below, FIG. 1). A connection of the heating wire to the contact wire, i.e. the current supply wire after every passage is not required. By contrast, almost unlimited variations of the heating power are possible by incorporating resistance wires of different diameters, by a variable mutual distance of the wires and by an individual connection to the contact conductor.
The contact conductor, whose wire size, width and material may be dimensioned at will, does not necessarily have to be arranged perpendicularly or horizontally with respect to the knitting direction, but it may be adapted to the predetermined ideal shape and thus be arranged obliquely or in the shape of a curve, as mentioned above.
If three-dimensional heating elements are desired, the heating element need not first be manufactured two-dimensionally and then shaped, but it may be designed as a multidimensional structure with a variable heating power, as the case may be. Thus, the heating power remains precisely reproducible even punctually since a surface modification by subsequent shaping to achieve the spatial form is no longer required.
The heating element of the invention is manufactured in the desired form, as opposed to being yard ware. An expensive subsequent transformation by tailoring and sewing is thereby superfluous.
The heating power can be designed variably by the density of the resistance wire rows, by corresponding dimensioning of the wires, by the row width according to the contact conductor arrangement, and also by the weave variant, of course. It is thus no longer necessary to interrupt one or a plurality of resistance wires in order to realize the desired heating power. By contrast, the heating element of one embodiment of the invention is provided with two or more areas of heating wires which are connected by means of current supply wires on one side or not at all. It is thus possible to adapt the heating power to possible special requirements by a series or parallel connection of the current supply wires in a very simple manner.
Since the heating element of the invention can be manufactured on a weaving-knitting machine in its desired three-dimensional form and thus does not need to be thermally deformed after its manufacture, it is possible to use any type of fibers besides synthetic fibers as working yarns. Consequently, all the technical fibers including sheathed fibers may be processed, also in combination.
The heating element of the invention may be provided with a corrosion resistant and non-inflammable finish by plasma treatment and also by traditional treatments, possibly of the fibers already.
The heating element of the invention can be manufactured on textile machines, preferably on computer-controlled flat knitting machines. In addition to the planar and the three-dimensional structure, a so-called "two-and-a-half-dimensional" construction with a loop pile or a spacing structure, respectively, may be produced.
For a further explanation of the object of the invention, individual possibilities of inserting current supply and resistance wires are described below.
Knit fabric of the heating element is knitted with a yarn which generally consists of a suitable synthetic fiber in the form of a monofilament or a staple fiber yarn or else of a microfiber yarn, such as polyester, polyurethane, polyamide, or high temperature resistant fibers such as Nomex. Of course, the material of yarn must be chosen such as to withstand the desired temperature of the heating element.
The current supply which may be a thin copper wire or a strand, and may be incorporated by the intarsia technique.
It is understood that a reduction of the extendability in the corresponding direction occurs if warp or weft wires respectively are used. Highly extendable heating elements according to the invention are therefore preferably produced with intarsia wires and interlaced heating wires.
The current supply wires may also be incorporated with the set-up line. The current is drained by the final set-up line through the adjacent knitting of any type containing heating wires. Thus a heating element with "horizontal" current supply wires and "vertical" resistance wires is obtained.
As additional possible knitting techniques, tucking and stitch transfer may be mentioned, and as additional applications, the construction of tool heaters, container heaters, pipe heaters, etc.
Other features and advantages of the present invention will become apparent from the following description of the invention which refers to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be described below with reference to several embodiments. With respect to said embodiments,
FIG. 1 shows a knitted fabric with warp threads incorporated therein as current feed wires and weft threads as filling threads and as resistance wires;
FIG. 2 shows another heating structure with current conducting mesh areas which are separated from each other by insulating mesh areas and filling threads incorporated as resistance wires;
FIG. 3 shows an embodiment having current feed wires in the form of warp threads and resistance wires present as mesh structure; and
FIG. 4 shows an embodiment in which both the current feed wires and the resistance wires are present as mesh structure.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a fabric in the form of a basic knitted mesh structure 2 of non-conductive threads, in which good, low resistance, current conductors 4 are incorporated as warp threads. The conductors are connected to each other by filling threads 6 in the form of resistance heating wires. The heating resistance wires 6 are thus superimposed, together with the current feed wires 4, as a woven structure on the basic knitted mesh structure so that this embodiment forms a woven mesh structure having the knitted mesh structure 2 as a support structure and the interwoven filling and warp threads as the heating element. By selecting quantity and placement of the resistance wires 6 incorporated as filing threads, the heating performance of the textile area in question can be adjusted.
FIG. 2 also shows a flexible knitted mesh fiber structure 10 which is knitted or is of some other hosiery or mesh type. It is connected at both of its edge regions to two separated current conducting mesh structures 12, 14. The connection of the central non-conductive structure to each outer conductive structure is by knitting each edge region over the adjacent edge region of the adjacent structure. Filling threads 16, 18 are introduced into and extend across the textile material formed by the three neighboring structures 10, 12, 14. Those filling threads are developed as resistance heating wires. In the conductive mesh structures 12, 14, the resistance heating wires 16, 18 are connected to the knitted current feeds in those structures. The current feed wires, which are also present as knitted mesh structures 12, 14, may comprise either an insulating thread which is wrapped by a current conductor or a current conducting thread. Also, in this embodiment, the number of, i.e., the distance between successive filling threads 16, 18 contributes to determining the heating performance.
FIG. 3 shows a flexible basic knitted mesh structure 20 which is entirely comprised of a resistance heating wire or of an insulating thread which is wrapped by a resistance heating wire. In the edge structures 22, 24 on the edge regions of the central mesh structure 20, a respective insulating thread 26, 28 is superimposed on the resistance heating wire 20 at the edge region. The insulating thread mechanically supports the mesh structure 20 of the resistance heating wire. The current feed wire pairs 30, 32 and 34, 36 are incorporated in the edge regions 22, 24, respectively. The current feed wire pairs 30, 32 and 34, 36, respectively, in each case, are acted on by the same voltage U 1 and U 2 . In the region 20 of the mesh structure, there is thus applied a voltage ΔU=U 1 -U 2 between the current feed wire pairs 30, 32 and 34, 36, respectively. That voltage is converted into heat corresponding to the ohmic resistance of the structure 20 present between the wire pairs. By using current feed wire pairs 30, 32 and 34, 36, and by having each pair (or even more wires than one pair) connected in electrical parallel, this assures the supply of current to the respective heating element even if one current feed wire 30, 32, 34, 36 breaks. Obviously, the structure of the resistance wire in this and the other embodiments provides similar assurance upon breakage of one resistance wire. The current feed wires are firmly maintained in the overall mesh structure in the form of the warp threads 30, 32, 34, 36 between the insulating thread 26 and the resistance heating thread of the structure 20. By direct application of the current feed wires 30, 32, 34, 36 to the resistance wires in several areas, smooth operation of the entire heating mesh structure is assured.
FIG. 4 also shows a mesh structure 40 which is entirely comprised of a resistance wire. Current conducting wires 44, 46, which have a very low resistance and serve as the current feeds, extend through two lateral sections 42, 43 which extend parallel to the central resistance wire mesh structure 40. The wire 40 extends into the lateral sections 42, 43. In the regions of the two lateral sections 42, 43, the resistance wire 40 is at a substantially identical potential due to the much lower resistance of the current feed wires 44, 46, while the resistance wire extends by itself over a central section 48. Thus, in the central section 48 between the two lateral sections 42, 43, the current flowing through the resistance wire 40 is determined by the potential difference ΔU=U 1 -U 2 , which is applied between the two regions 42, 43. Instead of the illustrated joint knitting of the resistance wire 40 and the current feed wires 44 or 46 in the lateral edge sections 42 and 43, the current feed wires 44, 46 and the resistance wire 40 can also be connected to each other merely at their adjoining edge regions, e.g., as shown in FIG. 2.
Insulating threads, which are wrapped by a resistance wire, can be used in all embodiments instead of a plain resistance wire. The function of the resistance wires is merely to produce heat, as a result of the voltage drop taking place along them. The current carrying or current conducting wires can also be comprised of insulated wires which are wrapped by a current conducting wire. For the current carrying wires, any conductive materials can be used provided the materials have a sufficiently low resistance as compared with the resistance heating wires.
According to the present invention, either the current carrying wires or the resistance heating wires or the support structure for those wires are formed of a knitted fabric so that the heating element is very elastic and retains its operability even when it is strongly deformed. The heating element furthermore retains its operability if a conductor breaks. In this case, only a very small amount of the heating element is lost for the further production of current since both the current feed and the generation of heat take place over several parallel current paths.
Although the present invention has been described in relation to particular embodiments thereof, many other variations and modifications and other uses will become apparent to those skilled in the art. It is preferred, therefore, that the present invention be limited not by the specific disclosure herein, but only by the appended claims.
|
An electric heating element is formed of a knit fabric and includes current supply wires and resistance wires which are incorporated in the heating element. The different types of wires extend mutually perpendicularly in the heating element. The conductive wires may be disposed in local or edge regions spaced apart with the knit fabric located therebetween. The knit fabric located between the conductive wires may be formed of non-conductive fibers or resistance wires.
| 7
|
FIELD OF THE INVENTION
[0001] The present invention provides novel compositions and methods for use in diagnosing the occurrence of certain serious disorders, especially certain bleeding disorders, and novel compositions and methods for use in treating such a disorder, in a person in which the disorder has occurred, and novel compositions and methods for use in avoiding such a disorder, in an individual who is susceptible thereto.
BACKGROUND OF THE INVENTION
[0002] Among the disorders, which the invention concerns, are those involving abnormal and excessive bleeding due to destruction of blood platelets (“platelets”).
[0003] These disorders include, but are not restricted to, post-transfusion purpura (“PTP”) and post-transfusion platelet refractoriness (“PTPR”), which are suffered by some persons who receive blood, platelets, leukocyte concentrates, or plasma from other persons by transfusion or the like.
[0004] The disorders also include one that is suffered by fetuses and newborns and is known as “neonatal alloimmune thrombocytopenia” (“NATP”). This disorder can cause death of fetuses and serious birth defects or death of newborns. NATP is estimated to affect about 1 in 1000 newborns. In NATP, fetal platelets, which enter the mothers blood stream, induce production in the mother of antibodies directed against fetal platelets. These maternal antibodies then pass with the mothers blood into the fetus and mediate destruction of platelets in the fetus.
[0005] A mother, whose fetus or newborn suffers from NATP, is at increased risk of suffering PTP or PTPR.
[0006] When platelets from a first human (a “donor”) are introduced into the blood system of a second human (a “recipient”) by transfusion, through the placenta (in the case of fetal blood entering the mother), or the like, the recipient may mount an immune response against the platelets from the donor. Such an immune response is referred to as an “alloimmune” response, because it involves antibodies reacting against antigens of a different individual of the same species. The alloimmune response to platelets is due to an immune response of the recipient against “alloantigens” (antigens of the same species as that mounting the immune response) on platelets from the donor. These alloantigens are found on membrane glycoproteins that occur in the cell membranes, which define the outer surfaces of platelets (“platelet membranes”). In this invention, the glycoprotein is anchored to the membrane in an atypical manner through an anchor consisting of glycosylphosphatidylinositol (GPI), which anchors an extracellular domain or segment of the glycoprotein exposed to the outside of the platelet. It is thought that alloantibodies, which are generated in an alloimmune response against platelet alloantigens, interact with the extracellular domains of the alloantigens.
[0007] The platelet alloantigens that a person has are determined by the person's genetics. A donor, because of his or her genetics, may have a platelet alloantigen, which a recipient, who receives blood, platelets, leukocytes or plasma from the donor, does not have, because of the recipient's genetics. In such a situation, the immune system of the recipient may recognize the donor's alloantigen as “non-self,” and raise an immune response against, the platelet alloantigen, which the donor has but the recipient does not.
[0008] Membrane glycoprotein alloantigens have been characterised for both human red blood cells and human platelets. It is noteworthy, however, that they also occur on other cell types, such as leukocytes and endothelial cells, where they may also occasion various disorders through alloimmune responses.
[0009] Recognised classes of red blood cell and platelet alloantigens have been described, over the past 30 years, based on observations of antibody reactions occurring when blood recipients have been exposed to blood from donors.
[0010] A recent review of human platelet alloantigen systems is provided by Ouwehand, W., and Navarrete, C., in Molecular Haematology , Provan, D. and Gribben, J. eds. Blackwell (1999).
[0011] Several biallelic platelet alloantigen “systems” have been characterised. In each of these systems, there are two alloantigens, each of which is provided by one of two alleles of the gene comprising the system. Because each gene occurs twice in the normal human genome, a person can be homozygous for one or the other of the two alloantigens, or heterozygous for the two alloantigens, comprising a biallelic system. The alloantigens described to date occur on glycoprotein molecules which may exist in various forms (transmembrane, GPI-linked and soluble, for example). In such a case, the alloantigens are found on each of the variant forms of the glycoprotein. For all of the biallelic platelet alloantigen systems that have been characterised at the level of protein and gene sequences, it has been found in all cases, except for one, that the difference between the two alleles is based on a single nucleotide polymorphism in the relevant gene.
[0012] One biallelic system of human platelet alloantigens is the Gov a /Gov b biallelic system associated with CD109, a membrane glycoprotein which occurs on platelets and various other cell types, including leukocytes and endothelial cells. Each Gov allele corresponds to one CD109 glycoprotein (Sutherland, D. R. et al, 1991; Smith et al., 1995; Berry, J. et al., 2000), consistent with the known tissue distribution of CD109. The frequencies for the Gov alleles are 0.4 for Gov a and 0.6 for Gov b in the Caucasian population. Thus, in this population, 40.7% are heterozygous for the Gov alleles, and will not mount an alloimmune response due to Gov incompatibility (not possessing the Gov alloantigen found on platelets received from another). In contrast, 19.8% of Caucasians are homozygous for the Gov a allele and thus may mount an immune response due to Gov alloantigen incompatibility against platelets received from anyone in the 80.5% of the Caucasian population that is not homozygous for the Gov a allele, while 39.8% are homozygous for the Gov b allele and thus may mount an immune response due to Gov alloantigen incompatibility against platelets received from anyone in the 60.2% of the Caucasian population that is not homozygous for the Gov b allele.
[0013] As indicated above, alloimmunization based on Gov incompatibility (the introduction into the blood stream of donor platelets bearing a Gov alloantigen not carried by the recipient) can result in bleeding disorders due to platelet destruction, including NATP, PTPR, and PTP. The location of the Gov antigens within the CD109 molecule, and the nature of the CD109 polymorphism which underlies the Gov a /Gov b alloantigen (both at the protein and at the gene level), have not heretofore been known.
[0014] Furthermore, it has not heretofore been possible to generate non-human antibody (polyclonal or monoclonal), as from a rat, mouse, goat, chicken, or the like, with specificity for the Gov a alloantigen but not the Gov b alloantigen (or vice-versa) sufficient for use in an immunoassay, for typing for Gov phenotype using platelets or CD109 molecules.
[0015] Previously developed technology, involving gene-specific amplification of platelet RNA-derived cDNA, followed by the determination of the nucleotide sequence of the amplified DNA, has been applied successfully to the elucidation of the molecular basis of other biallelic platelet alloantigen systems (Newman et al., J. Clin. Invest. 82, 739-744 (1988); Newman et al., J. Clin. Invest. 83, 1778-1781 (1989) (P1A or HPA-1 system); Lyman et al., Blood 75, 2343-2348 (1990) (Bak or HPA-3system); Kuijpers et al., J. Clin. Invest. 89, 381-384 (1992) (HPA-2 or Ko system); Wang et al., J. Clin. Invest. 90, 2038-2043 (1992) (Pen system). With one exception, it has been found in each case that a single amino acid difference at a single position differentiates the amino acid sequences of the two alleles, and that this difference arises from a single allele-specific nucleotide substitution in the coding region of the mRNA and gene. There remains a need to elucidate the molecular basis of the biallelic Gov platelet alloantigen system.
SUMMARY OF THE INVENTION
The Gova/Govb Cd109 Single Nucleotide Polymorphism
[0016] We have now discovered that a single amino acid difference in the CD109 glycoprotein distinguishes the Gov a and Gov b allelic forms. The two alleles differ at amino acid position 703 of the full-length 1445 amino acid CD109 molecule, with the Gov a allele [SEQ ID NO:2] containing a Tyr at this position, while the Gov b allele [SEQ ID NO:4] contains Ser.
[0017] Further, we have discovered that this difference in amino acid sequence between the allelic forms of CD109 is due to a single nucleotide polymorphism at position 2108 of the coding portion of full-length mRNA encoding CD109, or of the corresponding coding strand of the cDNA corresponding to this mRNA. Specifically, the Gov a allele [SEQ ID NO:1] contains adenine at position 2108, the second nucleotide of the codon encoding the amino acid at position 703 of the full-length CD109 protein, while the Gov b allele contains cytosine at position 2108, as shown in SEQ ID NO:3
[0018] The Gov a /Gov b single nucleotide polymorphism of CD109, lies at position 2108 in SEQ ID NO:1. SEQ ID NO:1 is the cDNA sequence encoding the full-length 1445 amino acid CD109 precursor encoding the Gov a allele In the Gov b allele form [SEQ ID NO:3], C occurs at position 2108, rather than A. The ATG at the 5′-end of the sequence in SEQ ID NO:1 corresponds to the translation start of the full-length precursor form (including leader peptide) of CD109. The triplet corresponding to the N-terminal amino acid of the mature CD109 protein is at positions 64-66 in SEQ ID NO:1.
[0019] The Gov a /Gov b single nucleotide polymorphism of CD109, lies at position 954 in SEQ ID NO:5. SEQ ID NO:5 is the genomic DNA sequence of human CD109 exon 19 and the contiguous introns, introns 18 and 19. The Gov a /Gov b single nucleotide polymorphism of CD109 is found within CD109 exon 19, and specifically is located at position 3 of CD109 exon 19. The sequence presented in SEQ ID NO:5 contains A at position 954, and thus corresponds to the Gov a allele. The corresponding Gov b sequence contains C at position 954 of SEQ ID NO:5 (nucleotide position 3 of exon 19).
[0020] In view of this discovery, it will be readily apparent to the skilled what the present invention provides:
[0000] Gov allele-specific oligonucleotides and polynucleotides: Based on the discovery, the present invention provides oligonucleotides and polynucleotides (seems repetitive), including (but not limited to) probes which can be used to determine whether a person is homozygous for one or the other of the Gov alleles, or heterozygous for these alleles, thereby to determine that person's Gov genotype, and by extension, their Gov phenotype (i.e., the Gov alloantigen(s) which their cells express). Further, the invention provides methods of using such oligonucleotides, and test kits to facilitate their use, in such Gov genotype and phenotype determinations. These oligonucleotides of the invention can be used to determine whether, in the CD109 gene, or in the mRNA encoding CD109, the internal nucleotide (nucleotide 2108) of the codon (in CD109 gene or in the mRNA encoding CD109) which corresponds to the amino acid at position 703 in the sequence of full-length CD109 is adenine or cytosine. Such probes will typically be cDNA but may be genomic DNA, mRNA or RNA, and may be labelled for detection. The oligonucleotides of the invention can be used as probes to detect nucleic acid molecules according to techniques known in the art (for example, see U.S. Pat. Nos. 5,792,851 and 5,851,788).
[0021] For example, an oligonucleotide of the invention may be converted to a probe by being end-labelled using digoxigenin-11-deoxyuridine triphosphate. Such probes may be detected immunologically using alkaline-phosphate-conjugated polyclonal sheep antidigoxigenin F(ab) fragments and nitro blue tetrazolium with 5-bromo-4-chloro-3-indoyl phosphate as chromogenic substrate.
[0000] Gov allele-specific antibodies: Still further, based on the discovery, which underlies the invention, of the molecular basis for the Gov a /Gov b alloantigen system, the invention provides non-human polyclonal and monoclonal antibodies, which can be used to distinguish one Gov allelic form of CD109 from the other, whether the CD109 is part of a complex embedded in or isolated from a membrane or is isolated. These antibodies of the invention, which are preferably provided in an aqueous buffer solution, and the immunoassays of the invention which employ such antibodies, are useful for determining whether a person has one or both of the Gov alloantigens and for Gov phenotyping. Methods of using the antibodies of the invention in the immunoassays of the invention, and in such determinations, are also encompassed by the invention. The invention also provides test kits to facilitate carrying out such immunoassays and determinations.
Gov allele-specific peptides and polypeptides: Again, based on the discovery that underlies the invention, of the molecular basis for the Gov a /Gov b alloantigen system, the invention provides peptides or polypeptides, which are useful for various purposes. These peptides or polypeptides are typically between 4 and 100, and more typically between 7 and 50, amino acids in length, and have amino acid sequences identical or having sequence identity to those of segments of the CD109 sequences, that include the amino acid at position 703 of full-length mature CD109. This amino acid (position 703) corresponds the triplet at positions 2107-2109 in the CD109 cDNA sequence presented in SEQ ID NO:1, or in the corresponding sequence for the CD109 cDNA that encodes the Gov b allelic form [SEQ ID NO:3]. These peptides or polypeptides may be synthetic, may be purified from native CD109 or may be prepared by recombinant means. For guidance, one may consult the following U.S. Pat. Nos. 5,840,537, 5,850,025, 5,858,719, 5,710,018, 5,792,851, 5,851,788, 5,759,788, 5,840,530, 5,789,202, 5,871,983, 5,821,096, 5,876,991, 5,422,108, 5,612,191, 5,804,693, 5,847,258, 5,880,328, 5,767,369, 5,756,684, 5,750,652, 5,824,864, 5,763,211, 5,767,375, 5,750,848, 5,859,337, 5,563,246, 5,346,815, and WO9713843. Many of these patents also provide guidance with respect to experimental assays, probes and antibodies, methods, transformation of host cells, which are described below. These patents, like all other patents, publications (such as articles and database publications) in this application, are incorporated by reference in their entirety.
Gov allele-specific peptides and polypeptides as antigens and immunogens, and Gov allele-specific polyclonal and monoclonal antibodies: These peptides or polypeptides are useful as antigens (usually coupled to a larger, immunogenic carrier [proteinaceous or otherwise], as known in the art) for making the polyclonal or monoclonal antibodies of the invention. The peptides or polypeptides are also useful in screening monoclonal antibody-producing cultures (hybridoma cultures/ E. coli cultures or so-called V gene phage antibodies) to identify those that produce monoclonal antibodies of the invention.
[0022] The invention also encompasses immunogenic compositions which comprise a peptide, polypeptide or fusion compound of the invention and which are immunogenic in a bird, including, without limitation, a chicken, or a mammal, such as, a mouse, rat, goat, rabbit, guinea pig, sheep or human. The compositions may include an immunogenicity-imparting “carrier” which may be but is not necessarily a protein as known in the art, that is immunogenic in a bird or mammal, coupled to at least one peptide or polypeptide of the invention, which has an amino acid sequence that is the same as that of a segment of the sequence for CD109, that includes the amino acid at position 703 of the full length CD109 molecule.
[0023] The present invention also provides methods of using the peptides, polypeptides and immunogenic compositions of the invention for making antibodies of the invention, and methods of using the peptides and polypeptides of the invention in screening monoclonal antibody-producing hybridoma cultures or bacterial clones for those that produce monoclonal antibodies or fragments thereof of the invention.
[0000] Therapeutic and diagnostic application of Gov allele-specific peptides, polypeptides, and antibodies: These peptides or polypeptides, as well as antibodies, which are specific for the Gov a [SEQ ID NO:2] or Gov b [SEQ ID NO:4], but not both, allelic forms of CD109 in the platelet membrane, and which can be produced by a mammal (including an human) immunized with the peptides or polypeptides, which themselves happen to be immunogenic, or the immunogenic compositions of the invention, are also useful both therapeutically and diagnostically. The invention also provides the methods of using the peptides and polypeptides of the invention, and antibodies made using the peptides that are immunogenic and the immunogenic compositions of the invention, in therapeutic and diagnostic applications.
[0024] The Gov allele-specific peptides or polypeptides can also be used diagnostically to detect the presence of Gov a or Gov b specific antibodies in human plasma or serum samples, using methods that are readily apparent to those skilled in the art. Such analyses would be useful in the investigation of cases of acquired alloimmune thrombocytopenia, including PTP, PTPR, and NATP. In the latter case, this approach could also be used to detect the presence of Gov allele-specific antibodies in the mother of the affected fetus or newborn. The presence of Gov allele-specific antibodies can also be detected using platelets of known Gov phenotype. However, this approach has numerous technical disadvantages that are eliminated by the use of Gov allele-specific peptides or polypeptides for Gov allele-specific antibody detection.
[0025] Administration to a person, who is suffering from, or at risk for, for example, PTP or PTPR, or a mother at risk for passing NATP-causing alloantibodies to her fetus, of one of the peptides or polypeptides, that would be bound by the anti-Gov alloantibodies in such a person, would inhibit the binding of the alloantibodies to the person's (or the fetus's platelets and thereby inhibit the platelet destruction and abnormal bleeding associated with the disorders. Alternatively, administration to such a person of antibodies (particularly human antibodies), which are produced using a peptide or polypeptide of the invention, which is immunogenic by itself, or an immunogenic composition of the invention, and which are specific for the Gov allelic form of the CD109 on the person's platelets which is associated with the PTP or PTPR, from which the person is suffering or may suffer, would induce the production of anti-idiotypic antibodies, which, in turn, would inhibit the platelet-destructive effects of the anti-Gov alloantibodies, which are generated by the person's own immune system and which are causing or threatening to cause the PTP, PTPR or NATP. These therapeutic applications of peptides and polypeptides of the invention would be especially useful in treating NATP in a newborn, because the alloantibody giving rise to NATP in the newborn is not continuously produced by the immune system of the newborn, but rather is acquired passively, and therefore in limited, non-replenished quantity, by the newborn from its mother.
[0026] Thus, in accordance with one aspect of the present invention, an oligonucleotideprobe is provided that hybridizes to a portion of the CD109 gene, or a portion of CD109-encoding mRNA or cDNA prepared from such mRNA, which portion includes a nucleotide corresponding to the internal nucleotide of the codon for the amino acid at position 703 of the full-length CD109 molecule, and that is capable of distinguishing one Gov allele from the other through the ability to hybridize under stringent conditions to the portion in question only when the nucleotide in question is A (or dA), when the probe is to detect the Gov a allele, or C (or dC), when the probe is to detect the Gov b allele. The nucleotide in question is at position 2108 of the coding region of the CD109 cDNA sequence and lies at position 2108 in SEQ ID NO:1. The cDNA sequence has A at this position, and so is the sequence corresponding to the Gov a allele. The nucleotide in question lies at position 954 of the sequence presented as SEQ ID NO:5 and contains an A in this position, and thus also corresponds to Gov a allele.
[0027] The Gov allele-specific oligonucleotide hybridization probes of the invention may comprise genomic DNA, cDNA, or RNA, although preferably it is DNA. Such oligonucleotide probes can be synthesised by automated synthesis and will preferably contain about 10-30 bases, although as understood in the oligonucleotide probe hybridization assay art, as few as 8 and as many as about 50 nucleotides may be useful, depending on the position within the probe where the potential mismatch with the target is located, the extent to which a label on the probe might interfere with hybridization, and the physical conditions (e.g., temperature, pH, ionic strength) under which the hybridization of probe with target is carried out.
[0000] In accordance with another aspect of the present invention, a test kit for Gov alloantigen typing is provided comprising:
(a) means for amplifying nucleic acid that comprises at least a portion of a CD109 gene, a CD109-encoding mRNA, or a CD109 cDNA made from such RNA, wherein the portion includes a nucleotide (nucleotide 2108 in SEQ ID NO:1, or nucleotide 954 in SEQ ID NO:5) corresponding to the internal nucleotide of the codon encoding amino acid 703 of the full length CD109 protein.
(b) an oligonucleotide probe of the invention, that distinguishes one Gov allele from the other. The “means for amplifying” will, as the skilled will readily understand, depend on the amplification method to be used. Thus, for example, these means might include suitable primers, a suitable DNA polymerase, and the four 2′-deoxyribonucleoside triphosphates (dA, dC, dG, dT), if amplification is to be by the PCR method. To cite another example, if the amplification is to be by a method relying on transcription, such as the 3SR method, the means will include two primers, at least one of which, when made double-stranded, will provide a promoter, an RNA polymerase capable of transcribing from that promoter, a reverse transcriptase to function in primer-initiated, DNA-directed and RNA-directed, DNA polymerization and possibly also in RNAse H degradation of RNA to free DNA strands from RNA/RNA hybrids, the four ribonucleoside triphosphates (A, C, G and U), and the four 2′-deoxyribonucleoside triphosphates. In another example, if the amplification is by the ligase chain reaction, the means will include two oligonucleotides (DNAs) and a suitable DNA ligase that will join the two if a target, to which both can hybridize adjacent to one another in ligatable orientation, is present.
[0028] The oligonucleotide probes of the invention will preferably be labelled. The label may be any of the various labels available in the art for such probes, including, but not limited to 32 P; 35 S; biotin (to which a signal generating moiety, bound to or complexed with avidin can be complexed); a fluorescent moiety; an enzyme such as alkaline phosphatase (which is capable of catalysing a chromogenic reaction); digoxigenin, as described above; or the like.
[0029] As indicated in the examples, RFLP analysis can be employed, using BstNI (or isoschizomers thereof), in analysing cDNA or genomic DNA (with or without amplification) to determine Gov genotype. As indicated further in the examples, electrophoretic SSCP analysis may be used to determine Gov genotype. And as indicated in the examples, the hybridization studies outlined above may use fluorescent probes, and may be directly coupled to the DNA amplification step, as in “Real-Time PCR” or related methods.
[0030] There has also been provided, in accordance with another aspect of the present invention, a method of typing for Gov allele-specific target sequence in a CD109 nucleic acid derived from a subject, comprising the steps of,
[0000] (a) obtaining, by a target nucleic acid amplification process applied to mRNA from human platelets, endothelial cells, or T cells, an assayable quantity of amplified nucleic acid with a sequence that is that of a subsequence (or the complement of a subsequence) of the mRNA that encodes a CD109 said subsequence including the nucleotide at the position in the mRNA corresponding to position 2108 in SEQ ID NO:1 or to nucleotide 954 in SEQ ID NO:5; and
(b) analyzing (e.g., in a nucleic acid probe hybridization assay employing an oligonucleotide probe or probes according to the invention) the amplified nucleic acid obtained in step (a) to determine the base or bases at the position in the amplified nucleic acid that corresponds to position 2108 in SEQ ID NO:1 or to nucleotide 954 in SEQ ID NO:5. It is noteworthy that, if the product of the amplification is double-stranded DNA, analysis for Gov genotype can be carried out by a RFLP (restriction fragment length polymorphism) analysis comprising exposing the amplified DNA to the restriction endonuclease BstNI (or isoschizomer thereof) under conditions whereby the DNA will be cleaved if it includes a site for cleavage by that enzyme. Such DNA, prepared from mRNA encoding the Gov b alloantigen, containing a C rather than an A at the position corresponding to nucleotide 2108 in SEQ ID NO:1 (or to nucleotide 954 in SEQ ID NO:5), includes a recognition site for that endonuclease, while such DNA prepared from mRNA encoding the Gov a alloantigen, does not. If the analysis, by whatever method, of the amplified nucleic acid reveals that there is only an A (or dA) at the position corresponding to position 12108, the platelets (and blood from which they came) have only the Gov a alloantigen, and the individual from whom the platelets came, is homozygous for Gov a . Alternatively, if the analysis of the amplified nucleic acid reveals that there is only a C (or dC) at the position corresponding to position 2108, the platelets (and blood from which they came) have only the Gov b alloantigen and the individual, from whom the platelets came, is homozygous for the Gov b allele. Finally, if the analysis indicates that there is either an A (or dA) or a C (or dC) at that position, the platelets (and blood from which they came) have both Gov alloantigens, and the individual from whom the platelets came, is heterozygous for Gov alloantigen.
[0031] In one application of the typing methods of the invention, the methods are applied to two individuals to determine whether blood or platelets from one would provoke an alloimmune response, and possibly PTP or PTPR, in the other. The typing method can be applied with a man and a woman, who are contemplating conceiving or have conceived a child together, to determine the risk that the child would be at risk for NATP and the risk that the woman would be at increased risk for PTP or PTPR. If the woman were heterozygous for the Gov alloantigens there would be, due to Gov alloantigen incompatibility, no risk of NATP and no increased risk for the woman of PTP or PTPR. If, however, the woman were homozygous for one of the Gov alloantigens, there would be, due to Gov alloantigen incompatibility, risk of NATP in a child and increased risk of PTP or PTPR for the woman, unless the man is homozygous for the same Gov alloantigen as is the woman.
[0032] In accordance with yet another aspect of the present invention, a method of typing an individual for Gov alloantigen is provided that comprises analyzing the genomic DNA of the individual to determine the Gov alloantigen(s) of the individual. Applications of this method are substantially the same as those of the method of the invention for typing for Gov alloantigen that begins with platelet, endothelial cell, or T cell mRNA.
[0033] This method of the invention, entailing analysis of genomic DNA, can be carried out in substantially the same way as outlined above for analysis of mRNA, namely first amplifying the genomic DNA and then analyzing to product of the amplification to ascertain whether there is only dA, only dC, or both dA and dC, at the position in the coding region of the genomic DNA corresponding to position 2108 in SEQ ID NO:1, or to nucleotide 954 in SEQ ID NO:5.
[0034] In accordance with a further aspect of the present invention, a test kit for Gov alloantigen typing is provided comprising a non-human antibody (or antibodies) that distinguishes the two allelic forms of CD109. The antibody (or antibodies) of the kit may be polyclonal, or preferably monoclonal, and in addition to its (their) specificity for either but not both Gov alloantigens (on the surface of platelets or separated therefrom) or the CD109 subunit of one but not both of such alloantigens, typically will recognise a polypeptide molecule encoded by a nucleotide sequence encoding at least amino acid 703 of a CD109 polypeptide (the amino acid at the position corresponding to nucleotides 2107-2109 in SEQ ID NO:1, or to nucleotides 953-955 in SEQ ID NO:5).
DETAILED DESCRIPTION OF THE INVENTION
Definitions
[0035] The following definitions are provided in order to aid those skilled in the art in understanding the detailed description of the present invention.
[0036] The term “alloantigens” refers to antigens of an individual that are responsible for eliciting an alloimmune response.
[0037] The phrase “alloimmune response” refers to an immune response, which occurs when antibodies from one individual react against antigens of a different individual of the same species.
[0038] The phrase “anti-idiotypic antibodies” refers to antibodies which can bind endogenous or foreign idiotypic antibodies and which can be used to treat or prevent pathological conditions associated with an immune response to a foreign alloantigen.
[0039] The phrase “Gov a /Gov b biallelic system” refers to a system of human platelet alloantigens in which an individual can be homozygous for either Gov a or Gov b allelic forms of CD109, or an individual can be Gov a /Gov b heterozygous for CD109.
[0040] “GPI” refers to glycosylphosphatidylinositol.
[0041] The term “NATP” refers to neonatal alloimmune thrombocytopenia.
[0042] “Nucleic acid” includes DNA and RNA, whether single or double stranded. The term is also intended to include a strand that is a mixture of nucleic acids and nucleic acid analogs and/or nucleotide analogs, or that is made entirely of nucleic acid analogs and/or nucleotide analogs.
[0043] “Nucleic acid analogue” refers to modified nucleic acids or species unrelated to nucleic acids that are capable of providing selective binding to nucleic acids or other nucleic acid analogues. As used herein, the term “nucleotide analogues” includes nucleic acids where the internucleotide phosphodiester bond of DNA or RNA is modified to enhance biostability of the oligomer and “tune” the selectivity/specificity for target molecules (Ulhmann, et al., 1990, Angew. Chem. Int. Ed. Eng., 90: 543; Goodchild, 1990, J. Bioconjugate Chem., I: 165; Englisch et al., 1991, Angew, Chem. Int. Ed. Eng., 30: 613). Such modifications may include and are not limited to phosphorothioates, phosphorodithioates, phosphotriesters, phosphoramidates or methylphosphonates. The 2′-O-methyl, allyl and 2′-deoxy-2′-fluoro RNA analogs, when incorporated into an oligomer show increased biostability and stabilization of the RNA/DNA duplex (Lesnik et al., 1993, Biochemistry, 32: 7832). As used herein, the term “nucleic acid analogues” also include alpha anomers (α-DNA), L-DNA (mirror image DNA), 2′-5′ linked RNA, branched DNA/RNA or chimeras of natural DNA or RNA and the above-modified nucleic acids. For the purposes of the present invention, any nucleic acid containing a “nucleotide analogue” shall be considered as a nucleic acid analogue. Backbone replaced nucleic acid analogues can also be adapted to for use as immobilised selective moieties of the present invention. For purposes of the present invention, the peptide nucleic acids (PNAs) (Nielsen et al, 1993, Anti-Cancer Drug Design, 8: 53; Engels et al., 1992, Angew, Chem. Int. Ed. Eng., 31: 1008) and carbamate-bridged morpholino-type oligonucleotide analogs (Burger, D. R., 1993, J. Clinical Immunoassay, 16: 224; Uhlmann, et al., 1993, Methods in Molecular Biology, 20, “Protocols for Oligonucleotides and Analogs,” ed. Sudhir Agarwal, Humana Press, NJ, U.S.A., pp. 335-389) are also embraced by the term “nucleic acid analogues”. Both exhibit sequence-specific binding to DNA with the resulting duplexes being more thermally stable than the natural DNA/DNA duplex. Other backbone-replaced nucleic acids are well known to those skilled in the art and may also be used in the present invention (See e.g., Uhlmann et al 1993, Methods in Molecular Biology, 20, “Protocols for Oligonucleotides and Analogs,” ed. Sudhir Agrawal, Humana Press, NJ, U.S.A., pp. 335).
[0044] The term “PTP” refers to post-transfusion purpura.
[0045] The term “PTPR” refers to post-transfusion platelet refractorines.
[0046] “SNP” refers to single nucleotide polymorphism.
[0047] The standard, one-letter codes “A,” “C,” “G,” and “T” are used herein for the nucleotides adenylate, cytidylate, guanylate, and thymidylate, respectively. The skilled will understand that, in DNAs, the nucleotides are 2′-deoxyribonucleotide-5′-phosphates (or, at the 5′-end, possibly triphosphates) while, in RNAs, the nucleotides are ribonucleotide-5′-phosphates (or, at the 5′-end, possibly triphosphates) and uridylate (U) occurs in place of T. “N” means any one of the four nucleotides. On occasion herein, dA, dC, dG and dT might be used for the respective 2′-deoxyribonucleotides.
[0048] Unless otherwise specified or required by the context, “nucleic acid” means DNA or RNA and “nucleotide” means ribonucleotide or 2′-deoxyribonucleotide.
[0049] Reference herein to a “full-length” CD109 molecule or protein means the 1445-amino acid-long polypeptide, for which the amino acid sequence, deduced from a cDNA sequence, is provided in SEQ ID NO:1 and in SEQ ID NO:3 and which is denoted as the full-length translated product (i.e., including the amino-terminal leader peptide, and excluding carboxyl-terminal processing associated with GPI anchor addition). The Gov a alloantigen bearing form of CD109 may be referred to herein as 703 Tyr CD109. The Gov b alloantigen bearing form of CD109 may be referred to herein as 703 Ser CD109.
[0050] It has been determined that a single nucleotide of the CD109 gene is responsible for the Gov polymorphism in CD109. Extensive serological studies initially demonstrated that the polymorphism underlying the Gov system resides solely on the CD109 molecule [Sutherland, D. R. (1991); Smith et al. (1995)]. Further, extensive deglycosylation of CD109 does not affect the binding the anti-Gov a and anti-Gov b antibodies to molecules of the appropriate phenotype, or to cells bearing the appropriate CD109 variant, indicating that carbohydrate residues are not involved in the formation of Gov antigenic epitopes. Further work has indicated that the Gov allele-specific antibody binding can however, be abrogated by denaturation of CD109 with the detergent SDS [Smith et al. (1995)]. Taken together, these observations indicate that the Gov alleles of CD109 are protein epitopes that are likely defined by the primary amino acid sequence of CD109.
[0051] Following the isolation of a CD109 cDNA the nature of the two Gov alleles was characterised further using platelet RNA-derived cDNA in the polymerase chain reaction (“PCR”). Platelet mRNA transcripts were obtained from serologically defined Gov a/a , Gov a/b and Gov b/b individuals. The RNA was then converted to cDNA, and the entire CD109 cDNA coding region was then amplified as a series of overlapping PCR products. The Gov a [SEQ ID NO:1] and Gov b [SEQ ID NO:3] alleles differ by an A to C substitution at position 2108 of the coding region of the CD109 cDNA. This single nucleotide polymorphism also results in a BstNI restriction site in the Gov b allele that is not present in its Gov a counterpart. On the basis of this BstNI site, Gov a can by distinguished from Gov b by restriction fragment length polymorphism (RFLP) analysis. This single nucleotide polymorphism can also be detected by SSCP analysis, and by allele-specific hybridization studies, including “Real-Time” PCR analyses.
[0052] As a result of this A 2108 C single nucleotide polymorphism, the Gov a allele [SEQ ID NO:2] of CD109 contains a Tyr at position 703 of the full-length protein, while the Gov b allele [SEQ ID NO:4] contains a Ser in this position. The polymorphism does not alter the ability of Gov a and Gov b homozygous platelets to adhere to collagen types I, III and V. Additionally, the binding of anti-Gov a and anti-Gov b antibodies to platelets of the appropriate phenotype did not interfere with platelet adhesion to any of the above collagen types. Thus, while the Tyr 703 Ser results in the formation of the Gov alloantigen epitopes, it does not appear to impair platelet function.
[0053] Identification and characterisation of the Gov alloantigen system permits pre- and post-natal diagnosis of the Gov phenotype of an individual, providing a warning for the possibility of NATP, PTP and PTPR. Allelic Gov typing of CD109 equates with the Gov status of the CD109 protein of an individual. The Gov system led to diagnostic and therapeutic strategies to avoid or control diseases that result from Gov incompatibility. The present invention can be applied to these tasks and goals in a variety of ways, illustrative examples of which are discussed below.
[0054] For example, an oligonucleotide probe can be synthesized, in accordance with the present invention, that will hybridize to a cDNA segment, derived from CD109 mRNA, that contains the nucleotide G at polymorphic nucleotide 2108 (nucleotide=guanylate). Alternatively, an oligonucleotide probe can be synthesized that will hybridize with a CD109 cDNA segment containing the base adenine at nucleotide 2108 (nucleotide=adenylate). These allele-specific probes can be appropriately labelled and added to the generated cDNA segments under annealing conditions, such that only one of the allele-specific probes hybridizes and can be detected, thereby identifying the specific Gov a or Gov b allele. In accordance with conventional procedures, the design of an oligonucleotide probe according to the present invention preferably involves adjusting probe length to accommodate hybridization conditions (temperature, ionic strength, exposure time) while assuring allele-specificity. A length of ten to thirty nucleotides is typical.
[0055] Diagnostic kits can also be used, in accordance with the present invention, for the determination and diagnosis of alloantigen phenotypes via the procedures described herein. Such a kit can include, among others, antibodies or antibody fragments to an antigenic determinant expressed by either of the above-described Gov a - and Gov b -encoding sequences. These antibodies would react with the blood sample of an individual so as to indicate whether that individual has a Gov a or Gov b phenotype. Alternatively, all the reagents required for the detection of nucleotide(s) that distinguish the Gov alloantigens, by means described herein, can be provided in a single kit that uses isolated genomic DNA, platelet (or other cellular) mRNA or total RNA, or corresponding cDNA from an individual. A kit containing a labelled probe that distinguishes, for example, nucleotide 2108 of CD109 can be utilised for Gov alloantigen genotyping and phenotyping.
[0056] A further beneficial use of the nucleotide sequences that distinguish the Gov a allele from the Gov b allele is to obtain or synthesize the respective expression product, in the form of a peptide or polypeptide, encoded by these nucleotide sequences. These polypeptides can be used to generate antibodies for diagnostic and therapeutic uses, for example, with regard to pathological conditions such as PTP, PTPR or NATP. These polypeptides can also be used diagnostically to detect the presence of Gov a or Gov b specific antibodies in patient plasma or serum, or used therapeutically (see below; assays may be adopted, for example, from U.S. Pat. No. 5,851,788).
[0057] A polypeptide within the present invention which can be used for the purpose of generating such antibodies preferably comprises an amino-acid sequence that corresponds to (i.e., is coincident with or functionally equivalent to) a fragment of the CD109 molecule that includes amino acid 703. When amino acid 703 is Tyrosine, the polypeptide can be used, as described above, to produce antibodies that specifically bind the Gov a form of CD109; in contrast, when it is Serine, antibodies can be obtained that specifically recognise the Gov b form. The class of polypeptides thus defined, in accordance with the present invention, is not intended to include the native CD109 molecule, but does encompass fragments of the molecule, as well as synthetic polypeptides meeting the aforementioned definition.
[0058] Although the length of a polypeptide within this class is not critical, the requirement for immunogenicity may require that the polypeptide be attached to an immunogenicity-imparting carrier. Such carriers include a particulate carrier such as a liposome or a soluble macromolecule (protein or polysaccharide) with a molecular weight in the range of about 10,000 to 1,000,000 Daltons Additionally, it may be desirable to administer the polypeptide with an adjuvant, such as complete Freund's adjuvant. For artificial polypeptides, as distinguished from CD109 fragments, maximum length is determined largely by the limits of techniques available for peptide synthesis, which are currently about fifty amino acids. Thus, a synthetic polypeptide of the present invention is preferably between four to about fifty amino acids in length.
[0059] In the context of the present invention, the term “antibody” encompasses monoclonal and polyclonal antibodies produced by any available means. Such antibodies can belong to any antibody class (IgG, IgM, IgA, etc.) and may be chimeric. Examples of the preparation and uses of polyclonal antibodies are disclosed in U.S. Pat. Nos. 5,512,282, 4,828,985, 5,225,331 and 5,124,147 which are incorporated by reference in their entirety. The term “antibody” also encompasses antibody fragments, such as Fab and F(ab′) 2 fragments, of anti-Gov a or anti-Gov b antibodies, conjugates of such fragments, and so-called “antigen binding proteins” (single-chain antibodies) which are based on anti-Gov a or anti-Gov b antibodies, in accordance, for example, with U.S. Pat. No. 4,704,692, the contents of which are hereby incorporated by reference. Alternatively, monoclonal antibodies or fragments thereof within the present invention can be produced using conventional procedures via the expression of isolated DNA that encodes variable regions of such a monoclonal antibody in host cells such as E. coli (see, e.g., Ward et al., Nature, 341:544-546 (1989)) or transfected murine myeloma cells (see Gillies et al., Biotechnol. 7:799-804 (1989); Nakatani et al., Biotechnol. 7:805-810 (1989)). For additional examples of methods of the preparation and uses of monoclonal antibodies, see U.S. Pat. Nos. 5,688,681, 5,688,657, 5,683,693, 5,667,781, 5,665,356, 5,591,628, 5,510,241, 5,503,987, 5,501,988, 5,500,345 and 5,496,705 that are incorporated by reference in their entirety.
[0060] While human alloantisera currently used for serological typing are specifically excluded from this definition, the use of CD109 or Gov allele-specific peptides to detect anti-Gov antibodies in human plasma or serum, or to determine the specificity of such alloantibodies, are specifically included. Similarly, the use of such CD109 peptides or Gov allele-specific peptides to purify CD109 antibodies, or allele-specific CD109 antibodies from human serum is specifically included. Similarly, the use in vitro of such CD109 peptides or Gov allele-specific peptides to deplete allele-specific antibody activity from human serum samples, or to block CD109 antibody binding, or allele-specific antibody binding, is specifically included.
[0061] Diagnostic applications of these antibodies are exemplified, according to the present invention, by the use of a kit containing an anti-Gov a or an anti-Gov b antibody, which undergoes a reaction with a sample of an individual's blood to determine a Gov a or Gov b platelet phenotype. Such a reaction involves the binding of anti-Gov a antibody to Gov a antigen or the binding of anti-Gov b antibody to Gov b antigen. The observation of antibody-antigen complex in a blood sample would indicate a positive result. A kit of this type could be used to diagnose, or to help prevent the occurrence of pathological conditions like PTP, PTPR, or NATP.
[0062] A polypeptide of the present invention that is recognised specifically by anti-Gov a or anti-Gov b antibodies can also be used therapeutically. Thus, antibodies raised against such a polypeptide can be employed in the generation, via conventional methods, of anti-idiotypic antibodies, that is, antibodies that bind an anti-Gov a or anti-Gov b antibody. See, e.g., U.S. Pat. No. 4,699,880, the contents of which are hereby incorporated by reference. Such anti-idiotypic antibodies would bind endogenous or foreign anti-Gov antibodies in the blood of an individual, which would treat or prevent pathological conditions associated with an immune response to a “foreign” Gov alloantigen. Alternatively, a polypeptide within the present invention can be administered to an individual, with a physiologically-compatible carrier, to achieve the same qualitative effect, namely, the selective reduction or elimination of circulating anti-Gov antibodies from a patient suffering or at risk from an immune response, or the abrogation by competitive binding to administered peptide, of the binding of Gov-specific antibodies to the platelets of such an individual
[0063] The present invention is further described below by reference to the following, illustrative examples.
Example 1
PCR Amplification and Analysis of PCR Products
[0064] Platelet total RNA was isolated from EDTA anticoagulated blood of Gov aa and Gov bb individuals in the manner described in Lymann et al., Blood 75:2343-48 (1990). First, platelet mRNA in 10 μl aliquots was heated to 70° C. for 10 minutes and quickly cooled on ice before reverse transcription. The first strand cDNA was then synthesized using 10 μM oligo dT, 40 units RNAsin (Promega), 2 mM of each dNTP (dN triphosphate) (Pharmacia), 500 units of cloned MMLV reverse transcriptase and 5× enzyme buffer (Gibco) in a total volume of 50 μl. The cDNA synthesis was carried out at 42° C. for 45 minutes and was stopped by chilling to 0° C.
[0065] Overlapping sets of oligonucleotide primers (Table 2) based on the sequence of CD109 were then used to amplify by PCR the entire coding region of platelet CD109 in 8 overlapping segments that spanned the entire CD109 open reading frame.
[0000]
TABLE 2
Annealing
Size
Temperature
Fragment
Sense Primer
Antisense Primer
(bp)
(° C.)
1
K1-80
(−24)
K1-650
544
568
59
5′ GTAGCCCAGGCAGACGCC 3′
5′ GTGACAACCACTGTTGGATCAA 3′
2
K1-1
445
K1-1120
1014
570
50
5′ CGCATTGTTACACTCTTCTC 3′
5′ TACATTTCTTGAAATACCTG 3′
3
K1-1022
910
K1-REV-1
1747
838
50
5′ GATTCTTCAAATGGACTTT 3′
5′ GGCTGTGTCACAGAGATC 3′
4
K1-1400
1291
GSP3
2165
875
55
5′ TGAATTCCCAATCCTGGAGGA 3′
5′ GCCACCCAAGAAGTGATAGA 3′
5
K1-M43
1898
6R4N
2998
1101
56
5′ TTCAGGAATGTGGACTCTGG 3′
5′ CGGCTTCAAGGAAACATCT 3′
6
K1-3080
2948
1-5N
3859
912
56
5′ CTGGGAGCACTTGGTTGTCA 3′
5′ CAGCAACATCTAAATCAAAGGC 3′
7
K1-3570
3462
7U3N
4337
876
50
5′ ACAATTTCAGACTTCTGAGG 3′
5′ CACAGCCAAAGTTCCATA 3′
8
K1-3920
3812
K1-4.600
4489
678
55
5′ GACGAAGATCTATCCAAAATC 3′
5′ GCTAGGACCTGTTGTACACC 3′
[0066] Table 2 lists the position of the 5′ end of each oligonucleotide with respect to the CD109 cDNA sequence, which includes both 3′ and 5′ untranslated regions, is noted in parentheses. The CD109 ORF encompasses nucleotides 1-4335 of the published CD109 cDNA, and corresponds exactly to the CD109 cDNA sequence presented in SEQ ID NO:1. The size of each PCR product, and the annealing temperature used for the corresponding primer pair, is listed.
[0067] PCR reactions (50:1) containing 1×PCR buffer (Gibco Life Technologies), 1.5 mM MgCl 2 , 200:M of each dNTP, 1:M of each primer, 1.25 units Taq polymerase (Gibco Life Technologies), and 3:1 cDNA underwent 40 cycles of 94° C. (45 seconds), primer-specific annealing temperature (Table 2; 45 seconds), and 72° C. (45-60 seconds), using a Perkin Elmer 2400 thermocycler. PCR products (30:1) were subsequently size-separated electrophoretically on a 1.2% agarose/TAE gel containing 1:g/ml ethidium bromide. Bands were subsequently excised and purified (50:1) using the QIAquick (Qiagen) kit for direct sequencing and subcloning. Sequencing reactions (3-5:I purified product per reaction) were carried out using the Thermosequenase Cy5.5 dye terminator sequencing kit (Amersham Pharmacia Biotech) and the same primers that had been used for initial PCR amplification (Table 2), or selected internal CD109-specific primers as appropriate, and were subsequently analysed using the Open Gene automated DNA sequencing system (Visible Genetics). In parallel, PCR products were cloned into Pmel-digested pMAB1, a pBS SK(−) (Stratagene) derivative containing a Pmel restriction site within the polylinker. Resultant plasmid clones were analysed by alkaline lysis/restriction digestion, and as appropriate (and following an additional overnight 13% PEG/1.6 M NaCl precipitation), by DNA sequence analysis as above. By combining direct PCR sequencing and the analysis of subcloned fragments, it was ensured that the DNA sequence of each PCR-derived cDNA fragment was obtained independently at least twice, with each fragment being sequenced in both directions in its entirety.
[0068] This analysis revealed that the CD109 cDNA sequences of Gov aa and Gov bb individuals differed by a single nucleotide at position 2108 of the sequence shown in SEQ ID NO:1. Gov a/a
[0069] individuals have an A at position 2108, whereas Gov b/b individuals have a C at the same position. This change results in a Tyr-Ser amino acid polymorphism at residue 703 of the full-length CD109 polypeptide chain. This single nucleotide polymorphism also results in a BstNI restriction site in the Govb allele that is not present in the Gov a allele. Analysis of the other regions of the CD109 cDNA in their entirety revealed no other nucleotide differences that segregated with Gov phenotype (i.e., that could be used to distinguish the Gov a allele from the Gov b allele).
[0070] To facilitate subsequent genomic DNA analyses of the Gov a/b alleles, the intron/exon junctions of the exon bearing the putative Gov-specific nucleotide substitution identified above, as well as the DNA sequence of the flanking introns, were determined. CD109 cDNA-specific oligonucleotides binding in the vicinity of this substitution were used for the direct sequencing of p4L10, a pCYPAC — 1-derived PAC clone bearing the human CD109 locus using the Open Gene system (Visible Genetics) as above. The nucleotide sequence of the Gov polymorphism-containing exon, as well as of the flanking introns, is presented in SEQ ID NO:5. The Gov polymorphism lies at nucleotide position 954 in SEQ ID NO:5. Subsequent work has mapped the intron-exon structure of the entire human CD109 locus, and has determined that the Gov single nucleotide polymorphism of CD109 lies in exon 19 of the CD109 gene.
Example 2
RFLP Analysis of PCR Amplified Genomic DNA
[0071] The A-C Gov CD109 polymorphism corresponds to the internal nucleotide of the first complete codon of exon 19 of the CD109 gene. As this exon comprises only 118 nucleotides, and the Gov polymorphism lies almost at the extreme 5′ end of this exon, we determined the nucleotide sequence of both introns flanking this exon to facilitate subsequent genomic DNA analyses of the Gov a/b alleles. The DNA sequence of CD109 exon 19 and its flanking introns (CD109 introns 18 and 19) is presented as SEQ ID NO:5. To confirm that the A to C polymorphism at position 2108 of the CD109 open reading frame (nucleotide 2108, SEQ ID NO: 1; nucleotide 954, SEQ ID NO:5) segregates with the Gov phenotype, RFLP analysis was carried out on PCR amplified genomic CD109 DNA using the BstNI restriction endonuclease, which recognises the DNA sequence 5′ CCAGG 3′ found in the Gov b cDNA (nucleotides position 2108-2112 in SEQ ID NO:3; the corresponding Gov a sequence, 5′ ACAGG 3′, is nucleotides 2108-2112 in SEQ ID NO:1). This enzyme does not cleave at 5′ ACAGG 3′ (found in Gov a ; nucleotides 2108-2112 in SEQ ID NO: 1). A 448 bp genomic fragment was PCR-amplified from Gov aa , Gov ab , and Gov bb individuals using the pair of oligonucleotides SEQ ID NO:9 and SEQ ID NO:10. These oligonucleotides flank exon 19. The former binds within intron 18 (nucleotides 875-892 SEQ ID NO:5), while the latter binds within intron 19 to the sequence complementary to nucleotides 1305-1322 of SEQ ID NO:5). The resultant 448 bp PCR product, when digested with BstNI, yielded the restriction fragments predicted on the basis that the A to C polymorphism at position 2108 (SEQ ID NO: 1) segregates with the Gov phenotype.
Example 3
Hybridization Analysis of PCR Amplified Genomic DNA
[0072] To further confirm that the A to C polymorphism at position 2108 of the CD109 open reading frame (nucleotide 2108, SEQ ID NO:1; nucleotide 954, SEQ ID NO:5) segregates with the Gov phenotype, we also performed an alternative analysis involving the selective hybridization of Gov allele-specific DNA probes to PCR amplified genomic CD109 DNA. Two primers flanking the polymorphic A-C site at position 2108 (SEQ ID NO:1; position 954, SEQ ID NO:5) were designed to amplify by PCR a 105 bp genomic DNA fragment containing the polymorphic site from genomic DNA isolated from Gov aa , Gov ab , and Gov bb individuals. The first primer (SEQ ID NO:11) binds within intron 18 to nucleotides 902-928 of SEQ ID NO:5. The second primer (SEQ ID NO:12) binds within exon 19 to the sequence complementary to nucleotides 977-1106 of SEQ ID NO:5. Two additional nucleotide probes were designed—one specific for the target sequence of the Gov a allele of the CD109 gene, and the other for the Gov b allele of the CD109 gene. The first probe (SEQ ID NO:13) overlaps the CD109 intron 18/exon 19 junction, binds to the Gov a allele at nucleotides 935-974 of SEQ ID NO:5, and was tagged with the fluorescent dye 6-FAM. The second probe (SEQ ID NO:14), also overlapping the CD109 intron 18/exon 19 junction, binds to the Gov b allele at the position corresponding to nucleotides 935-971 of SEQ ID NO:5, and was tagged with the fluorescent dye VIC. Genomic DNA was isolated from Gov phenotyped human peripheral blood leukocytes, and PCR/hybridization analysis was carried out using Taqman real-time PCR technology (Perkin Elmer). Genomic DNA was amplified using primers SEQ ID NO:11 and SEQ ID NO:12, with each reaction additionally containing 100 nM FAM-labelled Gov a probe and 200 nM VIC-labelled Gov b probe. Allelic discrimination, based on allele-specific fluorescence, was then determined using a post-PCR plate reader (Perkin Elmer). In all cases, PCR/fluorescence-based Gov genotyping correlated with the Gov phenotype, indicating that the A to C polymorphism at position 2108 (SEQ ID NO: 1) does indeed segregate with the Gov phenotype.
Example 4
SSP Analysis of PCR Amplified Genomic DNA
[0073] To further confirm that the A to C polymorphism at position 2108 of the CD109 open reading frame (nucleotide 2108, SEQ ID NO:1; nucleotide 954, SEQ ID NO:5) segregates with the Gov phenotype, we also performed an alternative analysis involving SSCP analysis of PCR amplified genomic CD109 DNA. Two Gov allele-specific antisense oligonucleotides—SEQ ID NO:6 and SEQ ID NO:7—differing by a single 3′ nucleotide (and binding to sequence complementary to nucleotides 954-976 of SEQ ID NO:5, and of the Gov b counterpart of SEQ ID NO:5, respectively), were combined with a common sense primer—SEQ ID NO:8 binds within intron 18 and which corresponds to nucleotides 752-773 of SEQ ID NO:5, to amplify a 225 bp genomic DNA fragment containing the Gov polymorphic site from genomic DNA isolated from Gov aa , Gov ab , and Gov bb individuals. In all cases, complete concordance between PCR-SSP analysis and Gov phenotyping was observed.
Sequences:
[0074] SEQ ID NO: 1 consists of the entire 4335 nucleotide CD109 cDNA open reading frame encoding the Gov a allele. The Gov a allele comprises an A at nucleotide position 2108.
SEQ ID NO:2 consists of the entire 1445 aa protein sequence produced from CD109 Gov a cDNA. The Gov a allele comprises a Tyr at amino acid 703.
SEQ ID NO: 3 consists of the entire 4335 nucleotide CD109 cDNA open reading frame encoding the Gov b allele. The Gov b allele comprises a C at nucleotide position 2108.
SEQ ID NO: 4 consists of the entire 1445 aa protein sequence produced from the CD109 Gov b cDNA. The Gov b allele comprises a Ser at amino acid 703.
SEQ ID NO: 5 consists of the CD109 genomic DNA comprising CD109 exon 19 and the flanking introns, introns 18 and 19. The 118 nucleotide exon 19, comprising nucleotides 952-1069 of SEQ ID NO:5, corresponds to nucleotides 2106-2223 of SEQ ID NO: 1. The A to C Gov polymorphism of CD109 (corresponding to nucleotide 2108 of SEQ ID NO: 1) therefore corresponds to nucleotide 954 of SEQ ID NO:5. In the Gov a allele, nucleotide 954 is A, while in the Gov b allele nucleotide 954 is C. Thus, SEQ ID NO:5 corresponds to the Gov a allele of CD109. Within SEQ ID NO:5, nucleotides 1-951 correspond to CD109 intron 18, while nucleotides 1070-2608 correspond to intron 19.
[0075] We note that nucleotides 2108-2112 of SEQ ID NO: 1, and the corresponding nucleotides 954-958 of SEQ ID NO:5, which consist of the sequence 5′ ACAGG 3′ (and which contains the Gov a allele-specific polymorphic nucleotide at its 5′ end), is not cleavable by the restriction endonuclease BstNI. However, in the corresponding Gov b allele, the corresponding sequence—5′ CCAGG 3′—is cleavable by BstNI, and that the two Gov alleles can be discriminated on this basis. We note also that a group of restriction endonucleases—Bst2UI, BstNI, BstOI, EcoRII, MaeIII, MspR91, MvaI, or ScrFI (or one of their isoschizomers)—is capable of differentiating between the Gov a and Gov b alleles on this basis.
[0076] SEQ ID NO:6-SEQ ID NO:14 comprise oligonucleotides for the PCR amplification of Gov polymorphism containing CD109 sequence from RNA, cDNA derived from RNA, or from genomic DNA, and for the Gov typing analyses of such amplified DNA fragments.
SEQ ID NO:6.
[0077] SEQ ID NO: 3, an antisense oligonucleotide specific for the Gov a allele, binds to exon 19 sequence complementary to nucleotides 954-976 of SEQ ID NO:5. SEQ ID NO:6 and SEQ ID NO: 7 (see below) differ by a single allele-specific 3′ nucleotide
SEQ ID NO:7.
[0078] SEQ ID NO:7, an antisense oligonucleotide specific for the Gov b allele, binds to exon 19 sequence complementary to nucleotides 954-976 of the Gov b counterpart of SEQ ID NO:5. SEQ ID NO:6 (see above) and SEQ ID NO:7 differ by a single allele-specific 3′ nucleotide.
SEQ ID NO:8.
[0079] SEQ ID NO:8 binds within intron 18, and corresponds to nucleotides 752-773 of SEQ ID NO:5.
SEQ ID NO:9.
[0080] SEQ ID NO:9 binds within intron 18 (nucleotides 875-892 SEQ ID NO:5).
SEQ ID NO:10.
[0081] SEQ ID NO:10 binds within intron 19 to the sequence complementary to nucleotides 1305-1322 of SEQ ID NO:5.
SEQ ID NO:11
[0082] SEQ ID NO:11 binds within intron 18 to nucleotides 902-928 of SEQ ID NO:5.
SEQ ID NO:12.
[0083] SEQ ID NO:12, binds within exon 19 to the sequence complementary to nucleotides 977-1006 of SEQ ID NO:5.
SEQ ID NO:13.
[0084] SEQ ID NO:13, specific for the Gov a allele, overlaps the CD109 intron 18/exon 19 junction, and binds to the Gov a allele at nucleotides 935-974 of SEQ ID NO:5.
SEQ ID NO:14.
[0085] SEQ ID NO:14, specific for the Gov b allele, overlaps the CD109 intron 18/exon 19 junction, and binds to the Gov b allele at the position corresponding to nucleotides 935-971 of SEQ ID NO:5.
|
Based on the discovery of the nucleotide and amino acid differences which distinguish the Gov a and Gov b allelic forms of the membrane glycoprotein CD109, and which comprise the biallelic Gov platelet alloantigen system, compositions and methods are provided for determining the Gov genotype and phenotype of individuals. Also provided, on the basis of this discovery, are compositions and methods for treating disorders associated with Gov alloantigen incompatibility, such as the bleeding disorders post-transfusion purpura, post-transfusion platelet refractoriness, and neonatal alloimmune thrombocytopenia. The two allelic forms of CD109 differ by a single amino acid. The Gov a allelic form has Tyr at amino acid position 703 in the CD109 sequence. The Gov b allelic form has Ser at the same position. This amino acid difference is due to a single change, from A for the Gov a allele to C for the Gov b allele, in the CD109 gene.
| 2
|
FIELD OF TECHNOLOGY
This disclosure generally relates to synthesizing an Iron (Fe) doped Zinc Oxide (ZnO) nano-particle photocatalyst and using the said novel photocatalyst as a solar light activated photocatalyst to remove hazardous and toxic chemicals.
BACKGROUND
Environmental pollution has received considerable attention due to their harmful effect on human health and living organisms. The industrial progress causes several severe environmental problems by releasing wide range of toxic compound to the environment. Thousands of hazardous waste locations have been produced worldwide consequential from the accumulation of organic pollutants in soil and water over the years. Monitoring of environmental pollution is therefore one of the most important needs for selecting pollution controlling option. Among various pollutants, organic dyes are hazardous and toxic pollutants and have adverse effect on living organisms. Dyes are carcinogenic, hazardous, mutagenic, toxic (cytotoxic and embryo-toxic) to mammals. Thus dyes are risky and unsafe for human health and environment. Because of its high solubility and stability in water, it has been found in freshwater, marine environments and industrial waste waters and is difficult to degrade by traditional techniques.
TiO 2 and ZnO have proven their self as a dynamic photocatalyst. However these photocatalyst only encourage photocatalysis upon irradiation by UV light because it absorb only in the UV region of round about 375 nm with the band gap (˜3.2 ev) in UV region. For solar light photocatalysis, a photocatalyst must promote photocatalysis by irradiation with solar light because solar light spectrum consists of 46% of solar light while the UV light is only 5-7% in the solar light spectrum. This least coverage of UV light in the solar spectrum, the high band gap energy (3.2 eV), and fast charge carrier recombination (within nanoseconds) of ZnO confines its extensive application in the solar light spectrum range.
Several researchers have made and used catalysts to remove contaminants using UV light. Dom et al. (2011) synthesized MgFe 2 O 4 , ZnFe 2 O 4 and CaFe 2 O 4 by low temperature microwave sintering and applied for the photocatalytic degradation of organic pollutant using solar light. They found high photocatalytic performance of these oxides by degradation of methylene blue in the presence of solar light. Raja et al. (2007) reported a solar photocatalyst based on cobalt oxide and found to be a good solar photocatalyst for the degradation of azo-dye orange II. Wawrzyniak et al. (2006) have synthesized a solar photocatalyst based on TiO 2 containing nitrogen and applied for the degradation of azo-dye which completely degraded under solar light. Wang et al. (2008) degraded L-acid up to 83% by using S-doped TiO 2 under solar light. Mohapatra and Parida (2011) have synthesized Zn based layered double hydroxide and applied for the degradation and found that layered double hydroxide will be a prominent solar photocatalyst for the degradation of organic chemicals. Zhu et al. (2010) have developed several solar photocatalyst based on Sm 3+ , Nd 3+ , Ce 3+ and Pr 3+ doped titanium-silica and found as good applicants for industrial applications. Zhao et al. (2008) synthesized TiO 2 modified solar photocatalyst and reported as good candidate for the photocatalytic degradation of plastic contaminants under solar light. Im et al. (2010) have synthesized hydrogel/TiO 2 photocatalyst for the degradation of organic pollutants under solar light. Pelentridou et al. (2009) treated aqueous solutions of the herbicide azimsulfuron with titanium nanocrystalline films under solar light and found photo degradation of herbicide in few hours demonstrated titanium as best candidate for purification of water containing herbicide. However, there is a need for a catalyst that is cheaper and faster to operate for decontamination use.
SUMMARY
The invention discloses a Fe doped ZnO nano-particle photocatalyst, a method of synthesizing Fe doped ZnO nano-particle photocatalyst. The instant invention also discloses a method of using the Fe doped ZnO nano-particle photocatalyst.
In one embodiment, method of synthesizing Fe doped ZnO nano-particle photocatalyst is described. In another embodiment, a characterization of Fe doped ZnO nano-particle photocatalyst is described. In another embodiment, using the Fe doped ZnO nano-particle photocatalyst and activating the said catalyst using the solar light to degrade organic contaminant in a sample is described. The sample may be water resources for example.
In one preferred embodiment, the synthesis and characterization of Fe doped ZnO nano-particle that can be used in a small amount in the degradation of organic pollutant is described. The present invention also presents the kinetics and mechanism of dye degradation using Fe doped ZnO nano-particle as solar light activated photocatalyst. The present invention also presents the photocatalytic activity of Fe doped ZnO nano-particle for degrading various dyes such as brilliant cresyl blue, indigo carmine and gentian violet.
In another embodiment, characterizations of several properties of the novel Fe doped ZnO nano-particle photocatalyst were performed. These characterizations were performed to prove the efficacy and effectiveness of the novel photocatalyst.
The novel Fe doped ZnO nano-particle photocatalyst composition, method of synthesizing the novel Fe doped ZnO nano-particle photocatalyst catalyst and method of using the novel Fe doped ZnO nano-particle photocatalyst in chemical reactions, disclosed herein, may be implemented in any means for achieving various aspects. Other features will be apparent from the accompanying figures and from the detailed description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
Example embodiments are illustrated by way of example and no limitation in the tables and in the accompanying figures, like references indicate similar elements and in which:
FIGS. 1A and 1B shows different magnification FESEM images of Fe doped ZnO nano-particle photocatalyst (Catalyst).
FIG. 2 XRD spectrum of the Fe doped ZnO nano-particle photocatalyst.
FIG. 3 FTIR spectra of the Fe doped ZnO nano-particle photocatalyst.
FIG. 4 UV-Vis. spectrum of Fe doped ZnO nano-particle photocatalyst.
FIG. 5 change in absorbance vs irradiation time for brilliant cresyl blue in the presence of Fe doped ZnO nano-particle photocatalyst.
FIG. 6 is a graph of percentage (%) degradation vs irradiation time for brilliant cresyl blue at various pH in the presence of Fe doped ZnO nano-particle photocatalyst.
FIG. 7 is a graph of A/A 0 vs irradiation time for brilliant cresyl blue at various pH in the presence of Fe doped ZnO nano-particle.
FIG. 8 is a graph representing Pseudo-first order kinetics for brilliant cresyl blue at various pH in the presence of Fe doped ZnO nano-particle photocatalyst.
FIG. 9 is a comparison of % degradation for brilliant cresyl blue, indigo carmine and gentian violet at pH 10 in the presence of Fe doped ZnO nano-particle photocatalyst.
FIG. 10 is a comparison of A/A 0 for brilliant cresyl blue, indigo carmine and gentian violet at pH 10 in the presence of Fe doped ZnO nano-particle photocatalyst.
FIG. 11 is a representation of Pseudo-first order kinetics for brilliant cresyl blue, indigo carmine and gentian violet at pH 10 in the presence of Fe doped ZnO nano-particle photocatalyst.
FIG. 12 is a schematic view of photo-catalytic reaction for Fe doped ZnO nano-particle photocatalyst.
Other features of the present embodiments will be apparent from the accompanying figures and the detailed description that follows.
DETAILED DESCRIPTION
Several embodiments for a method of making/preparing Fe doped ZnO nano-particle photocatalyst, method of using the Fe doped ZnO nano-particle photocatalyst for decontamination purpose are disclosed. Although the present embodiments have been described with reference to specific example embodiments, it will be evident that various modifications and changes may be made to these embodiments without departing from the broader spirit and scope of the various embodiments.
Preparation of Fe Doped ZnO Nano-Particle Photocatalyst:
Materials—Iron Nitrate (Aldrich), Zinc Nitrate (Aldrich), Sodium hydroxide (Aldrich), were commercially available and were used without further purification.
Iron nitrate and zinc nitrate (1:3 mole ratio) was dissolved in distilled water completely to obtain a homogeneous solution at an ambient temperature/room temperature (25° C.). The pH of the homogeneous solution was adjusted above 10.0 by adding 0.2M Sodium hydroxide (NaOH) solution drop wise while vigorously stifling the homogeneous solution at a constant pace and a pH adjusted homogeneous solution was obtained. The pH adjusted homogeneous solution is heated overnight at 60° C. with constant stifling. After overnight heating the solution is cooled to ambient temperature/room temperature (25° C.) to obtain a precipitate of Fe doped ZnO photocatalyst. The solution containing Fe doped ZnO photocatalyst precipitate is centrifuged at 2000 rpm. The supernatant is discarded the Fe doped ZnO photocatalyst precipitate is saved. The Fe doped ZnO photocatalyst precipitate is washed using ethanol and the process is repeated three times. The washed precipitate is dried first at ambient temperature/room temperature (25° C.) and then in oven at 60° C. The dried product is grinded to obtain Fe doped ZnO nano-particle particle photocatalyst. The size of the final Fe doped ZnO nano-particle photocatalyst is 100 nm. The Fe doped ZnO nano-particle photocatalyst is then stored in a clean, dry and inert plastic vials until further use.
Morphology of the Fe Doped ZnO Nano-Particle Photocatalyst:
The morphology of the Fe doped ZnO nano-particle photocatalyst that was prepared but not calcined was investigated by FESEM and the low and high magnified images were depicted in FIGS. 1A and 1B . FESEM images show that the low magnification and high resolution image of spherical nano-particles with average diameter of 50 nm.
Characterization of the Fe Doped ZnO Nano-Particle Photocatalyst:
The surface morphology of the nano-particles was studied using a JEOL Scanning Electron Microscope (JSM-7600F, Japan) used for taking FESEM in FIG. 1 . X-ray diffraction spectrum (XRD) was taken with a computer controlled X'Pert Explorer, PANalytical diffractometer and shown in FIG. 2 . FT-IR spectra were recorded in the range of 400 to 4000 cm-1 on PerkinElmer (spectrum 100) spectrometer. UV spectrum was recorded from 200-800 nm using UV-visible spectrophotometer (UV-2960, LABOMED Inc). The crystalinity and crystal structure of the as grown nano-particles were evaluated by XRD and the XRD spectrum is shown in FIG. 2 . XRD of Fe doped ZnO has been compared with pure ZnO. ZnO shows peaks corresponding to peaks at (100), (002), (101), (102), (110), (103), (200), (112) and (201). Fe doped ZnO exhibited slight shift of XRD peak positions which might be due to change in lattice spacing.
Structural Characterization of the Nano-Particles:
The Fe doped ZnO nano-particle photocatalyst is structurally characterized by FTIR which showed a high intense peak is at 530 cm −1 . This may be attributed to M-O of metal oxide. The results are shown in FIG. 3 .
Optical Properties of the Nano-Particles:
The UV spectrum showed a broad UV spectrum in the visible region from 400˜600 nm which confirm that as grown nano-particles can absorb light in the visible region and thus cause degradation under solar light. The results are shown in FIG. 4 .
Method of using the Fe Doped ZnO Nano-Particle Photocatalyst:
FIG. 12 depicts that heterogeneous photo-catalysis mechanism is involved for the degradation of brilliant cresyl blue, indigo carmine and gentian violet. Briefly, when Fe doped ZnO nano-particle photocatalyst were exposed to light having energy equal to or greater than the its band gap, formation of electron and hole pair take place on the surface of Fe doped ZnO nano-particle photocatalyst. If charge separation is maintained then this electron hole pair participates in redox reaction with organic substrate present in water in presence of oxygen. Hydroxyl radicals (OH • ) and superoxide radical anions (O 2 •− ) are supposed to be the main destructive agents (oxidizing species) and these oxidative reaction results in the oxidation of the brilliant cresyl blue (BCB), indigo carmine and gentian violet. The whole mechanism of photo-activity of Fe doped ZnO nano-particle photocatalyst is depicted in scheme and shown in FIG. 12 .
Several experiments were conducted to show the efficacy of using Fe doped ZnO nano-particle photocatalyst (catalyst) to degrade organic pollutants such as BCB, indigo carmine and gentian violet in solution using solar light to activate the catalyst. The photo-catalytic activity of Fe doped ZnO nano-particle photocatalyst was evaluated through degradation of brilliant cresyl blue, indigo carmine and gentian violet under solar light irradiation. The dye is stable under solar light irradiation in absence of photo-catalyst.
In photocatalysis degradation, different 100.0 mL, 1×10 −4 M of each dye solutions were taken in different beakers and adjusted the pH 5, 7, 8 and 10 respectively by drop wise addition of 0.2M NaOH solution under vigorous stirring then add almost 0.12 g catalyst into each reaction solution and then, irradiated the solution under solar light at constant stifling. The dye solution of about 4-5 mL were takes out at regular interval and measured the absorbance at λ max =595.0 nm by using spectrophotometer The controlled experiments were also performed under solar light without catalyst to measure any possible direct photocatalysis of dyes. Control experiments were performed using the dye solutions (BCB, indigo carmine and gentian violet). The pH for the dye solutions were adjusted and while stirring they were exposed to solar light without adding Fe doped ZnO nano-particle photocatalyst along with experimental samples.
In one embodiment, photo-catalytic degradation of brilliant cresyl blue was performed at pH 5, pH 7, pH 8, pH 10 using Fe doped ZnO nano-particle photocatalyst. First, the experiment without catalyst under solar light irradiation resulted in small amount of degradation indicating photolysis reaction exists. Second, photo-catalytic degradation of brilliant cresyl blue solution while stifling was carried out in presence of Fe doped ZnO nano-particle photocatalyst under solar light (visible range light) irradiation. The effect of pH on the photo-catalytic degradation of brilliant cresyl blue in the presence of Fe doped ZnO nano-particle photocatalyst under solar light irradiation was also conducted. Fe doped ZnO nano-particle photocatalyst showed efficient catalytic activity for degradation of brilliant cresyl blue at different pH under solar light irradiation.
In each photocatalysis degradation reaction, 100.0 mL of dye solutions (1×10 −4 M) was taken in beakers and adjusted the pH by drop wise addition of 0.2M NaOH solution under vigorous stirring. 0.1006±0.005 g of Fe doped ZnO was then added into reaction solutions and allowed them to keep in dark for physical adsorption of dye on catalyst surface. The solution was then irradiated under sunlight at constant stirring. At different time, 4-5 mL of solution was pipetted out at regular interval and measured the absorbance by using UV-visible spectrophotometer.
Aqueous suspension of brilliant cresyl blue was irradiated with solar light in the presence of Fe doped ZnO nano-particle photocatalyst and lead to change in absorbance as a function of irradiation time. FIG. 5 displays the change in absorption spectra for the photo-catalytic degradation of brilliant cresyl blue at different time intervals was done. The results showed decrease in absorption intensity. It was also observed that the maximum absorbance was at 595 nm and the absorbance gradually decreases with increase in irradiation time. FIG. 5 . shows that the change in absorbance vs. irradiation time for brilliant cresyl blue in the presence of Fe doped ZnO nano-particle photocatalyst.
In one example, as shown in FIG. 6 , percentage degradation of brilliant cresyl blue at various pH in the presence of Fe doped ZnO nano-particle photocatalyst. FIG. 6 shows the plot for the % degradation vs. irradiation time (min) at different pH for the aqueous suspension of brilliant cresyl blue in the presence of Fe doped ZnO nano-particle photocatalyst. It could be seen from the figure that 86.6, 95.5, 98.5, 98.8% of brilliant cresyl blue is degraded at pH 5, 7, 8 and 10 respectively in the presence of Fe doped ZnO nano-particle photocatalyst after 140 minutes of irradiation time. In the absence of Fe doped ZnO nano-particle photocatalyst no observable loss of brilliant cresyl blue was observed.
The effect of pH on the solar light photocatalytic degradation of brilliant cresyl blue was studied in pH range 5-10. The results showed that rate of decomposition of brilliant cresyl blue increases with increase in pH. At pH 10 brilliant cresyl blue was 98.8% degraded in the presence of Fe doped ZnO nano-particle photocatalyst. The photocatalytic performance of Fe doped ZnO nano-particle photocatalyst were attributed to the surface electrical properties, which facilitate the dye adsorption. The beneficial effect on the surface helps to promote the utilization of solar light generated charge carrier i.e. electron to the surface which leads to formation of hydroxide radical. Moreover, pH of the dye solution has substantial influence on the photocatalytic degradation process, in a preferred embodiment, pH 10 is considered optimal for degrading all the three dyes.
FIG. 7 shows the change in absorbance as a function of irradiation time for the brilliant cresyl blue in the presence of Fe doped ZnO nano-particle photocatalyst. Irradiation of an aqueous solution of brilliant cresyl blue in the presence of Fe doped ZnO nano-particle photocatalyst lead to decrease in absorption intensity.
Reaction kinetics for brilliant cresyl blue, indigo carmine and gentian violet at pH 10 in the presence of Fe doped ZnO nano-particle photocatalyst was performed to further characterize the catalyst. In order to realize the degradation behaviors we studied the degradation pattern of brilliant cresyl blue at different pH (pH 5-10) by Langmuir-Hinshelwood (L-H) model. Langmuir-Hinshelwood (L-H) model well defines the relationship among the rate of degradation and the initial concentration of brilliant cresyl blue at different pH in photo-catalytic reaction. The rate of photo-degradation was calculated by using Eq. (1):
r=−dC/dt=K r KC=K app C (Eq. 1)
Where r is the degradation rate of brilliant cresyl blue at pH 5, 7, 8, and 10, K r is the reaction rate constant, K is the equilibrium constant, C is the reactant concentration. When C is very small, then K C is negligible; so that Eq. (1) became first order kinetic. Setting Eq. (1) under initial conditions of photo-catalytic procedure, (t=0, C=C 0 ), it became Eq. (2).
r −ln C/C 0 =kt (Eq. 2)
Half-life, t 1/2 (in min) is
t 1/2 =0.693/ k (Eq. 3)
FIG. 8 shows that the degradation of brilliant cresyl blue at various pH followed first-order kinetics (plots of ln(C/C 0 ) vs time showed linear relationship). First-order rate constants, evaluated from the slopes of the ln(C/C 0 ) vs. time plots and the half-life of the degraded organic compounds can then be easily calculated by Eq. (3) [Mohapatra and Parida (2011)]. The rate constant for Fe doped ZnO nano-particle photocatalyst at pH 5, 7, 8, and 10 were found to be 0.017 min −1 (t 1/2 =40.8 min), 0.021 min −1 (t 1/2 =33.0 min), 0.029 min −1 (t 1/2 =23.9 min) and 0.032 min −1 (t 1/2 =21.7 min), respectively. Thus the kinetic study revealed that Fe doped ZnO nano-particle photocatalyst is a proficient photo-catalyst for degradation of organic pollutants.
The effect of varying the pH on photo-catalytic activity of Fe doped ZnO nano-particle photocatalyst was done and is shown in FIG. 8 . Brilliant cresyl blue exhibited same trend of degradation at all pH but Fe doped ZnO nano-particle photocatalyst shows different activity in the presence of brilliant cresyl blue at different pH under same condition as shown in FIG. 8 . Fe doped ZnO nano-particle photocatalyst exhibited high activity at pH 10 as compared to pH 5-8. Thus at high pH, the participation of OH − might be suggested to be responsible for the higher photo-catalytic activity of the catalyst. The results eludes to the conclusion that as prepared Fe doped ZnO nano-particle photocatalyst synthesized by very simple synthesis procedure shows considerable solar photo-catalytic activity. So it can be a beneficial solar photo-catalyst for organic pollutants.
Comparison of percentage degradation for brilliant cresyl blue, indigo carmine and gentian violet at pH 10 in the presence of Fe doped ZnO nano-particle photocatalyst. The percent degradation graph of indicates that BCB degrades more rapidly in short response time as compared to indigo carmine and gentian violet at pH 10 in the presence of Fe doped ZnO nano-particle photocatalyst as shown in FIG. 9 .
Comparison of A/A 0 for brilliant cresyl blue, indigo carmine and gentian violet at pH 10 in the presence of Fe doped ZnO nano-particle photocatalyst is shown in FIG. 10 . FIG. 10 clearly indicated that all dyes follow the same pattern of degradation at pH 10 in the presence of nano-particles.
Reaction kinetics for brilliant cresyl blue, indigo carmine and gentian violet at pH 10 in the presence of Fe doped ZnO nano-particle photocatalyst. Using Langmuir-Hinshelwood (L-H) model, we calculated the rate constant for brilliant cresyl blue, indigo carmine and gentian violet in the presence of Fe doped ZnO nano-particle photocatalyst which were found to be 0.032 min −1 (t 1/2 =21.2 min), 0.022 min −1 (t 1/2 =31.5 min) and 0.014 min −1 (t 1/2 =49.5 min). Thus the kinetic study revealed that Fe doped ZnO nano-particle photocatalyst is better photocatalyst for BCB as compared to indigo carmine and gentian violet as shown in FIG. 11 .
INDUSTRIAL APPLICABILITY
This photo-catalyst can simply degrade the organic pollutants in the presence of sun light. It is cheap, easy to handle, simple to grow and more effective photocatalyst.
In addition, the specification and drawings are to be regarded in an illustrative rather than as in a restrictive sense.
|
Toxic organic materials contaminate water resources and one need to find an easy and energy efficient way to decontaminate water resources. The current invention discloses a photocatalyst Fe doped ZnO nano-particle photocatalyst that enables the decontamination process by degrading toxic organic material such as brilliant cresyl blue, indigo carmine and gentian blue by using solar light. In the current disclosure many examples of characterization of the photocatalyst, optimal working conditions and efficient use of solar light has been described. The process described to use the photocatalyst to degrade toxic organic material using the solar light to activate the photocatalyst is cost efficient and cheap to clean our water resources.
| 8
|
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present non-provisional utility application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application No. 61/390,570 titled “Exercise Bicycle Frame with Bicycle Seat and Handlebar Adjustment Assemblies,” filed on Oct. 6, 2010, which is hereby incorporated by reference herein.
[0002] The present non-provisional utility application also claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application Nos. 61/390,572 and 61/390,577 titled “Exercise Bicycle with Mechanical Flywheel Brake” and “Exercise Bicycle with Magnetic Flywheel Brake”, respectively, and each filed on Oct. 6, 2010, which are hereby incorporated by reference herein.
[0003] The present application is also related to utility applications titled “Exercise Bicycle with Mechanical Flywheel Brake” and “Exercise Bicycle with Magnetic Flywheel Brake”, identifiable by attorney docket numbers 063174-432572 and 063174-432569 each of which were filed contemporaneously with the present application on Oct. 6, 2011, and which are hereby incorporated by reference herein.
FIELD OF THE INVENTION
[0004] Aspects of the present disclosure involve an exercise bicycle and adjustment assemblies that provide fore and aft adjustment for a handlebar, a seat, or other component.
BACKGROUND
[0005] Indoor cycling is a very popular and excellent way for people to maintain and improve fitness. Generally speaking, indoor cycling revolves around an exercise bicycle that is similar to other exercise bicycles with the exception that the pedals and drive sprocket are connected to a flywheel rather than some other type of wheel. Thus, while a user is pedaling, the spinning flywheel maintains some momentum and better simulates the feel of riding a real bicycle. To further enhance the benefits of indoor cycling, fitness clubs often offer indoor cycling classes as a part of their group fitness programs. With such a program, an instructor guides the class through a simulated real world ride including simulating long steady flat sections, hills, sprints, and standing to pedal for extended periods. While numerous different forms of indoor cycles exist, many suffer from common problems. For example, many indoor cycles are hard to adjust in order to provide the proper handlebar height, seat height, and separation between the handlebar and seat for the myriad of different body sizes of the people that might use the indoor cycle. Such difficulties are exaggerated in a group setting or club environment where time is limited and people are constantly adjusting the equipment.
[0006] It is with these issues in mind, among others, that aspects of the present disclosure were conceived.
SUMMARY
[0007] One aspect of the present disclosure involves an exercise bicycle comprising a receiver comprising an elongate aperture. The receiver may be connected to a post, such as a seat post or handlebar post, and may be configured for vertical adjustment. Alternatively, the receiver may include a seat or handlebar, and be configured for fore and aft adjustment. The exercise bicycle further includes a slider positioned within the elongate aperture of the receiver, the slider defining a first channel receiving a first member, such as a wedge block, moveable within the channel, the first member defining an engagement surface. The slider may include a seat or handlebar and may be configured for relative movement to a horizontally fixed receiver. Alternatively, the slider may be connected to a post and horizontally fixed and the receiver includes a seat or handlebar, as mentioned immediately above. The exercise bicycle further includes a handle operably coupled with the first member to move the first member within the channel in a first direction or a second direction such that the engagement surface causes a coupling between the slider and the receiver when the slider is moved in the first direction and releases the coupling when the slider is moved in the second direction.
[0008] The slider may define a second channel transverse to the first channel. The second channel may receive a second member, such as a second wedge block configured to interact with the first wedge block such that horizontal motion of the first wedge block translates to vertical motion of the second wedge block, within the second channel. In this configuration, the handle is operably coupled with the first member to move the first member within the channel in the first direction to drive the second member to engage the receiver, the engagement with the receiver causing a frictional coupling between the slider and the receiver, the handle operably coupled with the first member to move the first member within the channel in the second direction to release the engagement between the second member and receiver to allow relative movement between the slider and the receiver.
[0009] Another aspect of the present disclosure involves an exercise bicycle comprising a down tube extending angularly and upwardly from a rear portion to a front portion. The exercise bicycle further includes a seat tube extending upwardly and rearwardly from the rear portion of the down tube. In one particular example, the down tube is orientated at an angle of between 40 and 44 degrees and the seat tube is angled rearwardly at an angle of between 70 and 74 degrees. A brace extends rearwardly from the rear portion of the down tube to a rear support member and extends forwardly to a front support member. The exercise bicycle further includes a fork assembly extending from a position rearward of the front portion of the down tube to the front support member. In one particular implementation, a flywheel s mounted between a first fork and a second fork of the fork assembly and the flywheel having a radius of about 430 millimeters. Finally, a head tube is coupled with the front portion of the down tube.
[0010] The exercise bicycle may further include adjustable seat and handlebar assemblies adjustably supported by the seat tube and head tube, respectively. The assemblies support a seat and handlebars for fore and aft movement. The assemblies are similar in form and include a receiver comprising an elongate aperture. A slider is positioned within the elongate aperture of the receiver. The slider defines a first channel receiving a member moveable within the first channel. The member defines a first engagement surface. Finally, a handle is operably coupled with the member to move the member within the channel in a first direction or a second direction such that the engagement surface causes a coupling between the slider and the receiver when the slider is moved in the first direction and releases the coupling when the slider is moved in the second direction. The exercise bicycle may provide a space separation between the adjustable seat assembly and the adjustable handlebar assembly in a range of about 527 millimeters and about 627 millimeters.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The foregoing and other objects, features, and advantages of the present disclosure set forth herein will be apparent from the following description of particular embodiments of those inventive concepts, as illustrated in the accompanying drawings. It should be noted that the drawings are not necessarily to scale; however the emphasis instead is being placed on illustrating the principles of the inventive concepts. Also, in the drawings the like reference characters refer to the same parts or similar throughout the different views. It is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than limiting.
[0012] FIG. 1 is an isometric view of an exercise bicycle;
[0013] FIG. 2 is a front view of the exercise bicycle shown in FIG. 1 ;
[0014] FIG. 3 is a left side view of the exercise bicycle shown in FIG. 1 ;
[0015] FIG. 4 is a rear view of the exercise bicycle shown in FIG. 1 ;
[0016] FIG. 5 is a top view of the exercise bicycle shown in FIG. 1 ;
[0017] FIG. 6A is a right side view of the exercise bicycle shown in FIG. 1 ;
[0018] FIG. 6B is a right side view of the exercise bicycle shown in FIG. 1 with a chain guard removed to illustrate a drive sprocket and a flywheel sprocket, along with a chain connected therebetween;
[0019] FIG. 7 is a bottom view of the exercise bicycle shown in FIG. 1 ;
[0020] FIG. 8 is an isometric view of a seat adjustment assembly, with certain components of the view transparent;
[0021] FIG. 9A is a section view taken along line 9 - 9 of FIG. 3 , and illustrating the seat assembly positioned about midway between its forward most and rearward most positions;
[0022] FIG. 9B is section view similar to FIG. 9A with the seat assembly in its forward most position;
[0023] FIG. 9C is a section view similar to FIG. 9A with the seat assembly in its rearward most position;
[0024] FIG. 10 is a section view taken along line 10 - 10 of FIG. 4 ;
[0025] FIG. 11 is an isometric view of a slider mechanism for supporting a seat;
[0026] FIG. 12 is an isometric view of a handlebar adjustment assembly, with certain components of the view transparent;
[0027] FIG. 13A is a section view taken along line 13 - 13 of FIG. 3 , and illustrating the handlebar assembly positioned about midway between its forward most and rearward most position;
[0028] FIG. 13B is a section view similar to FIG. 13A with the handlebar assembly in the forward most position;
[0029] FIG. 13C is a section view similar to FIG. 13A with the handlebar assembly in the rearward most position; and
[0030] FIG. 14 is an isometric view of a slider mechanism supporting a handlebar.
DETAILED DESCRIPTION
[0031] Aspects of the present disclosure involve an exercise bicycle. The exercise bicycle includes various features that provide adjustability of the seat and handlebar positions, provide space for riders of various sizes, and provide space for mounting and dismounting the exercise bicycle, among other advantages. The exercise bicycle includes fore and aft adjustment mechanisms for the seat and handlebars that improve on conventional arrangements. Fore and aft adjustment may be set along any fore and aft position and is not constrained as in conventional designs. Many of the moving components of the adjustment mechanism, except for a knob that a user turns are captured within a slider and a receiver, providing for an elegant design with many mechanical components hidden. The frame design provides exceptional space between the seat, handlebars and frame members, while maintaining industry standard dimensioning for proper rider use and ergonomic adjustment of the exercise bicycle. For example, a head tube is positioned forward of the handlebars and eliminated as a point of contact for a rider, rearward movement of the seat and forward movement of the handlebars opens space providing the rider with less contact points and the down tube is relatively low and positioned at a relatively shallow angle providing excellent step over height and space.
[0032] Referring now to FIGS. 1-7 , one example of an exercise bicycle 10 is shown. The exercise bicycle is configured for use by a variety of riders in a club environment or for a single or limited number of riders in a home or other personal use environment. The exercise bicycle includes a frame 12 adjustably supporting an adjustable seat assembly 14 at the rear of the frame and adjustably supporting an adjustable handlebar assembly 16 at the front of the frame. The adjustable seat and handlebar assemblies provide fore and aft adjustment of a respective seat 18 and handlebar 20 . Further, the seat and handlebar assemblies may be vertically adjusted and fixed at various possible positions. Hence, the exercise bicycle provides for many different possible seat and handlebar positions to fit different riders and to provide riders with different configurations depending on the exercise being performed.
[0033] The frame includes a seat tube 22 that receives a seat post portion 24 of the seat assembly 14 . The seat post may be moved up and down relative to the seat tube to adjust the height of the seat assembly, and particularly to adjust the height of the seat 18 that is a part of the seat assembly. A pop pin 26 is connected with the seat tube and is configured to engage one of a plurality of apertures 28 defined in the seat post, and thereby secure the seat at a desired height. The pop pin may be spring-loaded such that it is biased in the locked position engaging the aperture.
[0034] The pop pin is shown extending forwardly from the seat tube. This configuration provides easy access for a rider to move the seat up or down during exercise. For example, indoor cycling classes often include some time where the user is standing and pedaling rather than seated, and at such times the rider may move the seat to a lower position. The pop pin is positioned for easy access by the rider. It is possible, however, to position the pop pin on the back side of the seat tube or at another location. Additionally, it is possible to use other mechanisms to facilitate seat height adjustment with or without pop pins. For example, a pawl on the fore and aft seat and handlebar assemblies may be used to vertically adjust the seat post (or tube) as well as the handlebar post.
[0035] In one particular implementation, the seat tube is rearwardly angled at approximately 72 degrees. The seat tube angle, along with other adjustment and dimensional relationships discussed herein, is optimized so that riders of all sizes can best fit the exercise bicycle. The seat tube 22 , along with other frame members discussed herein, is extruded aluminum and defines a racetrack-shaped cross section 30 with opposing flat side walls 30 A and opposing semicircular side walls 30 B. The seat post 24 defines a substantially matching racetrack-shaped cross section of a smaller dimension in order to fit within the seat tube. Other frame member shapes and materials may be used, such as steel square tubing or steel round tubing, in the construction of the frame assembly. However, the extruded aluminum race track shaped tubing provides a unique balance between strength, overall exercise bicycle weight and aesthetic appearance. Additionally, while the seat post is shown as telescoping out of the seat tube, this relationship may be reversed such that the post fits over the tube. This relationship may also be reversed for other tube and post arrangements discussed herein.
[0036] Returning again to the discussion of the frame 10 , a down tube 32 extends from a lower rear area of the exercise bicycle to an upper forward area of the exercise bicycle. Particularly, the down tube extends between a bottom portion of the seat tube 22 and a head tube 34 . The down tube is also a racetrack type extruded aluminum member. The down tube, in one particular arrangement, is at angle of about 42 degrees. The angular relationship of the down tube may be measured relative to a horizontal surface upon which the exercise bicycle sits or relative to a line between a front support member 36 and a rear support member 38 . The down tube is welded to the bottom of the seat tube, although other means of attachment and arrangements are possible. Further, a triangular rear gusset 40 with a substantially flat top 42 is connected to and above the intersection of the seat tube 22 and the down tube 32 . The rear gusset, like other frame members and arrangements, may be altered or removed. In the exercise bicycle frame illustrated, the gusset provides structural support to the seat tube and seat assembly, and also provides a step for riders mounting the exercise bicycle as well as other advantages. In the example shown, the flat top portion of the gusset, which provides the step, is slightly longer than 10 inches measured between the seat tube and down tube, a dimension not achievable by other designs which employ different frame configurations, larger flywheels and different gearing configurations.
[0037] A brace 44 extends from the rear support member 38 upward to the bottom of the seat tube 22 and then forward and downward to the front support member 36 . A lower gusset 46 is connected between the rear portion of the brace, the top of the rear support member 44 , and the lower rear portion of the seat tube 22 . The lower gusset is in substantial alignment and of substantially similar dimension as the down tube. The front support member 36 is connected to the front forks 48 and extends outwardly and transversely from each fork.
[0038] The head tube 34 is connected to the front of the down tube 32 . A portion 34 A of the head tube extends upwardly from the down tube and a portion 34 B of the head tube extends downwardly from the head tube. A front gusset 50 is connected between the downwardly extending portion 34 B of the head tube and the down tube 32 . The head tube receives a handlebar post 52 that extends downwardly from the fore and aft adjustable handlebar assembly 16 . The handlebar post may be moved vertically relative to the head tube to adjust the height of a handlebar assembly, and particularly to adjust the height of a handlebar 20 of the handlebar assembly. A second pop pin 54 is connected with the head tube 34 and is configured to engage one of a plurality of apertures (not shown) defined in the handlebar post, and hence secure the handlebars at a desired height. Other mechanisms may also be used in place of the pop pin, and the position of the pop pin or any other mechanism may be altered in alternative exercise bicycle implementations.
[0039] In the frame configuration illustrated herein, the front fork assembly 48 , which supports a flywheel 56 between opposing left 58 and right 60 fork legs, is coupled to the down tube 32 at a point between the head tube 34 and the seat tube 22 . In the particular arrangement shown, the down tube is about 561 mm between the rear of the head tube and the intersection between the rear gusset 40 and the down tube, and the fork is about 315 mm between the rear of the fork and the same intersection.
[0040] In the frame configuration shown, the forks are set at about the same angle as the seat tube. A pair of mounting brackets 62 , also referred to as “drop outs”, are integrated in the fork legs to support a flywheel axle 64 and the flywheel. The exercise bicycle discussed herein is particularly configured for indoor cycling and therefore includes a flywheel. It is nonetheless possible to deploy the frame and other components discussed, whether alone or in combination, in an exercise bicycle that does not include a flywheel. The drop outs have matching forwardly opening channels 66 that are perpendicular to the long axis of the fork legs, in one embodiment. Thus, the forward opening of the channels is higher than the rear of the channels. An adjustment screw 68 protrudes into the opening. The design is advantageous in that it allows a user to mount the flywheel from the open front area of the exercise bicycle without any hindrance, such as if the channels opened rearwardly. Moreover, the channels receive the axle and support the flywheel while a user adjusts the axle position by way of the adjustment screws to tension the chain and center the flywheel, such as during assembly or maintenance. It is also possible to orient the channels in other ways, such as horizontally and level, and include a lip or other retaining member at the opening of the channel to help retain the flywheel before the axle is locked in.
[0041] In many conventional exercise bicycle designs, the head tube is aligned with the forks. The exercise bicycle shown herein, however, has the head tube positioned at the front of the frame and forward of the fork assembly 48 . Additionally, as discussed herein, fore and aft adjustment of the handlebars occurs relative to the head tube such that the rear of the handlebars (and the adjustment knob) is the rearward most component of the handlebar assembly 16 relative to the user rather than the fixed head tube and handle bar post (stem) in conventional designs. Hence, the handlebars may be moved forward relative to the user opening up space between the handlebars and the seat. In many conventional designs, the handlebars are above and forward the head tube and the head tube is the rearward most component; thus, any possible fore or aft adjustment of the handlebars occurs with the head tube remaining stationary and does not provide additional space for the user between the seat and the handlebar.
[0042] The frame assembly 12 further includes a crank assembly 70 configured to drive the flywheel 56 . The drive sprocket is rotably supported in a bottom bracket 55 supported in the down tube 32 . In one example, the crank assembly includes a single drive sprocket 72 and the flywheel similarly includes a single flywheel sprocket 74 of a smaller diameter than the drive sprocket. A chain 76 connects the drive sprocket to the flywheel sprocket, although other mechanisms, such as a belt, may be used to connect the sprockets. The drive sprocket is fixed to a pair of crank arms 78 and the flywheel is fixed to the flywheel sprocket such that the drive sprocket and flywheel sprocket do not freewheel. Hence, with reference to FIG. 6B , clockwise rotational force on the crank arms, such as in conventional forward pedaling, rotates the flywheel in a clockwise manner. However, if the rider discontinues exerting a pedaling force on the cranks, the spinning flywheel will continue, via the chain, to drive the crank arms. It is, however, possible to include freewheel mechanisms with the drive or flywheel sprocket or other components.
[0043] In one particular implementation, the drive sprocket 72 includes 72 teeth and the flywheel sprocket 74 includes 15 teeth. A range of sprocket teeth counts are possible such as 70-74 teeth and 13 to 17 teeth, and an even broader range of 45 to 75 teeth on the drive sprocket. Moreover depending on the design, other sprocket arrangements are possible, as well as arrangements with a derailleur and multiple sprockets at both ends. This particular sprocket arrangement facilitates the use of a smaller flywheel 56 of 430 mm radius, relative to other designs. With a smaller flywheel, a shallower down tube angle (e.g. 42 degrees) is possible providing a larger gusset step size (e.g. 10 inches) and a larger area between the seat and handlebar assemblies relative to other exercise bicycle frame designs.
[0044] As discussed above, the frame provides for the height adjustment of the seat assembly 14 (with seat 18 ) and the handlebar assembly 16 (with handlebars 20 ) by way of the interactions between the seat tube 22 , seat post 24 and rear pop pin assembly 26 and the head tube 34 , handlebar post 52 and front pop pin assembly 54 , respectively. The exercise bicycle discussed herein also provides fore and aft adjustment of the seat and/or the handlebars through respective fore and aft seat and handlebar adjustment assemblies. In one possible implementation and with reference to FIG. 6A , when the seat height is about the same as the handlebar height, a range of about 527 mm (where the handlebars are completely rearward and the seat is completely forward) to about 627 mm (when the handlebars are completely forward the seat completely rearward) separate the seat and handlebar assemblies providing exceptional open space for the rider to mount and dismount the cycle.
[0045] Turning first to the seat adjustment assembly 14 , FIGS. 8-11 illustrate the fore and aft adjustable seat assembly. In this example implementation, a receiver 82 is connected to the seat post 24 . The receiver, which is extruded aluminum in one particular implementation, defines a slider aperture 84 arranged along the horizontal center line of the exercise bicycle and roughly parallel with the surface that the exercise bicycle is set on. The slider aperture receives a slider 86 that may be moved fore and aft within the slider aperture. Additionally, the slider may be fixed at various positions relative to the receiver. The seat 18 is attached to the slider (such as at a front end of the slider); hence, by adjusting and fixing the slider relative to the receiver, the fore and aft position of the seat may be adjusted.
[0046] The slider aperture, in cross section as shown in FIG. 10 , defines a complex shape with curved sides 88 connected by a substantially flat top 90 and an inverted W-shaped bottom 92 . The bottom surface includes two bearing or engagement surfaces ( 92 A, 92 B) that form a frictional engagement to matching surfaces ( 94 A, 94 B) on the slider 86 . The outer surface of the slider substantially matches the complex shape of the slider aperture albeit with a slightly smaller shape so that the slider may move horizontally relative to the slider aperture.
[0047] A lower wedge 96 and an upper wedge 98 are positioned within the slider 86 . Particularly, the slider defines a lower wedge aperture 100 along the longitudinal center of the slider and a top wedge aperture 102 intersecting the lower wedge aperture. The lower wedge 96 is configured to move horizontally within the slider, particularly within the lower wedge aperture 100 , while the upper wedge is trapped within and configured to move vertically within the top wedge aperture 102 . The top wedge aperture extends through the substantially flat top surface of the slider. Stated differently, the first wedge (lower wedge) moves within a first aperture transverse to a second aperture (the upper wedge aperture) where the second upper wedge moves.
[0048] As shown in the FIG. 8 , the lower wedge 96 has a sloped upper surface 104 and the upper wedge 98 has a matching sloped lower surface 106 . These surfaces are in contact. With the upper wedge constrained in the vertical wedge aperture, aft or rearward horizontal movement of the sloped surface of the lower wedge presses on the sloped surface of the upper wedge driving the upper wedge upward to lock the slider relative to the receiver. On the other hand, fore or forward horizontal movement of the lower wedge allows the upper wedge to drop down to release the slider so that the horizontal position of the slider and the seat can be adjusted. Therefore, fore and aft movement of the lower wedge translates into down and up movement of the upper wedge to release or unlock the slider for adjustment and to lock the slider into position when the seat is properly positioned.
[0049] The slider 86 is trapped within the slider aperture 84 of the receiver 82 . A strike plate, in one particular example, 108 is positioned above the wedge aperture 102 and is of sufficient length so that the upper wedge 98 will press on the strike plate in the forward most and rearward most positions. The strike plate is steel and is constrained in a channel 110 extruded in the aluminum receiver. The upper wedge pushes upward against the strike plate when the slider is being locked relative to the receiver. When the seat assembly 14 is being locked into a particular fore or aft position, the lower wedge also presses down on the slider 86 causing the outer lower surface ( 94 A, 94 B) of the slider to frictionally engage the respective bearing surfaces ( 92 A, 92 B) of the receiver. Particularly, the slider and the receiver engage on the outer portions of the inverted W but do not engage between the outer portions, as shown in FIG. 10 . Hence, in one particular implementation, the fore or aft position of the slider relative to the receiver may be locked in position through a frictional engagement between the upper wedge and the strike plate and along the opposing lower surfaces of the slider and slider aperture of the receiver.
[0050] A knob 112 is positioned at the rear of the slider 86 or otherwise at an end of the slider. The knob is fixed to a threaded shaft 114 that is threaded into a threaded aperture 116 in the bottom wedge 96 . The shaft is captured in the slider such that rotation of the shaft engages the threaded aperture of the lower wedge to move the wedge fore and aft. In one particular arrangement, an end cap 118 defining a smooth bore or tube section 120 is fixed to the end of the receiver. A bearing 122 is pressed in the tube section of the end cap and the bearing rotatably supports the shaft 114 . A clip 124 or shoulder is positioned on the shaft adjacent the bearing and end cap. The clip prohibits the shaft from moving rearward relative to the slider. The knob 112 is fixed to the end of the shaft, with the bearing and the end cap sandwiched between the clip and the knob. Hence, the knob prevents the shaft from moving forward relative to the slider. Thus, the shaft can only be rotated by turning the knob and does not move fore and aft relative to the slider. When a user rotates the knob, the knob and shaft rotate relative to the slider, end cap, bearing, etc. The rotating shaft, in turn, moves the lower wedge fore and aft through engagement between the shaft and the threaded aperture of the lower wedge. The lower wedge, in turn, engages or disengages the upper wedge to lock the fore and aft position of the seat or release the assembly so the seat can be moved.
[0051] A stub 126 extends upwardly at the forward end of the slider 86 . The seat is attached to the stub. A cap 128 prevents the slider from being completely withdrawn rearwardly from the receiver. Hence, in the rearward most aft position, the cap 130 abuts the receiver, as shown in FIG. 9 C. Similarly, the stop cap at the opposing end of the receiver prevents the slider from being completely withdrawn forwardly from the receiver. Hence, in the forward most position, the stop cap abuts the receiver, as shown in FIG. 9B .
[0052] While in both the adjustable fore and aft seat and handlebar assemblies, two wedges are shown, it is also possible to eliminate the upper wedge or alter the shape of either or both wedges. For example, the lower wedge and the strike plate can be dimensioned so that the lower wedge directly engages the strike plate with increasing or decreasing force as the wedge is moved aft or fore. In such an arrangement, the engagement of the lower wedge directly with the strike plate will push the strike plate upward and drive the slider down to create the appropriate frictional engagement. Similarly, the lower wedge may include a sloped surface as currently shown and the upper wedge may be a square or rectangular block, where the sloped, or otherwise oblique surface of the lower wedge, engages a corner of the block to press the block upward. The engaged corner of the block may include a bevel to distribute the load imparted by the lower wedge.
[0053] One example of a handlebar adjustment assembly 16 is illustrated in FIGS. 12-14 . The handlebar adjustment assembly is similar in form and function to the seat adjustment assembly and therefore like components will be referenced as such. The handlebar fore and aft adjustment assembly includes a slider 86 that may be positioned fore and aft within and relative to a receiver 82 . The receiver is attached to the handlebar post 52 . Accordingly, the receiver may be moved up and down relative to the head tube. The handlebar 20 is positioned at one end of the slider and an end cap 132 is positioned at the opposing end of the slider. As shown in FIGS. 13B and 13C , the handlebar or the end cap abuts the receiver depending on whether the handlebar is positioned most forwardly ( FIG. 13B ) or most rearwardly FIG. 13C ).
[0054] In the implementation discussed above, the slider mechanism moves relative to the receiver, and the receiver is attached to the seat post or handlebar post. Further, the seat or handlebars are connected to the slider mechanism. It is possible to alter this relationship and use the wedge (cam block) mechanism discussed herein. For example, in such an alteration, the slider structure is coupled to the post, at the forward or rearward end of the slider structure. Hence, the slider is fixed relative to the frame. At the end opposite the coupling to the post, the knob and shaft are supported. The slider includes substantially the same wedge block configuration or the alternative discussed herein. The receiver, in the altered implementation, has the seat or handlebars attached to it and it is configured to move fore and aft relative to the slider. A user locks or unlocks the receiver and moves it fore and aft to adjust the position in a like manner as discussed herein.
[0055] It also possible, to replace the knob shaft fore and aft lower wedge block actuation with a lever arm and with a camming surface configured to engage the receiver strike plate or the upper wedge block. In such an implementation, the lever arm is fixed to the slider or the receiver, and is configured push the camming surface up against the upper wedge block to create the same form of frictional engagement between the slider and the receiver. It is also possible to replace the knob and shaft with a lever arm and shaft coupled with the lower wedge block. The lever arm would act to move the shaft fore and aft rather than rotate the shaft. The shaft is fixed to the lower wedge block, and hence fore and aft movement of the lower wedge block would act to force the upper wedge block upward to allow it to fall downward, locking or unlocking engagement between the slider and receiver.
[0056] Although various representative embodiments of this disclosure have been described above with a certain degree of particularity, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the spirit or scope of the inventive subject matter set forth in the specification. All directional references (e.g., upper, lower, upward, downward, left, right, leftward, rightward, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise) are only used for identification purposes to aid the reader's understanding of the embodiments and do not create limitations, particularly as to the position, orientation, or use of the disclosure unless specifically set forth in the claims. Joinder references (e.g., attached, coupled, connected, and the like) are to be construed broadly and may include intermediate members between a connection of elements and relative movement between elements. As such, joinder references do not necessarily infer that two elements are directly connected and in fixed relation to each other.
[0057] In some instances, components are described with reference to “ends” having a particular characteristic and/or being connected to another part. However, those skilled in the art will recognize that the present disclosure is not limited to components which terminate immediately beyond their points of connection with other parts. Thus, the term “end” should be interpreted broadly, in a manner that includes areas adjacent, rearward, forward of, or otherwise near the terminus of a particular element, link, component, member or the like. In methodologies directly or indirectly set forth herein, various steps and operations are described in one possible order of operation, but those skilled in the art will recognize that steps and operations may be rearranged, replaced, or eliminated without necessarily departing from the spirit and scope of the present invention. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting. Changes in detail or structure may be made without departing from the spirit of the invention as defined in the appended claims.
|
An indoor cycling device including a unique frame arrangement with fore and aft adjustable seat and handlebar assemblies. The assemblies support a seat and handlebars for fore and aft movement. The assemblies may include a receiver with an elongate aperture with a slider positioned therein. The slider defines a first channel receiving a moveable member. A handle is operably coupled with the member to move the member within the channel in a first direction or a second direction such that a frictionally coupling is caused between the slider and the receiver when the slider is moved in the first direction and releases the coupling when the slider is moved in the second direction.
| 0
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a stack of bags which have been made from rectangular sections of synthetic thermoplastic film in that said sections have been folded onto themselves about bottom fold lines and provided with side seam welds and near their open ends with centrally disposed, punched grip holes and with laterally disposed corner portions, which are defined by perforation lines and formed with aligned stacking or hanger holes.
2. Description of the Prior Art
German Utility Model Specification 74 29 628 discloses a stack of bags which is of that kind and in which material is saved in that the hanger strips have been omitted, which are otherwise provided and extend over the width of the bag and are defined by perforation lines, along which the bag can be torn from the hanger strip, and provided with hanger holes.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a stack of bags which is of the kind described first hereinbefore and which can more easily be handled and results in a further saving of material.
In a stack of bags which is of the kind described first hereinbefore that object is accomplished in accordance with the invention in that only the rear wall of each bag is provided with perforation lines defining the two upper corner portions of said rear wall and the front wall of the bag is formed in its corner portions with apertures which are defined by cutouts, which are substantially congruent to and register with the perforation lines. Compared with the known stack of bags the stack of bags in accordance with the invention permits a saving of 50% of the material required for the corner portions because only the rear walls of the bags are provided with corner portions for stacking and holding the bags. Besides, each bag can be torn more easily from the stack of bags because this can be accomplished by a tearing along a perforation line formed in only one wall.
The perforation lines are suitably curved, and preferably define a quadrant of a circle and have portions which are approximately at right angles to the opening-defining edges and side edges, respectively.
In a special embodiment of the invention the perforation lines include lands which differ in length and the lengths of the lands are selected in such an adaptation to the forces exerted as the bags are torn off along the perforation lines and to any curvilinear shaped of the perforation line that the tearing along the perforation line will be facilitated. That feature is particularly desirable and suitable from the aspect of a simple and economical manufacture of the bags in accordance with the invention because the bags in accordance with the invention are suitably made from a flat plastic film web having side portions which are reversely folded onto the central portion of the web in such a manner that the side edges of the web are disposed short of the center line of the web. In the processing of the plastic film web which has thus been folded said web must take up tensile stresses before the individual bags are separated by hot wire welding and the web must transmit such tensile stresses substantially without elongation. As the infolded side portions of the plastic film web are weakened by punched semicircular apertures during the manufacture of the bags, a further weakening also of the central portion should be avoided. Because the perforation lines must be formed in the central portion of the web, a weakening of said central portion cannot entirely be avoided. For this reason the lengths of the lands of the punched perforation lines are so selected in accordance with the invention that the weakening of the web will be minimized and it will still be ensured that each bag can be torn from the block of bags without destruction.
The perforation lines may be designed to have relatively long lands adjacent to the opening-defining edge and the side edge of each bag and relatively short lands in an intermediate portion. That arrangement of relatively short and relatively long lands will take the tensile and shear stresses occurring in the web into account so that the web will not be subjected to appreciable elongation in spite of the punched perforation lines.
If the tearing of the bags from the stack of bags begins adjacent to the side edges of the bags, the longer lands of the tearable perforation lines will be tolerable because that portion has been weakened anyway by the seam weld along the side edge.
The lands in the perforation lines suitably decrease in length gradually from the long lands to the short ones so that a smooth tearing of the bags from the stack will be ensured when the tearing has begun at the side edges. A fact which should be taken into account in the distribution of the shorter and longer lands resides in that the film owing to the properties of its material tends to tear along a straight line.
In a curved tearable perforation line, shorter lands, which promote the tearing, should be provided particularly in the curved portion of said line.
The opening-defining top edge of the front wall of each bag is suitably disposed short of the opening-defining edge of the rear wall so that the latter comprises an exposed strip. Such a design of stacked bags is known per se from Published German Application 24 08 831.
Within the scope of the invention the bags in the stack may be blocked to each other at the perforated corners. A blocking may also be provided at the stacking or hanger holes.
A process of manufacturing the bags in accordance with the invention is characterized in accordance with the invention in that the side portions of a plastic film web are reversely folded onto the central portion of said web so that the side edges of the web are disposed short of the center line of the web, the plastic film web which has thus been folded is fed in steps amounting to one bag width each through punching and welding stations, in which perforation lines are formed along a closed line to define portions which will constitute the corner portions of the rear walls of four subsequently formed bags, which are juxtaposed and arranged in pairs of bags which are mirror images of each other, and the stacking or hanger holes are formed in the portions thus defined, thereafter aperture-defining lines of cut are formed in those portions which will constitute the front walls of the subsequently formed bags, thereafter the punched grip holes and the transverse hot wire-welded seams which will define the side seams of the bags, or pairs of such transverse hot wire-welded seams and transverse cuts extending between said seams, are provided, and the bags which are still joined in pairs are finally severed from each other by cuts effected along the center line of the plastic film web and are stacked.
Those cutting operations by which the tearable perforation lines and the punched corner apertures are formed may be effected along circular or elliptical annular lines although those cutouts which define the punched corner apertures are interrupted by the gap which exists between the infolded side edges of the web.
It will be particularly desirable to provide tearable perforation lines which have straight end portions, which are approximately at right angles to the side edges and to the opening-defining edges of the bag. For this reason it is contemplated within the scope of the invention to provide the annular cutouts and the annular tearable perforation lines in the form of a quadrangle having rounded corners or in the form of a polygon in such a manner that the perforation lines join the side edges and the opening-defining edges of the bag approximately at right angles thereto.
Apparatuses for carrying out the process in accordance with the invention will be defined in claims 10 to 12.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view showing a stack of bags.
FIG. 2 shows a corner portion of a bag.
FIG. 3 is a diagrammatic sectional view showing the means for punching the corner portions of the bags.
FIG. 4 is a top plan view showing a plastic film web provided with a circular cutouts and a circular perforation line.
FIG. 5 is a top plan view showing a plastic film web provided with a quadrangular cutouts and a quadrangular perforation line.
FIG. 6 is a top plan view showing a plastic film when provided with an octagonal cutout and an octagonal perforation line.
FIG. 7 is a sectional view showing a second embodiment of means for punching corner portions of the bags.
FIG. 8 is a view substantially identical to FIG. 2, but showing the perforation lines with gradually decreasing lengths.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Illustrative embodiments of the invention will now be explained more in detail with reference to the drawing.
The stack 1 consists of stacked bags 2 which have been formed from rectangular sections of plastic film in that the film has been folded on itself about the bottom fold line 3. The opening-defining edges 4 of the front walls of the bags are disposed short of the opening-defining edges 5 of the rear walls of the bags 2 so that the rear wall of each bag has an exposed strip 6 at the open end of each bag 2 opposite bottom fold line 3. Adjacent to the open end of each bag 2, it is provided in the usual manner with punched grip holes 7. In those corner portions of each bag 2 which are adjacent to its open end, the front wall is formed with approximately quadrant-shaped cutout portions, which are defined by cutouts 8. The rear wall of each bag is formed with approximately quadrant-shaped perforation lines 9, which are substantially congruent to and register with said cutouts. The corner portions 10 of the rear wall are defined by the perforation lines 9 and are formed with punched holes 11, which are used to stack and/or suspend the stacked bags 2.
It is apparent from FIGS. 2 and 8 that the perforation lines 9 join the opening-defining top edges and the side edges of the bags approximately at right angles thereto. Adjacent to the opening-defining edges 5 and adjacent to the side edges the perforation lines 9 have relatively long lands 12, 13, which are represented by solid lines. Between the portions formed with the relatively long lands 12, 13, each perforation line has relatively short lands in an intermediate portion.
The cutouts 8 and the perforation lines 9 defining each corner portion of a bag are, i.e. parallel approximately congruent radially to and offset slightly so as to register with each other; they are shown in a relatively substantially offset arrangement in the drawing for the sake of clearness.
Each bag 2 is provided with seam welds along its side edges in the usual manner.
When it is desired to tear a bag 2 from the stack 1, that bag is grasped and is pulled from the stack 1 in the direction indicated by the arrow A.
The manufacture of the bags will now briefly be explained with reference to FIG. 3.
In the manufacture of the bags, the side portions 15, 16 of a plastic film web are reversely folded about fold lines 3 onto the central portion 17 of the web in such a manner that the infolded side edges 18, 19 are disposed short of the center line 20 of the web. The double-folded web 21 which has thus been prepared is then moved through the punching station 22 in steps corresponding to the width of one bag each, as is known per se. In said punching station the lines defining corner portions of the subsequently formed bags are punched.
The punching means comprise a stationary cutter plate 23, which is provided with four punching cutters 24, which have an annular cutting edge each and serve to punch the stacking or hanger holes 11, and with perforating cutters 25, which surround respective punching cutters 24 and serve to punch the perforation lines 9. When it is desired to punch the stacking or hanger holes 11 and the annular perforation lines 9 surrounding said holes, an abutment is lowered onto the adjacent central portion 17 of the plastic film web. The abutment plate 26 is operable by the fluid-operable cylinder 29, which is fixed to the machine frame and has a piston rod 28, to which the abutment plate 26 is secured. The top surface of the abutment plate 26 constitutes an abutment for cutters 30, which are also approximately circular and are carried by a cutter plate 31, which is operated by means of fluid-operable cylinders 34, 35, which are secured to a mounting plate 36 and have piston rods 32, 33, to which the cutter plate 31 is secured. The mounting plate 36 is secured to the piston rod 28 of the cylinder 29.
The gap left between the infolded side edges 18, 19 of the film web 21 is so wide that the piston rod 28 can extend through that gap so that the abutment plate 26 can extend between the central portion 17 and the infolded side portions 15, 16 of the film web 21.
The cylinders 29, 34, 35 are provided with supply hoses, which are not shown and serve to supply a pressure fluid, such as oil or compressed air, to the cylinders.
The annular cutter 30 provided on the underside of the cutter plate 31 serve to punch the corner apertures, or cutouts 8 of the infolded web portions in the regions which will constitute the corner portions of the bags to be formed.
The width of the cutters 25 for cutting the perforation lines 9 is so selected that each perforation line has long lands 12 extending transversely to the longitudinal direction of the web and short lands 13 extending in the longitudinal direction of the web.
When the web 21 has been punched in those regions which will form the corner portions of the bags, the several bags are separated by a formation of hot wire-welded transverse seams along the transverse lines 40 indicated by dotted lines. The double bags thus formed, which are still joined along the center line of the web, are subsequently separated by longitudinal cuts.
The punched grip holes 7 may be punched as the hot wire-welded transverse seams are formed or in a separate operation.
FIG. 5 is a top plan view showing a plastic film web 41, which in the bags are still joined and in which the portions which will constitute the corner portions of said bags are defined by a quadrangular annular perforation line 42 and an aperture-defining, annular cutout 43, which is approximately congruent to and registers with the perforation line 42 and is interrupted adjacent to the longitudinal center line 20 of the film web by the gap that has been left between the inner edges 44, 45 of the infolded web portions.
The square perforation line and the square cutout have rounded corners and have such a configuration that the opening-defining edges and side edges of the subsequently formed bags will be joined by said perforation lines and cutouts at right angles to said edges.
The perforation lines 42 have relatively long lands adjacent to the side edges and opening-defining edges of the subsequently formed bags and have shorter lands in an intermediate portion.
FIG. 4 is a top plan view showing a plastic film web in which the bags are still joined and in the portions which will constitute the corner portion of said bags are defined by a circular perforation line 46 and by an aperture-defining cutout 47, which is also circular and is approximately congruent to and registers with the perforation line 46. In the illustrated angular regions which include the opening-defining edges and side edges of the subsequently formed bags the perforation lines have lands which have a length of 0.5 mm each. Between said portions the lands of the perforation lines have a length of only 0.3 mm each.
FIG. 6 is a top plan view showing a plastic film web in which the subsequently formed bags are still joined and in which the regions which will constitute the corner portions of said bags are defined by an octagonal perforation line 48 and by a cutout 49, which is approximately congruent to and registers with the perforation line 48. Owing to the octagonal configuration of the perforation lines it is ensured that the opening-defining edges and side edges of each of the subsequently formed bags will be joined by the perforation line at right angles thereto. Those legs of the punched perforation lines which are approximately at right angles to the opening-defining edges and side edges of the subsequently formed bags are formed with relatively long lands.
A second embodiment of punching means for defining the regions which will constitute the corner portions of the subsequently formed bags will now be explained more in detail with reference to FIG. 7. A cutter plate 51 provided with a circular perforating cutter 52 is secured to a beam 50 of the frame. Guide pins 53, 54 are provided above that perforating cutter 52 and a holder 55 for an abutment plate 56, which overlies the perforating cutter 52, is secured to said guide pins 53, 54, which are longitudinally slidably guided in bores formed in a guide plate 57 of the machine frame. Compression springs 58 urge the abutment plate 56 to its uppermost position.
A circular punching cutter 60 is disposed above the abutment plate 56 and is secured to the piston rod 61 of the pneumatic cylinder 62.
The guide pins 53, 54 extend into the gap which has been left between the inner edges of the infolded side portions of the film web 45 so that the abutment plate 56 extends between the central portion and the infolded side portions of the film web 45.
When the piston rod 61 is operated to lower the circular punching cutter 60, the latter will strike against the top face of the abutment plate 56 and the latter will be stabilized and forced down by the punching cutter 60 as the latter is lowered further. The abutment plate 56 finally engages the serrations of the circular lower perforating cutter 52. When a suitable pressure is then applied by the pneumatic cylinder 62, the aperture-defining cutouts and the annular perforation lines are then punched.
As the upper punching cutter 60 is subsequently raised, the compression springs lift the abutment plate 56 from the lower perforating cutter 52 so that the web 45 can be advanced by another step.
The hanger holes are formed by punching cutters 65, which are carried by a plate 66, which is secured to the piston rod 67 of a pneumatic cylinder 68. The punching cutters 65 extend through the cutter plate 51 and through the abutment plate 56 in suitable bores, which serve also as guides. During the punching cuts and the formation of the annular perforation lines the punching cutters 65 are extended and subsequently retracted to punch the hanger holes.
|
A stack of bags is provided, which have been made from rectangular sections of synthetic thermoplastic film. The sections have been folded onto themselves about bottom fold lines and provided with side seam welds. Their open ends, the sections are also provided with centrally disposed, punched grip holes and with laterally disposed corner portions, which are defined by perforation lines and formed with aligned stacking or hanger holes. Only the rear wall of each bag is provided with perforation lines defining the two upper corner portions of the rear wall. The front wall of the bag is formed in its corner portions with apertures which are defined by cutouts, which are substantially congruent to and register with the perforation lines. A process of manufacturing such stack of bags and an apparatus for carrying out such process are also disclosed.
| 1
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a National Stage application of International patent application PCT/EP2013/069383 filed on Sep. 18, 2013, which claims priority to German patent application No. 2012018384.4 filed on Sep. 18, 2012, the disclosures of which are incorporated herein by reference in their entirety.
TECHNICAL FIELD
The present invention relates to a composite application device for the application of flowable light-polymerizable composites.
The present invention relates to a composite application device according to the preamble of claim 1 , as well as a method according to the preamble of claim 23 .
Definitions and Abbreviations
Polymerization: Conversion of the composite which is still plastic or flowable into a solid state in which it can withstand occlusal loads.
Carpule: Off-the-shelf container filled with composite material from which the composite material can be expressed using a piston. The carpule can be provided with a short or elongated squirting tube 1 .
Cavity, tooth cavity: Hollow space in dental technology, in dentures and tooth crowns.
Cavity wall: Tooth structure which confines the hollow space of a cavity.
Composite, filling material, composite material: Material which serves to fill cavities and which seals these cavities tightly and permanently.
Measuring unit: Device for measuring the amount of composite applied per unit of time.
Control unit: Device for controlling the light intensity of the inventive light source depending on the amount of composite applied per unit of time. The control unit processes the data of the measuring unit and controls the light intensity of the light source.
Tensile stress: Mechanical stress which stresses the bonding at the contact surface between the cavity wall and the composite and which can destroy the bonding upon exceeding the strength of the bonding.
BACKGROUND OF THE INVENTION
In restorative and preventive dentistry, filling cavities, dental defects or root canals of teeth is of special importance. Apart from a plurality of different materials (e.g. gutta-percha, amalgam, gold), composites are also used as filling materials. Composites are mixtures of a polymerizable plastic matrix with organic and inorganic filling materials. The polymerization of these composites is triggered by exposure to visible blue or ultraviolet light after the composites have been applied into the cavity. Thus, the method which is currently common is comprised of first applying the composite into the cavity and subsequently hardening the composite by exposure to light.
All composites tend to form gaps due to their shrinkage behavior during hardening such that in case of the formation of a gap the tooth cavity will not be hermetically sealed. Due to this lack of hermetic sealing of the tooth cavity bacterial infestation of the gaps is possible and thus new caries and pain can be caused.
STATE OF THE ART
The disadvantage of all known light-polymerizable composites is that they shrink upon hardening. If the composites are adhered to the walls of the cavity, then this bonding is subjected to tensile stress after the hardening process. If this tensile stress is sufficiently large to exceed the strength of the bonding, the bonding will break and a gap will be formed between the filling and the tooth.
There are two basic approaches to reduce the shrinkage of the applied composite during and after the hardening process: On the one hand, by applying the composite more slowly and in layers, and on the other hand, by changing the chemical composition of the composite. Both approaches have significant disadvantages: A known process of reducing tensile stresses acting on light-polymerizable composites is to introduce the composites into the cavity which needs to be filled one after the other in small amounts (having a layer thickness of about 1.0 to 2.0 mm), and to harden every layer separately by light exposure.
Every new layer can only be applied when the previous layer has hardened. This process is very labor-intensive and time-consuming. The patient concerned has to hold out on the dental chair in an uncomfortable position and a bacterial contamination of the cavity that has not yet been filled to completion is the more likely, the longer it takes to fill the cavity.
By the use of particularly light-sensitive and translucent composites, layer thicknesses of up to 4.0 mm are possible. This means that the cavity can be filled more rapidly; however, the larger the layer thickness is, the larger the stresses will become during hardening.
In the second approach to reduce shrinkage during or after the hardening of the applied composite, the number or density of the new bonds between the monomer molecules which are formed during polymerization is reduced such that altogether polymerization shrinkage is reduced. However, this method has the substantial disadvantage of a considerably reduced strength of the composite due to the reduced number of chemical bonds.
Another solution comprises the opening of bonds of ring molecules during the polymerization reaction in addition to the formation of new bonds such that in addition to the shrinkage as a result of the polymerization, an expansion of the composite takes place, too, which makes possible to partially compensate for the shrinkage. These composites which have been chemically changed have the disadvantage of only being capable of being bonded to the wall of the cavity using particular adhesion agents, and this is why they have not become established.
From DE 295 17 958 U1 it is known to cure a radiation curable material using a curing lamp which is connected to the opening of the dispensing nozzle. This device is said to have the advantage of curing the exact location at which the dispensing nozzle dispenses the material. Here, the material is cured in one go, i.e. completely, and the same problems as mentioned earlier with regard to the formation of marginal gaps will arise.
Furthermore, it has already been suggested to use an optically opaque, tubular dispensing element for an application tip for the application of a light-curable material to the surface of a tooth, as well as a modeling section which is translucent and disc-shaped in this case, and to expose it to light during the application. This solution takes the beginning of the light curing closer to the surface of a tooth which is basically favorable. However, the quality of the application is highly dependent on the ability of the dentist or dental technician applying the material and on the guidance of the tool. If, for instance, the tool is pressed against the cavity too strongly, the mass to be polymerized is squeezed out to the side of the application area, and if the pressure is too low, fissures and the like will not be filled with material.
In addition, with regard to the formation of marginal gaps the above mentioned disadvantages arise as a result.
SUMMARY OF THE INVENTION
The task of the present invention is to provide a device and a method for the application of flowable light-polymerizable composites, which enable a time-saving processing of light-polymerizable composites and reliably prevent the formation of gaps of the composite during the polymerization process for the filling of cavities.
This task is inventively solved by the appended claims.
Extensive studies on the origins of stresses during the hardening process of composites have found that a large part of the shrinkage which is mainly responsible for the formation of stresses takes place before the composite has hardened completely. The polymerization of the composite turns the composite that has initially been plastic or flowable into a composite with a slightly deformable gel-like consistency, the so-called gel phase. This part of the shrinkage does not become effective in the filling of a cavity built up of thin layers, as in the polymerization of a thin layer the entire filling is initially transformed into the gel phase, which cannot build up stresses on its own and only then is fully polymerized.
The second part of the shrinkage, the so-called post-gel shrinkage, occurs when the composite has already been polymerized, and constitutes the smaller part of the entire shrinkage. This part of the shrinkage cannot be avoided, and therefore always contributes to the formation of stresses. For thick layers, i.e. when the composite is applied in one go in a conventional manner, gel and post-gel shrinkage occurs simultaneously:
While the top side of the thick layer facing the polymerization lamp has already been polymerized completely, a subjacent layer is only in the gel phase due to the light absorption of the composite. Since the surface of the thick layer has already been polymerized, composite material cannot be replenished from above and compensate for the shrinkage of the gel phase: This causes high shrinkage stresses as the shrinkages of the gel phase and the post-gel phase are accumulated.
Thus, in the method according to the invention, sufficient light is supplied during the application of the composite into the cavity such that the composite flows to the walls of the cavity and the gel shrinkage is triggered immediately afterwards so that the gel shrinkage has already taken place, before the composite has been polymerized to completion by a polymerization lamp. It is especially favorable to control the light intensity already during the application of the composite such that when the composite is applied more rapidly (i.e.when larger amounts of composite are applied per unit of time) the light intensity is enhanced, and when the composite is applied more slowly (i.e. when smaller amounts of composite are applied per unit of time) the light intensity is reduced.
Preferably, the inventive device consists of a combination of a spray gun or any other composite application device which serves to squeeze the composite from a suitable storage container, e.g. a commercially available carpule (preferably through the squirting tube of the carpule), and a suitable light source, for instance a light-emitting diode. The light source has to have a suitable light intensity and spectral distribution of the light wave length which is suitable to trigger the first phase of the polymerization of the composite (and thus the gel shrinkage of the composite), while the composite is applied into the cavity simultaneously. By means of a suitable device (the inventive measuring unit), the amount of the composite applied per unit of time is measured and transferred to the inventive control unit as a measured value.
The control unit uses said measured value to control the light intensity of the light source. A potentiometer is preferably used as a measuring unit, especially preferably a sliding potentiometer. The inventive light source emits light while the cavity is filled with composite depending on the amount of the composite applied per unit of time. In addition, the inventive light source can continue to emit light even after the cavity has been filled with composite in order to achieve the final strength of the composite.
While the cavity is filled with composite material, the inventive light source can advantageously emit light colors which do not contribute to a polymerization of the composite. Preferably, light colors are used which can be perceived by the human eye and which enable the treating person (dentist) to gain a better overview of the treatment site (cavity, tooth and its environment). Advantageously, these light colors can be switched on and off independently of the application of the composite.
The light source can be supplied with electricity by one or several batteries or accumulator batteries or by connecting the inventive device with the grid. The inventive application of the composite requires the composite to be flowable to a certain degree in an unexposed state such that when the cavity if filled with the composite, the composite contacts the walls of the cavity and thus bonds to the tooth structure.
For composites which are very viscous in the unexposed state and can thus not meet these requirements it is advantageous to vibrate the carpule or the squirting tube of the carpule 1 or the composite itself using a suitable sound generator in order to liquefy the composite. Depending on the material of the carpule or the squirting tube 1 of the carpule and depending on the composite used audible sound or even ultrasound vibrations can be used.
According to the invention it is favorable that the fluid composite which has been applied or introduced by the application device and which still comprises numerous monomers and free radicals in this state has a relatively low viscosity and can drop into the cavity in this state and forms a thin layer. Due to the thinness, i.e. a state in which the fluid has a very low viscosity, preferably between 1.0 and 1.8 cPs, the composite will also fill small cracks and gaps in the cavity.
After completion of the pre-gel phase, the composite has a tensile bending strength or bending strength of about 20 MPa in the gel state, a strength gradient being present between the surface of the corresponding layer and its deeper regions. For instance, the strength at the surface of a 2 mm layer can be 30 MPa and only 10 MPa at a depth of 2 mm.
According to the invention, it is taken advantage of this strength gradient by applying pressure with the regions of lower viscosity in order to refill gaps and fissures in the cavity—be it with the help of the tool tip of the application device, or with the help of the subsequent layer.
After the composite has been polymerized to completion, it still achieves a final strength of 90 to 100 MPa, and thus fulfills the EN ISO 4049 requirements for occlusal stress bearing regions, too.
According to the invention, it is also favorable for transforming the composite into the gel state if the control device determines a dosage of light which corresponds to a predetermined amount of the dosage of light for a full polymerization of the respective amount of composite, wherein the gelling dosage of light corresponds to 20 to 90, preferably 40 to 65, and in particular about 50 percent of the dosage of light for a full polymerization. The polymerization time per phase, i.e. pre-gel and post-gel phase, amounts to between 1 and 10 seconds, naturally depending on the available power of the light source and the resulting exposure rate, but also on the size and shape of the composite applied per layer.
In the pre-gel phase the exposure rate favorably amounts to less than 100 mW/cm 2 , in the post-gel phase preferably to more than 500 mW/cm 2 .
It is especially favorable to alternate the application and polymerization processes, with changes every 10 seconds, every second, or even every 100 msec. This enables a fast application without having to fear the danger of an early polymerization.
For reducing the viscosity of the applied composite a heat source, for instance a heating coil which surrounds a small metallic nozzle pipe, or any other heating, for instance an induction or a microwave heating, is preferably attached to the dispensing nozzle.
According to the invention, the markedly thin composite which preferably comprises microfilled complex materials as a filling material is gelled by the polymerization radiation applied. In said pre-gel phase 90% or up to 95% of the total shrinkage occurs which can amount to 1 to 6% by volume in commercially available composites.
The layer which has been applied can be processed, if necessary, by the dispensing nozzle of the application device which is configured as a tool, for instance in the form of a spatula. This pressure seals the marginal gaps of the composite in the gel state.
According to the invention, pressure is applied to the underlying layer by the composite conitnuing to flow, without even the use of a tool. Once the bottom layer is in the gel state, microscopically small gaps are refilled as a result of this, while at the same time the next layer is gelling and curing simultaneously as the surface stress increases.
Of course, “resqueezing” the composite which continues to flow is preferably carried out with fillings in the lower jaw region, however, in the upper jaw region, too, a recompaction of the material using the dispensing nozzle is detectable.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages, details and features may be taken from the following description of several exemplary embodiments in conjunction with the drawings:
FIG. 1 shows a schematic view of an inventive composite application device;
FIG. 2 shows a circuit diagram of a part of the control unit for the composite application device according to FIG. 1 , in the form of a block diagram;
FIG. 3 shows a detailed circuit diagram of the control unit according to FIG. 2 ; and
FIG. 4 shows different embodiments of the dispensing nozzle for the composite application device according to FIG. 1 in the embodiments of FIG. 4 a , FIG. 4 b and FIG. 4 c.
DETAILED DESCRIPTION
Close to the squirting tube of the carpule 1 a light source 2 , for instance in the form of a light-emitting diode, is attached. The light source may be attached in a fixed or detachable manner. If the light source is attached in a detachable manner, it can be removed for the cleaning of the inventive device. By actuating the lever mechanism 10 of the spray gun 3 the composite 4 is applied from the carpule 5 into the cavity 6 of the concerned tooth ( 7 ). In doing so, the measuring unit 8 is activated, for instance by moving the slide of a sliding potentiometer, thus changing the resistance of the potentiometer.
This change is registered in the control unit 9 and converted into a flow of current through the light source 2 , in such a way that a larger current is produced when the lever mechanism 10 is moved rapidly than in case of a slow movement of the lever mechanism 10 such that, when the movement is faster, the light source radiates a brighter light into the cavity than in case of a slower movement of the mechanism. An exact dosage of the light dosage is required, depending on the amount of composite applied per unit of time.
If the dosage of light is too high, it prevents the composite from flowing to the cavity wall by immediate gelling, if the dosage of light is too low, however, the gelling process cannot be activated.
It is especially advantageous to measure the amount of composite applied per unit of time in the manner previously described, and to use it to control the light source attached to the spray gun. Here, the light source can be a light-emitting diode which is attached close to the squirting tube of the carpule 1 . The light source can also be located at any other desired location at the spray gun and light can be radiated into the cavity by means of a light guide. It is also possible to integrate the light source into the carpule itself or to integrate one or several light guides into the carpule which receive light from the light source and radiate it into the cavity close to the squirting tube. The light source must be provided with contacts or any other suitable optical or electrical connections to the control unit. Lower tensile stresses are produced as follows compared to the conventional layer technique (Table 1).
TABLE 1
Processing according
Processing
to manufacturer's
in 3 layers
instructions
(layer or increment
(material is applied in
technique, every
Processing
one go, subsequently
layer is hardened
according to
Material
hardened)
separately)
the invention
SDR
6.3 MPa
5.2 MPa
3.3 MPa
(Dentsply
Corp.)
x-tra base
8.9 MPa
7.3 MPa
7.0 MPa
(VOCO
Corp.)
It is especially advantageous that in this type of composite processing the treating person (dentist) can introduce the composite into the cavity in good viewing conditions. While in the layer technique, the field of action must usually only be illuminated sparsely to prevent the composite from polymerizing early, here, a certain amount of light is supplied in a targeted manner such that the composite is transformed into the gel state and cannot flow away anymore. Thus, the light source may also advantageously be configured to not only emit blue light suitable for polymerization but also, for instance, white light with a high blue content, as is emitted by commercially available white light-emitting diodes. In this way it is possible to fill the cavity under good, non-dazzling illumination conditions.
A composite comprising a matrix based on acrylic resins, such as HEMA or TEGDMA, is preferably used. For the inorganic phase, i.e. the filling materials of the composite, glasses such as barium-aluminum-glass, glass ceramics, silicates, or silicon dioxides can be used which comprise both a small amount of macro fillers with a form size of more than 5 mm, but to a large degree micro fillers with a form size of less than 0.2 mm.
According to the invention, the large amount of micro fillers results in a good polishability. While the polymerization shrinkage in composites with a large amount of micro fillers is typically stronger, according to the invention, the formation of marginal gaps is suppressed by the formation of gel during the pre-polymerization process such that the inventively applied composites do not have the same disadvantages as previous composites with a high amount of micro fillers in spite of the extremely smooth surface which is possible in this context.
For instance, the weight portion of micro fillers can amount to 30 to 50% and it is also possible to use nano particles, i.e. fillers with particle sizes of less than 20 nm. By all means, these particles can constitute up to 50% by weight, wherein it is particularly advantageous that the viscosity is not changed by these particles, i.e. remains very low.
According to the invention, it is favorable if the light source 2 is switched on during the application of the composite material. As an alternative, it is also possible to alternate the application of the composite and the polymerization by switching-on the light source 2 , for instance with a change in frequency of one Hertz such that composite is applied and the light source is turned on alternately every second.
In this connection, the light source can apply pulsed light, for instance at an impulse/break ratio of 1:1. The output of the light source can be adjusted by pulse width modulation in a way known without any power losses being present.
The composite may, for instance, comprise camphorquinone as a photoinitiator. Preferably, the light source or at least one LED chip of the light source comprises an emission peak of a wave length of approximately 440 nm, and then the main emission range of the LED chips is between 400 and 500 nm.
In an advantageous embodiment the light source 2 comprises at least one LED chip which emits visible light in the range of between 530 and 700 nm and which in this way illuminates the composite when it is applied. It is also possible to switch on the illumination radiation during the application and to switch on the polymerization radiation in application intervals.
It is to be understood that laser diodes can inventively be used as light sources 2 instead of LED chips.
By implementing an additional ultrasonic source in the squirting tube 1 of the carpule the viscosity of the composite can inventively be reduced during the application. Additionally or alternatively, the squirting tube 1 can also be heated in order to further reduce the viscosity and to increase the reactivity of the composite present in monomers. When the composite is heated to, for instance, 30 or 32° C., the double-bond conversion can be increased in the polymerization of the matrix.
In a further advantageous embodiment, the application of the composite is supported by a mechanical drive which can be realized as an electric motor or a pneumatic pressure source. In this embodiment, the control unit 9 controls both the light source 2 and the mechanical drive.
While the invention is described in the context of a spray gun as a preferred embodiment of an application device, it is to be understood that any desired other design of an application device can also be realized. For instance, a stick applicator can also be used, and the light source and the composite source can be configured remote from a handpiece such that the composite is delivered via a composite line to the handpiece of the composite application device and the light via a corresponding light guide.
Initially, a pre-polymerization process takes place in the inventive application or introduction of the composite into the cavity. Here, a particular gelatinizing light dosage is applied which corresponds to between 20 and 80 percent, preferably about 50 percent of the light dosage to completely polymerize the composite. In doing so, the composite gelates, and according to the invention, if desired, finishing can be realized using the dispensing nozzle according to FIG. 4 which is configured similar to a tool. Only then, the final polymerization process takes place.
Thus, the amount of the composite applied is known and the time necessary for the final polymerization can be determined via the energy balance, and applied by the light source —or by the heat source in the squirting tube 1 .
It is to be understood that the filling process can inventively be implemented in two steps to form one single layer but it is also possible to repeat the pre-polymerization and final polymerization processes in a cyclical manner for every single layer.
FIG. 4 a shows one possible shape of an inventive dispensing nozzle 14 . In this embodiment, the end of the squirting tube 1 is surrounded by a tool 16 . The dispensing channel 18 extends through the tool 16 which channel comprises the same internal diameter as the squirting tube 1 , or possibly a tapered cross section towards its end, the shape of which resembles a nozzle.
In the exemplary embodiment illustrated, its end is located at the side of the tool 16 . The part of the tool 16 surrounding the squirting tube 1 is further surrounded by an optical system 20 of the source 2 . The optical system 20 can be a hollow tube, which is e.g. mirrored on the inside and bundles light towards the tool 16 , and thus towards the site of application. It can, however, also be provided with light guides in a way known. Preferably, the end of the optical system 20 is provided with a concave end face 20 which comprises an additional bundling effect.
In this exemplary case, the optical system 20 transmits both light from the LED chips which emit polymerization radiation and light from the LED chips for illumination.
In a way known, the tool 16 is made from an elastic plastic material. With the help of the working tip 24 which is configured similar to a soft spatula the surface of the applied composite can be evened out and pressed which proves advantageous for the adhesion of the composite in the cavity.
A modified embodiment of the tool 16 is illustrated in FIG. 4 b . In this embodiment, the dispensing channel 18 extends through the tool 16 in a central and coaxial manner relative to the squirting tube 1 . Here too, the optical system 20 can surround the squirting tube 1 and the upper part of the tool 16 . In every case, the tool 16 is preferably an exchangeable tool. It can be configured as a disposable part, or is also cleanable.
Preferably, its upper end is mounted to the squirting tube 1 such that it cannot be lost accidentally.
A further modified embodiment of a tool 16 is illustrated in FIG. 4 c . Here, the tool 16 is configured so as to be coaxial to the squirting tube 1 and extends in a blunt manner subsequent to the tube. It is held by the surrounding optical system 20 , and, in turn, the dispensing channel 18 extends through it which ends at the side of the tool 16 in this exemplary embodiment to provide a very effective tool tip 24 .
|
The present invention relates to a device and a method for the application of composites in tooth cavities. The device consists of a spray gun with integrated lighting for light-polymerizable composites, a measuring unit and a control unit. The composites are applied under controlled, precisely dosed exposure to polymerization light. According to the invention, the composite initially runs onto the walls of the cavity or onto previously introduced filling material and then, as a result of the light exposure, is transformed into the gel state. Thus, a large part of the polymerization shrinkage of the composite occurs while the composite is still plastically deformable so that any formation of gaps is compensated by the composite continuing to flow. It is only at this point in time that a sufficiently high dosage of light is applied for complete curing to occur.
| 0
|
CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims priority on provisional application Ser. No. 61/095,697 filed Sep. 10, 2008, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
Certain references are cited herein. These references are incorporated by reference herein.
Medical image composition is the act of joining image volumes from separate views from a medical image scanner into one consistent seamless whole volume. This is done via the method of composing (also called stitching or mosaicing).
In “stitching”, an algorithm is used to fill in the voxels of the output larger volume according to the locations computed by alignment. Where only one input volume overlaps an output voxel location, data is copied directly from the input to the output. Where two or more input volumes overlap at an output voxel, program logic is used to determine how to choose between the input datapoints, or to blend them together. Where no input volume overlaps the output, black voxels are used to fill. FIG. 1 illustrates this concept.
The goals of blending the component volumes are to limit artifacts that can occur from image volume distortion or patent/anatomy motion. These include, (a) limiting visible seams or creases; (b) limiting contrast variation; and (c) limiting ghosting effects due to blending.
The increase of the field strength of newer MR imaging machines (such as the Siemens Trio) provides the opportunity for much improved image resolution and quality. A challenge with these systems is that the increased magnetic strength has resulted in magnifying B0 effects (a magnetic loading distortion effect). B0 effects present themselves as a localized distortion in the volume. B0 distortion can occur anywhere within the volume, but is most pronounced in the regions on the periphery of the iso-center of the volume. Much effort has been made to correct for these effects in the design of MRI installations [1].
Whole body scans of a patient can take up a plurality of 3-5 individual volume acquisitions which are then composed together in order to capture a complete scan of an individual. Since B0 effects are most evident in the leading or trailing edges of a MR volume, having sufficient volume overlap and discarding the leading or trailing regions is a possible solution. However, these kinds of solutions will inevitably result in the need for more volumes, and the more volumes that are required for an individual, the more time individual subject workflow takes which can cut into the efficiency of a MR installation. Also, there is no certainty as to the location(s) where B0 effects might occur in a volume. This makes narrowing the field of view of a volume an expensive and imprecise solution.
B0 effects are not the only artifacts that can interfere with successful composition. Movement of the patient or anatomy between scans can also interfere, and should also be taken into account.
SUMMARY OF THE INVENTION
The invention provides a method and system which uses a process of registration to develop a distortion field between the overlapping regions of two adjoining volumes. Then the method and system includes gradual displacement morphing, and intensity blending is performed to create a seamless transition between the two volumes.
The invention provides a method for composing image volumes obtained using a medical scanning device, comprising the steps of: using a medical scanning device to obtain data of at least two image volumes of a patient, said image volumes having an overlap region; processing the data from the two image volumes to determine the overlap region and to register the two image volumes with each other using rigid registration; determining a non-rigid deformation between the two image volumes using an elastic registration algorithm; performing an alpha-morphing on each overlapping region of each image volume using the non-rigid deformation; and obtaining a blend region of the overlap region by performing an alpha-blending which blends the two image volumes by varying the relative contribution of the two image volumes using the results of alpha-morphing.
The invention provides an article of manufacture comprising a computer-usable medium having computer-readable program code embodied therein for composing a composite image from at least two smaller images, the computer-readable program code having instructions for performing the following steps: obtaining data of at least two image volumes of a patient, said image volumes having an overlap region; processing the data from the two image volumes to determine the overlap region and to register the two image volumes with each other using rigid registration; determining a non-rigid deformation between the two image volumes using an elastic registration algorithm; performing an alpha-morphing on each overlapping region of each image volume using the non-rigid deformation; and obtaining a blend region of the overlap region by performing an alpha-blending which blends the two image volumes by varying the relative contribution of the two image volumes using the results of alpha-morphing.
The invention provides a system for composing an image from two smaller image volumes of data obtained using a medical scanning device, comprising: a scanner for obtaining image data for at least two image volumes of a patient, wherein the image volumes have an overlap region; a processor for: processing the data from the two image volumes to determine the overlap region and to register the two image volumes with each other using rigid registration; determining a non-rigid deformation between the two image volumes using an elastic registration algorithm; performing an alpha-morphing on each overlapping region of each image volume using the non-rigid deformation; and obtaining a blend region of the overlap region by performing an alpha-blending which blends the two image volumes by varying the relative contribution of the two image volumes using the results of alpha-morphing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration which shows stitching aligned volumes together by blending first and second volumes in the overlap area of the first and second volumes;
FIG. 2 is a functional flowchart showing the steps involved in the method according to the invention;
FIG. 3 is a composite original image overlap region with no blending, showing only a midpoint outline, for one case example;
FIG. 4 is an image overlap region like that of FIG. 3 , but with alpha-blending only, showing ghosting effects, for the one-case example;
FIG. 5 is an image overlap region with both alpha-morphing and alpha-blending, for the one-case example of FIGS. 3 and 4 ;
FIG. 6 is a composite original image, like that of FIG. 3 , but for a second-case example;
FIG. 7 is an image overlap region like that of FIG. 4 , but for a second-case example;
FIG. 8 is an image overlap region like that of FIG. 5 , but for a second-case example; and
FIG. 9 is a block diagram of a medical imager system which may be used to practice the method according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A preferred embodiment of the invention will be described, but the invention is not limited to this embodiment.
The invention provides a method for composing image volumes obtained using a medical scanning device, comprising the steps of: using a medical scanning device to obtain data of at least two image volumes of a patient, said image volumes having an overlap region; processing the data from the two image volumes to determine the overlap region and to register the two image volumes with each other using rigid registration; determining a non-rigid deformation between the two image volumes using an elastic registration algorithm; performing an alpha-morphing on each overlapping region of each image volume using the non-rigid deformation; and obtaining a blend region of the overlap region by performing an alpha-blending which blends the two image volumes by varying the relative contribution of the two image volumes using the results of alpha-morphing.
The medical scanning device may be selected from the group consisting of MRI, CT, Ultrasound, Radiography, and PET imagers. The elastic registration algorithm may be based on the maximization of an intensity-based similarity metric between the two image volumes. The metric may be selected from the group consisting of Local Cross Correlation and Mutual Information. The elastic registration algorithm may model the deformation as a smooth vector field that indicates, for each pixel in one of the image volumes, its corresponding pixel location in a second image in the other image volume. The deformation and its inverse may be estimated iteratively by maximizing an intensity-based similarity metric and are regularized using a low-pass filter. The method may include computing values of I m1 and I m2 , according to the following equation:
I m1 =I 1 °(αø k )
I m2 =I 2 °((1−α)φ k )
wherein I m1 represents a first intermediate image volume result. I m2 represents a second intermediate image volume result. α is a parameter with a range [0.0,1.0] which linearly increases from the top to the bottom of the blend region, where ø k represents a deformation field mapping the calculated non-rigid displacement of I 1 to I 2 , where φ k represents a calculated non-rigid displacement of I 2 to I 1 , where I 1 represents a top overlapping image volume, and where I 2 represents a bottom overlapping image volume. The may include computing values of I blend according to the equation of:
I blend =(1−α)I m1 +αI m2 ,
wherein α is a parameter with a range [0.0,1.0] which linearly increases from the top to the bottom of the blend region, where I blend represents a composed overlap region, wherein I m1 represents a first intermediate image volume result, and I m2 represents a second intermediate image volume result. The image volumes may be partial volumes of a patient's entire anatomy. The method may further include the step of displaying at least a portion of the two image volumes, including the overlap region. The portion may be a slice which extends over the two image volumes, including the overlap region.
The invention provides an article of manufacture comprising a computer-usable medium having computer-readable program code embodied therein for composing a composite image from at least two smaller images, the computer-readable program code having instructions for performing the following steps: obtaining data of at least two image volumes of a patient, said image volumes having an overlap region; processing the data from the two image volumes to determine the overlap region and to register the two image volumes with each other using rigid registration; determining a non-rigid deformation between the two image volumes using an elastic registration algorithm; performing an alpha-morphing on each overlapping region of each image volume using the non-rigid deformation; and obtaining a blend region of the overlap region by performing an alpha-blending which blends the two image volumes by varying the relative contribution of the two image volumes using the results of alpha-morphing.
The medical scanning device may be selected from the group consisting of MRI, CT, Ultrasound, Radiography, and PET imagers. The elastic registration algorithm may be based on the maximization of an intensity-based similarity metric between the two image volumes. The metric may be selected from the group consisting of Local Cross Correlation and Mutual Information. A deformation field may be determined by obtaining a smooth vector field that indicates for each pixel in one of the image volumes, its corresponding pixel location in a second image in the other image volume. The deformation and its inverse may be estimated iteratively by maximizing an intensity-based similarity matrix and are regularized using a low-pass filter. The instructions may include computing values of I m1 and I m2 , according to the following equation:
I m1 =I 1 °(αø k )
I m2 =I 2 °((1−α)φ k )
wherein I m1 represents a first intermediate image volume result, I m2 represents a second intermediate image volume result, α is a parameter with a range [0.0,1.0] which linearly increases from the top to the bottom of the blend region, where ø k represents a deformation field mapping the calculated non-rigid displacement of I 1 to I 2 , where φ k represents a calculated non-rigid displacement of I 2 to I 1 , where I 1 represents a top overlapping image volume, and where I 2 represents a bottom overlapping image volume. The instructions may include computing values of I blend according to the equation of:
I blend =(1−α) I m1 αI m2 ,
wherein α is a parameter with a range [0.0,1.0] which linearly increases from the top to the bottom of the blend region, where I blend represents the composed overlap region, wherein I m1 represents a first intermediate image volume result, and I m2 represents a second intermediate image volume result. The image volumes may be partial volumes of a patient's entire anatomy. The instructions may include displaying at least a portion of the two image volumes, including the overlap region. The portion may be a slice which extends over the two image volumes, including the overlap region.
The invention provides a system for composing an image from two smaller image volumes of data obtained using a medical scanning device, comprising: a scanner for obtaining image data for at least two image volumes of a patient, wherein the image volumes have an overlap region; a processor for: processing the data from the two image volumes to determine the overlap region and to register the two image volumes with each other using rigid registration; determining a non-rigid deformation between the two image volumes using an elastic registration algorithm; performing an alpha-morphing on each overlapping region of each image volume using the non-rigid deformation; and obtaining a blend region of the overlap region by performing an alpha-blending which blends the two image volumes by varying the relative contribution of the two image volumes using the results of alpha-morphing.
The medical scanning device may be selected from the group consisting of MRI, CT, Ultrasound, Radiography, and PET imagers. The elastic registration algorithm may be based on the maximization of an intensity-based similarity metric between the two image volumes. The metric may be selected from the group consisting of Local Cross Correlation and Mutual Information. The processor may determine a deformation field by obtaining a smooth vector field that indicates for each pixel in one of the image volumes, its corresponding pixel location in a second image in the other image volume. The deformation and its inverse may be estimated iteratively by maximizing an intensity-based similarity matrix and are regularized using a low-pass filter. The processor may perform an alpha-morphing by computing values of I m1 and I m2 , according to the following equation:
I m1 =I 1 °(αø k )
I m2 =I 2 °((1−α)φ k )
wherein I m1 represents a first intermediate image volume result, I m2 represents a second intermediate image volume result, α is a parameter with a range [0.0,1.0] which linearly increases from the top to the bottom of the blend region, where ø k represents a deformation field mapping the calculated non-rigid displacement of I 1 to I 2 , where φ k represents a calculated non-rigid displacement of I 2 to I 1 , where I 1 represents a top overlapping image volume, and where I 2 represents a bottom overlapping image volume. The processor may obtain a blend region by computing values of I blend according to the equation of:
I blend =(1−α) I m1 +αI m2 ,
wherein α is a parameter with a range [0.0,1.0] which linearly increases from the top to the bottom of the blend region, where I blend represents a composed overlap region, wherein I m1 represents a first intermediate image volume result, and I m2 represents a second intermediate image volume result. The image volumes may be partial volumes of a patient's entire anatomy. The system may include a display for displaying at least a portion of the two image volumes, including the overlap region. The portion may be a slice which extends over the two image volumes, including the overlap region.
A method will be described using an example of two volume regions which overlap each other. As illustrated in FIG. 1 , each volume has a region which overlaps with the adjoining volume. FIG. 2 shows first steps of inputting image data for input volume 1 and input volume 2 in the overlap region. Offsets of the two volumes are initially determined either from the machine parameters of the scanner, or via an initial alignment stage.
The next steps involve registration and deformation field determination. The base method used for determination of the deformation field is based on previous research [2] [3], and is as follows.
The correspondence between overlapping areas of an image pair is established via elastic registration. The algorithm estimates a deformation that maximizes the local cross-correlation between one of the images (arbitrarily defined as reference) and the second image. In our experiments, this criterion has proved quite robust to intensity changes, signal inhomogeneities, and noise. In addition, such intensity-based approach does not require the extraction of anatomical landmarks. The deformation is represented by a smooth vector field that gives for each pixel on the reference, its corresponding location on the second image. Due to the nature of the distortions expected at the boundary of the field of view, deformations are constrained along the read-out direction. The algorithm estimates simultaneously, the deformation and its inverse, by composition of small displacements, incrementally maximizing the similarity criterion. This process, which can be seen as the numerical implementation of a transport equation, provides a large capture range.
The smoothness of the deformation is imposed by applying a low-pass filter to the vector field increments. The process is implemented in a multi-scale approach, from coarse to fine resolution, which increases the speed and provides improved convergence.
The pseudo code which is used may have the following steps:
Input:
I 1 , I 2 , σ (regularization parameter)
Output:
ø k and φ k (deformation and its approximated inverse)
1:
ø 0 = id
2:
while k max_iter do
3:
compute v k = ∇S(I 1 , I 2 , ø k ) (gradient of the local cross-
correlation)
4:
regularize v k by convolution with a Gaussian window
w k = G σ * v k
5:
update ø k+1 = ø k (id +tw k )
6:
update φ k+1 = (id −tw k ) φ k
7:
set k ← k + 1
8:
end while
The method used for registration according to the invention varies from the prior known methods in at least two respects.
First, the method uses constraint deformation to better model B0 distortion which occurs mainly in the readout (horizontal direction). This has caused a substantial improvement in computation time, and quality of result.
Second, the method according to the invention simultaneously generates a compatible inverse deformation to assist in the alpha morphing stages.
In alpha morphing, the deformation field describes a one-to-one correspondence between voxels in the two overlap regions. However, in order to avoid seams in the blending area at the two interfaces (Volume 1 <−>Blend Region, and Blend Region<−>Volume 2 ), the effects of blending should be gradual, because instantaneous changes will cause visible discontinuities at these interfaces:
I m1 =I 1 °(αø k )
I m2 =I 2 °((1−α)φ k )
where I m1 represents the first intermediate image volume result, I m2 represents the second intermediate image volume result, α is a parameter with a range [0.0,1.0] which linearly increases from the top to the bottom of the blend region where ø k represents the deformation field mapping the calculated non-rigid displacement of I 1 to I 2 , where φ k represents the calculated non-rigid displacement of I 2 to I 1 , where I 1 represents the top overlapping image volume, and where I 2 represents the bottom overlapping image volume. The operator “°” represents the displacement of the elements of an image field by the matrix represented in the deformation field (in voxels).
Alpha blending is a technique of combining two images (or volumes) by varying relative contributions over a blend region. This is used to finally combine the resultants from alpha morphing to create the final elastic blend region. I blend is calculated using:
I blend =(1−α) I m1 +αI m2
where α is a parameter with a range [0.0,1.0] which linearly increases from the top to the bottom of the blend region, where I blend represents the composed overlap region, I m1 represents the first intermediate image volume result, and I m2 represents the second intermediate image volume result.
The method according to the invention has been shown to result in significant improvement in the presence of many kinds of distortion and motion, not just B0-effects.
Two case examples were performed. The first example case is shown in FIGS. 3-5 , and the second example case is shown in FIGS. 6-8 .
FIGS. 3-5 shows the advantages of using the method according to the invention in the first case. In this case, areas with B0-effects were mosaiced. The seam between two volumes suffered from mild distortions due to B0.
FIG. 3 shows an original overlap region with no blending. The horizontal midpoint outline can be seen by the side arrows.
FIG. 4 shows an image overlap region with alpha-bending only. The ghosting effects can be seen at the midpoint cutline between the side arrows.
FIG. 5 shows an image overlap region with alpha-morphing and alpha-blending. The region between the side arrows appears to be free of artifacts and anomalies, at the region between the side arrows.
FIGS. 6-8 show images like that of FIGS. 3-5 , but for a second-case example. Similar results were obtained in the alpha-blending only ( FIG. 7 ), and in the alpha-morphing and alpha-blending ( FIG. 8 ).
The invention also provides a system which practices the method, and a computer-readable storage medium having stored therein, computer executable instructions for practicing the method.
FIG. 9 is a block diagram of a medical imager system, which may be in the form of an MRI system, CT system, Ultrasound system, Radiography system, PET imager or other imager. The system can acquire image data, and comprises a processor, program memory, an image storage memory and a display device, as well as appropriate user input controls.
Although one preferred embodiment has been described, the invention is not limited to this embodiment, and the scope of the invention is defined by way of the following claims.
REFERENCES
[1] J. Sled, G. Pike, Correction for B 0 and B 1 Variations in Quantitative Measurements Using MRI, Magnetic Resonance in Medicine, Vol. 43, No. 4, 2000, p. 589-593
[2] Flows of Diffeomorphisms for Multimodal Image Registration , C. Chefd'hotel, G. Hermosillo, O. Faugeras, Proceedings of the IEEE International Symposium Biomedical Imaging , July, 2002, Washington, D.C., USA
[3] A Variational Approach to Multimodal Image Matching , C. Chefd'hotel, G. Hermosillo, O. Faugeras, Proceedings of the ICCV Workshop on Variational and Level Set Methods in Computer Vision, July, 2001, Vancouver, B.C., Canada
|
A method and system for improving the quality of composing image volumes using deformable registration, and a gradual elastic morphing to create a seamless whole body volume image from several component volumes from a 3D medical imager.
| 6
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a product quality test in a winding step of the entire manufacturing process of a deflection yoke, which is a core part of a display device employing a cathode ray tube such as a color TV or a monitor, and in particular, to a magnetic field measuring system of a deflection yoke that can predict screen characteristics in light of coil characteristics and can perform a total inspection of the coil characteristics and a coil grouping to enhance a product quality and a productivity by introducing a magnetic field measuring system in the process of manufacturing a horizontal deflection coil and a vertical deflection coil, which are core parts of a deflection yoke.
[0003] 2. Description of the Prior Art
[0004] In general, the deflection yoke is classified into a saddle-toroidal type, a saddle-saddle type, etc., and functions to accurately deflect electron beams scanned from an electron gun to a fluorescent film coated on a screen of a cathode ray tube.
[0005] [0005]FIG. 1 shows a construction of a conventional deflection yoke. As shown in FIG. 1, a deflection coil 100 comprises a horizontal deflection coil and a vertical deflection coil, and functions to change the progressing direction of electron beams from a cathode ray tube (CRT) of a TV. Here, the horizontal deflection coil is seated around an internal periphery of a separator 200 formed in a horn shape, while the vertical deflection coil is seated around an external periphery of the separator 200 .
[0006] The deflection coil 100 for horizontally and vertically deflecting the progressing direction of electron beams from a CRT is wound several times by a winding machine in a saddle shape so as to be seated on internal and external peripheries of the separator 200 . FIG. 2 shows the deflection coil 100 comprising an upper flange 110 section including upper pinholes 111 , a lower flange section 120 including a lower pinhole 121 , and a body 130 located between the upper flange section 110 and the lower flange section 120 .
[0007] Here, the upper pinhole 111 and the lower pinhole 121 function to smoothly adjust convergence by varying an inductance value and an impedance value to properly control the deflected degree of the electron beams.
[0008] The deflection yoke constructed as above is mounted on a neck of the CRT to deflect the electron beams R, G, B emitted from an electron gun of the CRT and determine the scanning positions of the electron beams on a screen, when a saw tooth wave pulse is applied to the horizontal deflection coil and the vertical deflection coil, and when magnetic fields are subsequently generated according to the Fleming's left-hand rule.
[0009] Here, the deflection force deflecting the electron beams R, G, B is mainly generated by the horizontal deflection coil and the vertical deflection coil among all the parts of the deflection yoke.
[0010] The horizontal and the vertical deflection coils play a significant role of realizing colors by receiving a signal from a control section of a display device and by deflecting the electron beams to desired positions. Of course, the quality as well as the functionality is a significant factor to be considered for evaluating a deflection yoke. Thus, it would be absurd to discriminate the parts of the deflection yoke in light of their functionality alone. However, it is obvious that the horizontal and vertical deflection coils perform the most essential function of the deflection yoke.
[0011] Therefore, it is one of the most important step in the entire process of manufacturing the deflection yoke to quantize the characteristics of the horizontal and the vertical deflection coils by using the relationship between the degree of generating the magnetic fields and the screen characteristics.
[0012] The process of manufacturing the horizontal and the vertical deflection coils, which are core parts of the deflection yoke in general, comprises the step of molding magnetic wires by means of a winding machine. Here, the winding machine includes a winding zig suitable for realizing the characteristics of diverse kinds of deflection yoke.
[0013] The quality of the coils manufactured through the above step can be evaluated by roughly measuring the magnetic fields or based on the screen characteristics after manufacturing the deflection yoke. However, the aforementioned two methods are capable of sampling tests only but insufficient to evaluate the entire products that have been manufactured. Further, the evaluation based on the screen characteristics has a drawback of failing to test the characteristics of the coils only due to the fabricating nature and influence of other minor materials.
[0014] In general, the conventional method of testing characteristics of the horizontal and the vertical deflection coils is to evaluate screen characteristics that is actually displayed after completing manufacture of the deflection yoke and to determine the coil characteristics based on the evaluated result. However, this method consumes a considerable period of time for manufacturing the deflection yoke, and subsequently increases the time for feeding back faults in its characteristics, if found any, thereby causing a managerial loss.
[0015] Under these circumstances, a compact managing method has been recently suggested to sample coils by using the relationship between the magnetic field characteristics and the screen characteristics, and to measure the magnetic fields of the sampled coils. If the measured magnetic fields are within a set standard, manufacture of the coils is proceeded with. However, this compact managing method has a limit of inspecting the sampling, thereby posing a problem of failing to prepare a proper countermeasure against a feasible dispersion in the manufacturing process.
SUMMARY OF THE INVENTION
[0016] It is, therefore, an object of the present invention to provide a magnetic field measuring system of a deflection yoke that is related to a product quality test in a winding step of the entire manufacturing process of a deflection yoke, which is a core part of a display device employing a CRT such as a color TV or a monitor, and in particular, to a magnetic field measuring system of a deflection yoke that can predict screen characteristics in light of coil characteristics and can perform a total inspection of coil characteristics and a coil grouping to enhance a product quality and a productivity by introducing a magnetic field measuring system in the process of manufacturing a horizontal deflection coil and a vertical deflection coil, which are core parts of a deflection yoke.
[0017] In other words, an object of the present invention is to introduce a coil measuring system into a winding system for manufacturing coils as well as to establish a system capable of a total inspection of coil characteristics by using the coil measuring system.
[0018] To achieve the above object according to one aspect of the present invention, there is provided a winding zig for measuring magnetic fields of a deflection yoke, comprising: a plurality of magnetic field sensors mounted inside of the A-shaped winding zig; a digital signal generator for receiving output signals from the magnetic field sensors for sensing magnetic field characteristics of a deflection coil wound around the A-shaped winding zig, and amplifying and converting the received signals to digital signals; a digital signal interface for converting data outputted from the digital signal generator to serial data; and a radio signal transmitter for receiving the signals processed to serial data by the digital signal interface, converting the received signals to radio signals, and transmitting the converted signals.
[0019] The digital signal generator in the winding zig for measuring magnetic fields of a deflection yoke comprises: amplifiers matched with each magnetic field sensor wound around the A-shaped winding zig for amplifying the signals sensed by the magnetic field sensors to a predetermined gain, and outputting the amplified signals; and A/D converters matched with each amplifier for converting the amplified signals to digital data.
[0020] According to another aspect of the present invention, there is provided a winding zig for measuring magnetic fields of a deflection yoke, comprising: a plurality of magnetic field sensors installed inside of the A-shaped winding zig; a digital signal generator for receiving output signals from the magnetic field sensors that sense magnetic field characteristics of a deflection coil wound around the A-shaped winding zig, amplifying the received signals, and converting the amplified signals to digital signals; a digital signal interface for converting the data outputted from the digital signal generator to serial data; an independent current source for supplying a driving current to drive the magnetic field sensors; a radio signal transmitter for receiving signals processed as serial data by the digital signal interface, converting the received signals to radio signals, and transmitting the converted signals; and an independent voltage source for supplying a driving voltage to drive the digital signal generator and the digital signal interface.
[0021] To achieve the above objects, there is also provided a magnetic field measuring system of a deflection yoke, comprising: a plurality of magnetic field sensors installed inside of an A-shaped winding zig; a digital signal generator for receiving output signals from the magnetic field sensors that sense magnetic field characteristics of a deflection coil wound around the A-shaped winding zig, amplifying the received signals, and converting the amplified signals to digital signals; a digital signal interface for converting the data outputted from the digital signal generator to serial data; an independent current source for supplying a driving current to drive the magnetic field sensors; a radio signal transmitter for receiving signals processed as serial data by the digital signal interface, converting the received signals to radio signals, and transmitting the converted signals; a radio signal receiving section for receiving magnetic field measuring data of a radio signal type transmitted through the radio signal transmitter; a data parallel processor for receiving the data received through the radio signal receiving section, converting the received data to parallel data, and processing the converted data by reference to a predetermined index in accordance with an associate relationship between screen characteristics and magnetic field values; and a liquid crystal display for visually displaying the data processed by the data parallel processor to an inspector or a worker.
[0022] According to another aspect of the present invention, there is provided a magnetic field measuring system of a deflection yoke, comprising: a plurality of magnetic field sensors installed inside of an A-shaped winding zig; a digital signal generator for receiving output signals from the magnetic field sensors that sense magnetic field characteristics of a deflection coil wound around the A-shaped winding zig, amplifying the received signals, and converting the amplified signals to digital signals; a digital signal interface for converting the data outputted from the digital signal generator to serial data; an independent current source for supplying a driving current to drive the magnetic field sensors; a radio signal transmitter for receiving signals processed as serial data by the digital signal interface, converting the received signals to radio signals, and transmitting the converted signals; a radio signal receiving section for receiving magnetic field measuring data of a radio signal type transmitted through the radio signal transmitter; a data parallel processor for receiving the data received through the radio signal receiving section, converting the received data to parallel data, and processing the converted data by reference to a predetermined index in accordance with an associate relationship between screen characteristics and magnetic field values; an image processing controller for receiving data processed by the data parallel processor, and realizing the processed data into images of three or two dimensions; and a liquid crystal display for visually displaying the images of three or two dimensions in accordance with an associate relationship between screen characteristics and magnetic field values to an inspector or a worker.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The above objects, features and advantages of the present invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings, in which:
[0024] [0024]FIG. 1 is a perspective view of a separator comprising a conventional deflection coil;
[0025] [0025]FIG. 2 is a perspective view of a conventional deflection coil;
[0026] [0026]FIG. 3 is a diagram exemplifying a winding zig for winding a deflection coil;
[0027] [0027]FIG. 4 is a diagram exemplifying a main part of an A-shaped winding zig among all types of winding zigs;
[0028] [0028]FIG. 5 is a diagram exemplifying an A-shaped winding zig according to the present invention; and
[0029] [0029]FIG. 6 is a diagram illustrating a construction of a magnetic field measuring system of a deflection yoke according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] Preferred embodiments of the present invention will now be described with reference to the accompanying drawings. In the following description, same drawing reference numerals are used for the same elements even in different drawings. The matters defined in the description are nothing but the ones provided to assist in a comprehensive understanding of the invention. Thus, it is apparent that the present invention can be carried out without those defined matters. Also, well-known functions or constructions are not described in detail since they would obscure the invention in unnecessary detail.
[0031] First to be described will be a brief comparison of the technical concept of the present invention with the conventional art.
[0032] [0032]FIG. 3 shows a deflection coil winding machine for winding a deflection coil 100 . Referring to FIG. 3, the drawing reference numeral 300 identifies the deflection coil winding machine. The deflection coil winding machine 300 comprises a male winding mold (or an A-shaped winding zig) 310 and a female winding mold (or a B-shaped winding zig) 320 for leading a coil wound around a coil bobbin (not shown in the drawing), and turning and forming the lead coil to the deflection coil 100 of a saddle shape.
[0033] The male winding mold and the female winding mold identified by the drawing reference numerals 310 and 320 are also referred to as an A-shaped winding zig and a B-shaped winding zig as well. Both terms will be mixedly used in the following description.
[0034] Here, the male winding mold 310 comprises a male disk member 311 rotated by an external power source, and a male winding mold saddle 312 assembled with the male disk member 311 . The female winding mold 320 comprises a female disk member 321 rotated by an external power, and a female winding mold saddle assembled with the female mold saddle 322 .
[0035] An upper pin axis 313 and a lower pin axis, which are protruded and incoming through an axial hole 312 a by an air cylinder to form an upper pin hole 111 and a lower pin hole 121 of the deflection coil 100 , are respectively installed on corner surfaces of the male winding mold saddle 312 .
[0036] Here, the axial hole 312 a has a diameter identical to those of the upper pin axis 313 and the lower pin axis formed on the corner surfaces of the male winding mold saddle 312 .
[0037] The following is a description of a winding operation of the deflection coil winding machine 300 constructed as above.
[0038] If the male winding mold 310 and the female winding mold 320 are rotated in an anti-clockwise direction by the external power source, the coil supplied through the coil bobbin turns around an upper flange section 110 , a lower flange section 120 , and a body section 130 forming a saddle shape between the male winding mold 310 and the female winding mold 320 .
[0039] During the rotation of the male winding mold 310 and the female winding mold 320 , the upper pin axis 313 and the lower pin axis 314 are protruded through the axial hole 312 a by a pressure of the air cylinder. The upper pin hole 111 and the lower pin hole 121 are respectively formed in the upper flange section 110 and the lower flange section 120 of the deflection 100 by means of the upper pin axis 313 and the lower pin axis 314 .
[0040] [0040]FIG. 4 is a diagram exemplifying a curved section of a conventional A-shaped winding zig.
[0041] Thus, the characteristic of the present invention lies in that characteristics of a horizontal deflection coil and a vertical deflection coil, which are essential parts of a deflection yoke, can be induced by continuing a predetermined current in a coil upon completion of winding of a deflection coil wound by a winding machine, measuring magnetic fields generated from the corresponding windings in numerous spots, and comparing the measured magnetic fields so as to predict screen characteristics and totally inspecting coil characteristics based on the coil characteristics only by introducing a magnetic field measuring system to a process of manufacturing the horizontal deflection coil and the vertical deflection coil. In the present invention, a plurality of magnetic field sensors MSa, MSb, MSn are mounted inside of the conventional A-shaped winding zig, as shown in FIG. 5.
[0042] Here, it should be noted that the drawing reference numerals MSa, MSb and MSn assigned to represent the magnetic field sensors do not have any particular meanings in terms of alignment.
[0043] [0043]FIG. 6 shows a basic construction of a magnetic field measuring system employing the winding zig according to the present invention that has magnetic sensors for measuring magnetic fields after winding as shown in FIG. 5.
[0044] The construction of the basic system comprises a winding zig, magnetic field sensors mounted inside or outside of the zig, and a control section for processing values measured by the magnetic field sensors. Here, the part blocked by two chain lines in FIG. 6 represents a construction of the winding zig. The other parts represent a construction of the control section.
[0045] Thus, the following description will be made by dividing the construction of the magnetic field measuring system into the winding zig and the control section. A detailed construction of the winding zig will first be described herein below.
[0046] As shown in FIG. 5, the winding zig comprises magnetic field sensors MSa, MSb, MSn mounted inside of the A-shaped winding zig AWJ, a current source CS for supplying a driving current to operate the magnetic field sensors MSa, MSb, MSn, a digital signal generator DSG, a voltage source VS for supplying a driving voltage to drive the digital signal generator, a digital signal interface DSI for converting the data outputted from the digital signal generator DSG to serial data, and a transmitter PST for receiving and transmitting the signals processed to serial data by the digital signal interface DSI.
[0047] Here, it is preferable to realize the transmitter PST into a radio signal transmitter for converting the inputted data to radio signals, and transmitting the converted signals so as to prevent twist of the signal lines.
[0048] The digital signal generator DSG comprises amplifiers matched with the respective magnetic field sensors MSa, MSb, MSn mounted on the A-shaped winding zig, and A/D converters matched with each of the amplifiers. No drawing reference numeral was assigned to those constitutional elements.
[0049] The following is a detailed description of the construction of the control section.
[0050] The control section comprises a receiver PSR for receiving the signals transmitted from the transmitter PST, a data parallel processor DPP for converting the data received by the receiver PSR to parallel data, and processing the converted data by reference to a predetermined index in accordance with an associate relationship between the screen characteristics and magnetic field values, an image processing controller IPC for receiving the data processed by the data parallel processor DPP, and realizing the received data into images of two or three dimensions, and a liquid crystal display LCD device for visually displaying the images of two or three dimensions in accordance with an associate relationship between the screen characteristics and the magnetic field value processed by the image processing controller IPC.
[0051] It is preferable to realize the receiver PSR into a radio signal receiver for receiving magnetic field data of a transmitted radio signal type to prevent twist of the transmitted signal lines.
[0052] An operation of the magnetic field measuring system according to the present invention will now be described under an assumption that the transmitter and the receiver transmit or receive radio signals.
[0053] As shown in FIG. 3 where the A-shaped winding zig in FIG. 5 is attached, a deflection coil is wound by combining the A-shaped winding zig with the B-shaped winding zig. Once the winding is completed, the magnetic field sensors MSa, MSb, MSn sense magnetic field characteristics of the deflection coil wound around the A-shaped winding zig through the driving current supplied by the current source CS.
[0054] The output signals of the magnetic field sensors MSa, MSb, MSn are amplified by the amplifiers matched with each of the magnetic field sensors MSa, MSb, MSn, and are converted to digital signals by the A/D converters matched with each of the amplifiers.
[0055] The output data from the digital signal generator comprising the amplifiers and the A/D converters are parallel data. Therefore, the digital signal interface receives the parallel data, and converts the same to serial data so as to be transferred to the transmitter PST.
[0056] The transmitter PST converts the magnetic field data signals, which have been processed by the digital signal interface into serial data, to radio signals. The reason is because the signal lines for transfer are highly likely to be twisted or shortened when transferring the data through wire by nature of the winding machine. Therefore, it is critical to transfer the data wirelessly, and conversion of the data into serial data is unavoidable.
[0057] The following is a description of an operation of the control section corresponding to the winding zig.
[0058] The magnetic field measuring data of radio signal type are received by the receiver PSR. The serial data received by the receiver are converted to parallel data by the data parallel processor DPP. Then, an associate relationship between the screen characteristics and the magnetic field characteristics is calculated by reference to a predetermined index, which indicates an influence of the magnetic field characteristics measured by the magnetic field sensors MSa, MSb, MSn onto the screen characteristics.
[0059] The data processed by the data parallel processor DPP are received by the image processing controller IPC and displayed by the liquid crystal display device LCD. The image processing controller realizes the influence of the magnetic field characteristics of the winding coil onto the screen characteristics into images of three or two dimensions so as to be easily recognized by a user.
[0060] Also, storability of the measured results is enhanced by using a database (not shown in the drawing) or a peripheral device such as a printer.
[0061] In short, according to the present invention, a winding machine winds coils by using wires. The coils are formed, and magnetic fields of the coils are measured. The measured values of the magnetic fields are transferred to the control section so as to be displayed on a screen.
[0062] Employing a grouping method in accordance with the magnetic field characteristics of the coils serves to reduce dispersion of the screen characteristics. Where a significant managerial point exists in the screen characteristics of a deflection yoke, the coil property values can be totally inspected in association with the point and the magnetic field property values, thereby enhancing quality of the product.
[0063] The problem of unbalance between the left and right side characteristics of the deflection yoke can be resolved by checking the difference between the left and right sides through direct measurement of the magnetic field property values of the coils. Therefore, the screen testing time can be reduced with the same effect.
[0064] As described above, the magnetic field measuring system according to the present invention is directed to measuring magnetic fields of wound coils in the coil winding system. Measuring the magnetic fields after winding exempts the process of evaluating screen characteristics and improves the existing sampling test to a total inspection for product quality control, thereby realizing an establishment of a system drastically enhancing the product quality.
[0065] The magnetic field measuring system according to the present invention also serves to resolve the feasible problem when evaluating the coil characteristics based on the conventional screen characteristics, i.e., the problem caused by failure to accurately evaluate the coil characteristics when based on the screen characteristics, which are the results of complex factors including not only the characteristics of the coil as a unit product but also the assemblability of the coil.
[0066] Further, evaluation of characteristics is variable depending on the above factors. Therefore, the magnetic field measuring system provided by the present invention serves to resolve this problem by measuring an extent of the deflecting force that can be generated from the coils by means of magnetic field sensors. Also, the magnetic field measuring system according to the present invention is also expected to enhance the product quality control in the winding process by evaluating the characteristics of the coil as a unit product.
[0067] While the invention has been shown and described with reference to certain preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
|
Disclosed is a product quality test in a winding step of the entire manufacturing process of a deflection yoke, which is a core part of a display device employing a cathode ray tube such as a color TV or a monitor, and in particular, a winding zig for measuring magnetic fields of a deflection yoke and a magnetic field measuring system of a deflection yoke using the winding zig. The winding zig and the system according to the invention include a plurality of magnetic field sensors mounted inside of the A-shaped winding zig, a digital signal generator for receiving output signals from the magnetic field sensors that sense magnetic field characteristics of a deflection coil wound around the A-shaped winding zig, amplifying the received signals, and converting the amplified signals to digital signals, a digital signal interface for converting the data outputted from the digital signal generator to serial data, and a transmitter for receiving signals processed as serial data by the digital signal interface, and transmitting the received signals.
| 7
|
BACKGROUND OF THE INVENTION
This invention relates to a screening apparatus for macerating and screening a paper feedstock in a paper manufacturing process, and more particularly to a strainer suitable for use in a pulper for macerating a paper feedstock or the like.
In general, a pulper for paper making or the like includes a strainer for screening a paper feedstock of good quality macerated through a rotor rotating.
A strainer which has been conventionally used for this purpose is generally constructed as shown in FIG. 1. More particularly, a conventional strainer which is generally designated by reference numeral 100 in FIG. 1 includes a flat straining body or plate 102 formed into a disc-like shape and provided with a number of through-holes or apertures 104 functioning as straining apertures. The strainer 100 also includes a plurality of cutters 106 mounted on an upper surface of the straining plate 102 using fixing means 108 such as bolts or the like in a manner to be perpendicular to a direction of rotation of a rotor (not shown) arranged so as to rotate in proximity to the strainer 100. The strainer 100 thus constructed permits its maceration ability to be enhanced by cooperation of the cutters 106 with the rotor rotating.
Unfortunately, the conventional strainer constructed as described above has a lot of disadvantages.
One of the disadvantages encountered with the conventional strainer is that the cutters 106 account for a considerable part of the surface area of the straining plate 102, resulting in an area of distribution of the straining apertures 104 on the straining plate 102 being reduced.
Another disadvantage of the prior art is that the cutters 106 are arranged on the upper surface of the straining plate 102 in a manner to project therefrom, to thereby cause a gap between the rotor and the straining plate 102 to be increased, so that a screening effect exhibited by the straining apertures 104 of the straining plate 102 due to vortex resulting from rotation of the rotor may be reduced.
A further disadvantage of the prior art is that the length of a cutting edge formed at each of the cutters 106 is restricted.
Also, the conventional strainer has still another disadvantage that there is a possibility of causing the fixing means 108 such as bolts or the like for fixing the cutters 106 on the straining plate 102 to be loosened during the screening operation, leading,to removal of the cutters 106 from the straining plate 102.
In addition, the conventional strainer causes the number of parts required for forming the strainer 100 to be increased.
Yet another disadvantage encountered with the conventional strainer is that the manufacturing is highly troublesome and time-consuming because it is required to manufacture the individual cutters 106 and mount them on the straining plate 102 by means of bolts or the like.
SUMMARY OF THE INVENTION
The present invention has been made in view of the foregoing disadvantages of the prior art.
Accordingly, it is an object of the present invention to provide a strainer for paper making which is capable of accomplishing the maceration and screening of a paper feedstock with high efficiency.
It is another object of the present invention to provide a strainer for paper making which is capable of being significantly simplified in structure.
It is a further object of the present invention to provide a strainer for paper making which is capable of enhancing safety in the operation.
It is still another object of the present invention to provide a strainer for paper making which is capable of being readily and simply manufactured.
In accordance with one aspect of the present invention, a strainer for paper making arranged in proximity to a rotating rotor for screening a paper feedstock to be macerated is provided, wherein a plurality of recesses are formed on a surface of said strainer opposite to the rotor.
Such construction effectively prevents a decrease in area of distribution of the straining apertures and permits an edge of each of the recesses to function as a cutter. Also, the present invention constructed as described above permits micro-vortexes to occur in the recesses when the rotor passes above the recesses. Thus, it will be noted that the strainer of the present invention exhibits an excellent maceration function, as well as a satisfactory screening function.
The recesses may be formed into any suitable shape such as a circular shape or the like from the viewpoint manufacturing.
In a preferred embodiment of the present invention, the recesses may be formed into the same size. Alternatively, they may comprise a combination of recesses formed into sizes different from each other.
An edge of each of the recesses acting as a cutting edge may be formed into a desired length.
In a preferred embodiment of the present invention, the recesses may be arranged in a zigzag manner. Alternatively, they may be radially arranged.
In accordance with another aspect of the present invention, a screening apparatus for paper making for macerating and screening a paper feedstock is provided. The screening apparatus comprises a tank, a rotor rotatably arranged in the tank, and a strainer arranged in proximity to the rotor and formed with through-holes for passing an available fiber material therethrough in a manner to be distributed substantially all over a surface thereof. The strainer is formed on a surface thereof opposite to the rotor with a plurality of recesses, each of which has an edge functioning a cutter which cooperates with the rotor.
In a preferred embodiment of the present invention, the strainer is formed into a plate-like shape and arranged on an inner side of a bottom of the tank to partition an interior of the tank into an upper chamber and a lower chamber, and the rotor is arranged above the strainer.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and many of the attendant advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings; wherein:
FIG. 1 is a perspective view showing a conventional strainer;
FIG. 2 is a schematic vertical sectional view showing an embodiment of a pulper or screening apparatus according to the present invention;
FIG. 3 is a perspective view showing an embodiment of a strainer according to the present invention;
FIG. 4 is a fragmentary enlarged perspective sectional view of the strainer shown in FIG. 3;
FIG. 5 is a vertical sectional view of the strainer of FIG. 3 showing the relationship between the strainer and a rotor;
FIG. 6 is a fragmentary vertical sectional view of the strainer of FIG. 3 showing the flow of a material in a recess of the strainer; and
FIG. 7 is a perspective view showing another embodiment of a strainer according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now, a screening apparatus and a strainer according to the present invention will be described hereinafter with reference to FIGS. 2 to 7, wherein like reference numerals designate like or corresponding parts throughout.
FIG. 2 generally shows an embodiment of a pulper or a screening apparatus according to the present invention therein. The pulper exemplified in FIG. 2 includes a leg or support section 10 and an upright tank 12 formed into a substantially cylindrical shape and supported on the leg section 10. The tank 12 is provided on an inner side of a bottom thereof with a rotor 14 in a rotatable manner, which functions to permit a paper feedstock incorporated into and mixed with water in the tank 12 to flow round. Below the rotor 14 in the tank 12 is provided a strainer 16 of a disc-like shape which is an embodiment of the present invention and acts to partition the interior of the tank 12 into an upper treating chamber 18 and a lower treating chamber 20 therethrough in the vertical direction. The strainer 16 is fixedly arranged in the tank 12. The rotor 14 is positioned in proximity to an upper surface of the strainer 16 and mounted on an upper end of a drive shaft 22 downward extending through the tank 12 to the exterior of the tank. The drive shaft 22 is mounted on a lower end thereof with a transmission member 24 such as a pulley or the like, which is then connected to a motor (not shown) directly or through a suitable transmission mechanism. Also, the tank 12 is provided on the bottom thereof with an outlet passage 26 for feeding an available fiber material which is passed through the strainer 16 from the lower treating chamber 20 therethrough to the exterior of the tank and a discharge passage 28 for discharging any foreign matter included in the paper feedstock and separated by maceration in the pulper from the upper treating chamber 18 therethrough to the exterior of the tank.
The strainer 16 may be constructed in such a manner as shown in FIG. 3. More particularly, the strainer 16 is generally formed into an annular shape so as to have a hole provided at a central portion thereof, through which a drive shaft of the rotor 14 is inserted. The strainer 16 is formed with a number of small through-holes or apertures 30 in a manner to be distributed all over a surface thereof. The apertures thus formed each serve as a straining aperture. Also, the strainer 16 is provided on an upper surface thereof with a plurality of circular recesses 32 which form curvilinear cutting edges, which, in the embodiment shown in FIG. 3 are arranged in a zigzag manner. The recesses 32 each have an upper edge 34 defined on the same level as the upper surface of the strainer 16 and opposite to the rotor 14. The upper edge 34 each functions as a cutting edge, which cooperates with the rotor 14 as described hereinafter. The straining apertures 30, as shown in FIG. 4, are formed not only on the outside of the recesses 32 but on the inside thereof. Also, the straining aperture 30 may be formed so as to extend from a portion of the strainer at which the recess 32 is formed to a portion of the strainer 16 at which the recess 32 is not formed. This results in a part of the cutting edge of the recess 32 being discontinued, however, such discontinuation does not adversely affect the strainer of the illustrated embodiment.
The strainer 16 is formed by subjecting a perforated plate to cutting to form the recesses 32, cutting it into a donut-like shape, and fitting the donut-like plate on a frame through inner and outer peripheries thereof to fix it integral with the frame. In this instance, the recesses 32 laid across the inner and outer peripheries of the strainer, as shown in FIG. 3, partially wane; however, this does not adversely affect the strainer of the illustrated embodiment.
In the pulper of FIG. 2 which is so constructed that the thus-formed strainer 16 is fixed on the inner surface of the bottom of the tank 12, as shown in FIG. 5, the rotor 14 and strainer 16 can be arranged in such a manner that the lower end of the rotor 14 and the upper surface of the strainer 16 are positioned in proximity to each other. Therefore, when the rotor 14 is driven by means of the motor (not shown), the paper feedstock in the tank 12 is caused to flow round due to rotation of the rotor 14. Also, this results in micro-vortexes V occurring in each of the recesses 32 when the rotor 14 passes above the recess, as shown in FIG. 6. The so-produced micro-vortexes V promote maceration of a paper feedstock and the screening of the paper feedstock through the straining apertures 30.
FIG. 7 shows another embodiment of a strainer according to the present invention. A strainer of the illustrated embodiment generally designated at reference numeral 16 is generally formed into an annular shape and provided with a plurality of small through-holes or apertures 30 functioning as straining apertures. Also, the strainer 16 is also formed with a plurality of first circular recesses 32a of a large size and a plurality of second circular recesses 32b of a small size. The first recesses 32a are radially arranged and the second recesses 32b each are arranged in a manner to be surrounded by four such first recesses 32a adjacent to each other. The first and second recesses 32a and 32b have Upper edges 34a and 34b defined so as to be flush with an upper surface of the strainer 16, respectively, so that the upper edges each may function as a cutting edge.
The remaining part of the strainer 16 shown in FIG. 7 may be constructed in substantially the same manner as that shown in FIG. 2.
Thus, the strainer 16 of the illustrated embodiment constructed as described above may exhibit substantially the same functions as the embodiment described above.
As will be readily noted from the above, in the present invention, the recesses arranged on the strainer so as to provide the cutting edges may be formed into the same configuration and size. Alternatively, they may be formed into different configurations and/or sizes or they may comprise a combination of recesses formed into configurations and/or sizes different from each other. The size, number and configuration of the recesses may be suitably selected to permit the cutting edge defined by the upper edge of each of the recesses to be formed into a desired length. The recesses each are preferably formed into a circular shape from the viewpoint of manufacturing of the strainer. For example, the recesses may be formed into a diameter of about 20 to 150 mm and a depth of about 0.5 to 5.0 mm. Alternatively, the recesses may be formed into any suitable shape such as an elliptic shape, a rectangular shape, a triangular shape or the like other than a circular shape.
The strainer of the present invention may be manufactured according to any suitable process other than the above-described process. For example, it may be manufactured by subjecting a single plate material to cutting to form the recesses and then forming the plate with the straining apertures. Alternatively, it may be produced by superposing a plate formed with through-holes corresponding to the recesses and a blank plate on each other and then forming the plates with the straining apertures.
As can be seen from the foregoing, the strainer of the present invention for paper making which is arranged in the vicinity of a rotor for screening a paper feedstock macerated is formed with a plurality of the recesses on the surface thereof opposite to the rotor, to thereby eliminate the mounting of cutters on the strainer as required in the prior art, resulting in effectively preventing a decrease in area of the straining apertures. Also, the strainer of the present invention permits the cutting edges to be formed into a desired length. Thus, the strainer of the present invention can exhibit a satisfactory maceration function and an excellent screening or straining function. In addition, the present invention permits the number of parts required for forming the strainer to be significantly reduced and the manufacturing to be readily carried out.
While preferred embodiments of the invention have been described with a certain degree of particularity with reference to the drawings, obvious modifications and variations 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.
|
A strainer for paper making capable of accomplishing maceration and screening of a paper feedstock with high efficiency and being simplified in structure and manufacturing. The strainer is arranged in proximity to a rotor and formed with a plurality of recesses on a surface thereof opposite to the rotor. Also, a screening apparatus for paper making which uses such a strainer is disclosed.
| 3
|
BACKGROUND OF THE INVENTION
The present invention relates to a carrier strip assembly as well as the interface between the lead pins on the carrier strip assembly and an electrical component package. More particularly, this invention relates to a carrier strip assembly which has round lead wires with integrally formed clamps on the free ends of the lead wires for connection to electrical component packages. The present invention is also directed to the method of fabricating the carrier strip or lead frame assembly having the round lead wires with integrally formed clamps on their free ends.
Inherent in the competitive environment of manufacturing electronic products is the utilization of low-cost rapid high volume manufacturing processes. A widely practiced approach to the assembly of electrical component packages having in-line pin devices for connection to various circuit assemblies or subassemblies is the attachment of a lead frame carrier or carrier strip assembly to the electrical component substrate to facilitate a continuous automated process. The carrier strip assembly includes the leads which are to be attached to the electrical component.
Generally, the carrier strip is made by stamping or etching some type of continuous band of thin gauge metal into a particular form wherein the strip becomes not only the carrying mechanism for the electrical component during its assembly, but also a source of the lead pins for the electronic component device. The typical presently used carrier strip assembly has the lead pins integrally formed thereon and they have a generally rectangular or square cross-sectional shape. However, in some instances it is desirable for the lead pins to have a round or circular cross-sectional shape.
It is recognized that in some electrical component modules straight rond lead wire pins have been utilized. However, these pins are generally affixed to the large area surface of the component substrate and are positioned along one edge of the substrate, so that the pin is offset from the centerline of the edge thickness of the substrate. In the construction of electrical component packages, having a substrate to which lead pins are connected, it is important that the longitudinal centerline of the pin be aligned with the centerline or center of the substrate edge thickness. Otherwise, the lead pins become offset from the center of the substrate edge thickness and present an unbalanced non-symmetrical lead pin arrangement with respect to the edge of the component package. This offset arrangement of the lead pins requires more room on the board assembly to which the component is attached. Also, the offset pins may cause more stress on the pin/substrate connection when the lead pins are inserted into a board assembly.
The typical rectangular cross-sectionally shaped lead pins which are formed on the carrier strip normally require the incorporation of tie bars adjacent the free ends of the lead wires to maintain their proper location with respect to each other. This necessitates the additional step of cutting away the tie bars after the component has been assembled.
SUMMARY OF THE INVENTION
The carrier strip assembly of the present invention utilizes a series of suitable lengths of round wire transversely mounted upon a continuous longitudinally traversing band wherein the outer ends of the round wire leads have a clamping connection integrally formed thereon for attachment to the edge of the electronic component substrate. The present invention also provides the method for making this improved carrier strip incorporating a series of round wire leads.
The utilization of the present invention provides for the placement of round lead wires on electrical components which are carried on a transporting carrier strip in such a manner that the longitudinal centerline of lead wires is aligned with the center of the edge thickness of the substrate. Once the assembly process is completed, the lead wires are cut from the carrier strip, resulting in each of the electrical component packages having one or more lead wires extending from its perimeter to provide connection into an assembly board.
Round lead wires allow the user to insert the wires in a board and bend them, not only at a right angle onto the board's opposing side, but also at any radial angle. On the other hand, rectangularly or square cross-sectionally shaped lead wires can be bent at a right angle onto the board's opposite side, but are limited in flexibility with respect to the radial direction they can be bent.
Round cross-sectional lead wires can be moved by aligning combs for proper positioning of the lead wires along the edge of the substrate, so that the need for tie bars is eliminated for round lead wires. Consequently, the additional step of removing the tie bars after completion of component assembly is eliminated.
Hence, the present invention combines the advantages of automated assembly of electrical component packages using a carrier strip assembly with the unique feature of being able to incorporate round lead wires in the carrier strip in such a manner that they can be connected to the packages in alignment with the center of the edge thickness of the substrate. In addition, the present approach of utilizing round lead wires with integrally formed connecting clamps provides a more efficient and inexpensive method of forming the overall electrical component package.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view showing the band portion of the carrier strip in the first stage of its formation;
FIG. 2 is a plan view of the carrier strip similar to FIG. 1 wherein the lead wire holder portions have been formed;
FIG. 3 is a sectional view taken along the lines 3--3 in FIG. 2;
FIG. 4 is a sectional view taken along the lines 4--4 in FIG. 2;
FIG. 5 is a plan view of a portion of the carrier strip band with the round lead wires traversely mounted on the carrier strip;
FIG. 6 is an end view of the carrier strip band with the lead wire mounted thereon;
FIG. 7 is an end view of the lead wire with its ends formed into thin portions to form clamps;
FIG. 8 is a plan view of the carrier strip assembly with the round lead wires having the free ends formed into trifurcated clamps;
FIG. 9 is an end view of the carrier strip showing the general shape of the clamped ends of the lead wires;
FIG. 10 is a plan view of the carrier strip assembly showing the attachment of the clamps of the lead wires to the electrical component substrate;
FIG. 11 is an end view showing the interface between the clamp end of the lead wires and the substrate;
FIG. 12 is a plan view of the carrier strip showing the encapsulation of the electrical component substrate and the clamp end of the lead wires; and
FIG. 13 is an end view showing the encapsulation of the interface between the clamp end of the lead wire and the component package.
DETAILED DESCRIPTION OF THE INVENTION
In the manufacture of the carrier strip assembly of the present invention, a long continuous band or strip of thin gauge metal 10 in FIG. 1 is subjected to a stamping or etching process to form a plurality of precisely spaced indexing holes 12, as well as a plurality of precisely spaced holder tabs 14 which will receive lead wires as will be explained. Each holder tab 14 contains a neck portion 16 and two flange sides 18. The indexing holes 12 are utilized in the overall automatic assembly of electronic components and interface with sprockets or other drive means to propel and control the movement of the carrier strip assembly.
As shown in FIG. 2, in the next stage of the formation of the carrier strip assembly the holder tabs 18 are bent upward in a vertical direction to be somewhat perpendicular to the central portion 20 of the holder 14.
As shown in FIG. 3, the neck portion 16 of the holder portion 14 is bent in a somewhat perpendicular direction with respect to the main portion 22 of the carrier strip assembly and also perpendicular to the bottom portion 20 of the holder 14. Consequently, the bottom portion 20 of the carrier holder 14 is slightly raised above and parallel to the main portion 22 of the carrier strip.
In FIG. 4 the U-shaped or cup-shaped receptacle of the holder 14 is shown for receipt of the round lead wire 24. Reference is made to FIG. 5 showing the placement of lead wires 24 within the holder members 14. The flange members 18 of each holder 14 are crimped and pressed around the lead wires 24 to securely hold them in a precise location with respect to each other in a transverse orientation with respect to the carrier band or strip 10. The lead wires 24 have a round or circular cross-section. As the carrier strip 10 moves through the assembly process, the lead wires 24 are carried thereon with each lead wire 24 slightly raised above the main portion 22 of the carrier strip 10 as shown in FIG. 6.
The free ends 26 of the lead wires are inserted into a die form press to flatten the end of the wire as shown in FIG. 7 so that the flattened portion 28 is aligned with the longitudinal centerline 30 of the lead wire 24. The die is shaped so that the ends 26 of the wires are formed in the offset shape 31 as shown in FIG. 8 with one side of the flattened portion extending laterally further beyond the longitudinal centerline 30 of the lead wire than the other side of the centerline of the lead wire. This offset flattened portion 31 is placed in alternating sequence with respect to each adjacent wire as shown in FIG. 8. The next step which is accomplished within the same die forming process is to cut slits 32 into the flattened offset portion 31 of the ends of the lead wires. The cut ends of the lead wires are then formed to establish the clamp arrangement 34 shown in FIG. 9 with one or more bottom prongs or fingers 36 and one or more top prongs 38. Although a trifurcated clamp is shown in the Figures, it is envisioned that a two-prong or more than three-prong type of clamp could be utilized if desired.
When the clamps 34 are formed on the ends 26 of the lead wires, the carrier strip assembly 40 in FIG. 8 is completed and is ready for receipt of electrical component substrates. The carrier strip assembly 40 then moves the lead wires with their integrally formed trifurcated clamp ends 34 in FIG. 10 to a position adjacent electrical component substrate 42 which have contact pads 44 for interface with the clamp ends 34 of the lead wires in the carrier assembly 40. To insure the proper alignment between the clamps 34 and the contact pads 44, retractable combs or guide fingers are used to precisely position the lead wires to provide the necessary alignment with each respective contact pad 44. The round configuration of the lead wires enhances the guide combs' ability to precisely align each lead wire clamp. The use of guide combs to align the lead wires eliminates the need for tie bars on the lead wires.
The clamp 34 in FIG. 11 is designed in such a manner that when it is attached to the substrate 42, the centerline 30 of the wire is in alignment with the centerline 48 of the edge thickness 50 of the substrate 42. This is important with respect to the formation of the clamp 34, because the fingers or prongs 36 and 38 of the clamp must be formed in such a manner that they are equally spaced from the centerline 30 of the wire. This, therefore, provides the on-center alignment between the wire 24 and the edge 50 of the substrate in the electrical component.
As previously discussed, the offset die formed shape 31 of the lead wire end 26 which forms the clamp 34 is offset laterally from the lead wire centerline 30. The direction of the offset is alternated between successive lead wires 24 as shown in FIG. 8. The utilization of this offset arrangement with any given lead spacing and using an even number of leads minimizes the substrate length required. In other words, a component could be made so that the length of its substrate does not exceed the span between its first and last lead wire. The ultimate advantage of this arrangement is that the number of components that can be mounted in a board is maximized.
The electrical component substrates 42 are then moved by the carrier strip assembly 40 through the remaining processes in completing the construction of the electrical component. As shown in FIG. 10, both ends of each lead wire 24 have the trifurcated clamps 34, so that an electronic component 42 is carried on each end of the lead wires.
As shown in FIGS. 12 and 13, the entire electrical component substrate package is preferably encapsulated with an insulating layer or cover 46 which encloses the interface between the substrate 42 and the clamp ends 34 of the lead wires. The elimination of the need for tie bars on the round lead wires enhances the molding process of encapsulating the substrate package. In the case of rectangular cross-sectional lead wires having tie bars any precision alignment of the individual lead wires with the openings in the mold is not possible. Consequently, is some instances the movement of the mold onto the substrate may pinch or damage a nonaligned lead wire. However, the use of round lead wires with no tie bars permits the use of additional aligning means for the individual lead wires prior to positioning of the mold around the substrate. The wires can be properly aligned and will not be damaged by the mold.
In some instances the substrate may be simply coated or dipped as opposed to complete molded encapsulation. After additional processing and curing of the package, the lead wires are severed at the desired length and the main portion 22 of the carrier strip is removed, leaving the lead pins extending from the electrical component package. These lead pins are then utilized to provide connection between the electrical component package and its insertion or connection to some other electrical subassembly or board.
|
A carrier strip assembly of continuous length having transversely mounted round lead wires with an integrally formed resilient clamp on each end of each lead wire for connection with an electrical component substrate. The carrier strip provides the transporting means for the attached electrical component substrate for the assembly stages of the electrical component. The lead wires are severed from the carrier strip portion to provide outwardly extending round lead pins or external connects for interface with an electrical circuit assembly. The method for making the carrier strip assembly is disclosed.
| 8
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Applicant hereby claims foreign priority benefits under U.S.C. § 119 from German Patent Application No. DE 10 2006 019 804.2 filed on Apr. 28, 2006, the contents of which are incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The invention concerns a hydraulic steering with a steering motor arrangement, a steering valve arrangement and a pressure supply comprising a first pump and a second pump.
BACKGROUND OF THE INVENTION
[0003] Such a hydraulic steering is known from, for example, DE 101 59 297 A1. Each pump supplies its own steering valve, and each steering valve is connected to a steering motor. This provides two steering circuits. If an error occurs in one of the steering circuits, this steering circuit is deactivated and the other steering circuit is activated. For this purpose, it is necessary to change over a valve in each steering circuit. An exactly simultaneous change-over, however, involves unjustifiably large efforts, so that the driver of a vehicle having such a steering will feel the change-over and in some cases be bothered by it.
[0004] The hydraulic steering of the present invention is also called “steer-by-wire”. Usually, in this connection, a mechanical, active connection no longer exists between a steering member, for example a steering handwheel, and the steering motor that eventually deflects the wheels. Accordingly, a high degree of safety must be available, and it is endeavoured to provide this safety by means of two or more pumps.
SUMMARY OF THE INVENTION
[0005] The invention is based on the task of making a change-over of the supply from the pumps as unperceived as possible.
[0006] With a hydraulic steering as mentioned in the introduction, this task is solved in that the steering valve arrangement is connected to the first pump through a valve with pressure compensation function and to the second pump through a compensation valve.
[0007] Thus, the steering of the vehicle still takes place via the steering valve arrangement, which is supplied by one of the two pumps. If the first pump is used, the valve between the first pump and the steering valve arrangement has a pressure compensation function, that is, the valve ensures that the pressure drop across the steering valve arrangement remains the same. Among other things, this has the effect that the flow of the hydraulic fluid supplied to the steering motor arrangement now only depends on the position of the steering valve arrangement. Thus, the pressure of the first pump is not important, as long as the pressure supplied by the first pump is sufficiently high. As also the second pump supplies the steering valve arrangement through a compensation valve, a failure of the first pump will not make the second pump control the pressure drop across the steering valve arrangement directly, but through the compensation valve. When the pressure compensation function of the valve is set in accordance with the pressure set by the compensation valve, a change-over between the first pump and the second pump will occur automatically in such a manner that the driver will practically not feel such a change-over.
[0008] Preferably, the valve is made as a priority valve. The valve is then able to perform an additional function. It can namely supply a working hydraulic, when the steering does not consume the whole amount of hydraulic fluid supplied by the first pump. Such an embodiment is particularly advantageous in trucks and self-propelled vehicles.
[0009] Preferably, the valve is acted upon in the closing direction by the pressure at its outlet and in the opening direction by the force of a first spring and a load-sensing pressure ruling at the outlet of the steering valve arrangement, and the compensation valve is acted upon in the closing direction by the pressure at its outlet and in the opening direction by the force of a second spring and the load-sensing pressure, the first spring producing a larger force than the second spring. In this case, it can be ensured that, also when both pumps are active, that is, are supplying a sufficient pressure to the steering valve arrangement, the supply of the steering valve arrangement takes place via the first pump. The first pump is preferably driven by a combustion engine, in particular the vehicle engine, which also ensures the advance of the vehicle. Under the conditions stated, the compensation valve remains closed as long as the first pump can supply a sufficient amount of hydraulic fluid under the required pressure. When, however, for some reason the first pump cannot supply the sufficient flow, the second pump can contribute via the compensation valve. This also applies, when the first pump still works and, in a manner of speaking, the second pump only covers the deficiency of the first pump.
[0010] Preferably, the compensation valve ends between a first non-return valve opening in the direction of the steering valve arrangement and the steering valve arrangement in a pipe between the valve and the steering valve arrangement. This ensures in a simple manner that during the supply of the steering valve arrangement the total amount of hydraulic fluid supplied by the second pump can only reach the steering valve arrangement and does not flow through the valve to the first pump. This also prevents errors, which could, for example, occur in the valve.
[0011] Preferably, the compensation valve is connected to the first pump via a second non-return valve opening in the direction of the compensation valve. The second non-return valve is connected to the inlet of the compensation valve, which is also connected to the second pump. In this way, it is possible to supply the compensation valve also via the compensation valve, so that malfunctions of the valve can be overcome.
[0012] Preferably, the second pump has an electrical drive, the outlet of the second pump being connected to a hydraulic accumulator, the electrical drive being controlled in dependence of the pressure in said tank. Thus, it is possible always to maintain the required pressure at the outlet of the second pump, also when the second pump does not work permanently. This gives a particularly economical and energy-saving operation. Here, another advantage of the second non-return valve occurs. As long as the steering does not consume the total amount of hydraulic fluid from the first pump, the second non-return valve can also lead this fluid to the hydraulic accumulator, which is connected to the inlet of the compensation valve. As long as the pressure in the hydraulic accumulator can be generated by the first pump, the second pump does not have to be activated.
[0013] Preferably, the steering valve arrangement comprises one single steering valve. The steering valve is usually so reliable that here no malfunctions must be anticipated. Accordingly, the required reliability of the complete steering can also be ensured, when only one single steering valve is available. In most cases also one single steering motor will be sufficient.
[0014] In an alternative embodiment, it is ensured that the steering valve arrangement comprises a primary steering valve and a secondary steering valve, the compensation valve being located between the second pump and the secondary steering valve. When the steering motor arrangement is then controlled via the second steering valve, also the second steering valve will be supplied with the accordingly compensated pressure, the compensation valve ensuring that the pressure drop across the secondary steering valve remains constant. Also in this case the pressure conditions can be set so that the driver will practically not feel a transition from the first pump to the second pump.
[0015] Preferably, a stop valve arrangement is provided that interrupts a connection between the first pump and the primary steering valve and releases a connection between the secondary steering valve and the steering motor arrangement in case of a fault. Changing over the stop valve arrangement is a simple way of realising the transition from the primary steering valve to the secondary steering valve or vice versa.
[0016] Preferably, the primary steering valve has a first load-sensing circuit acting upon the valve, and the secondary steering valve has a second load-sensing circuit acting upon the compensation valve. In this case, it can be avoided that a fault in a load-sensing circuit is copied to the elements not connected to this load-sensing circuit. On the contrary, both load-sensing circuits work independently of each other and can accordingly control the valve or the compensation valve, respectively, in the desired way.
[0017] Preferably, the outlet of the secondary steering valve is connected via a pipe to the inlet of the primary steering valve, a stop valve being located in said inlet. In many cases, it is not necessary to use the secondary steering valve for steering. This particularly applies, when the first pump does not supply sufficient hydraulic fluid, and the second pump has to take over the pressure supply, the primary steering valve yet still working satisfactorily. The secondary steering valve then practically only assumes the function of leading the hydraulic fluid from the second pump through the stop valve to the primary steering valve. Also here the compensation valve is then active, so that the pressure drop across the primary steering valve can be kept constant.
[0018] Alternatively, it may be provided that the outlet of the compensation valve is connected via a pipe to the inlet of the primary steering valve, the stop valve being located in said pipe. In this case the secondary steering valve can only be used for steering. When the primary steering valve is still functional and merely the pressure supply switches from the first pump to the second pump, the secondary steering valve does not have to be activated.
[0019] It is also advantageous, when the stop valve arrangement comprises a part, which is located between the valve and the primary steering valve. This particularly applies, when the valve is a priority valve. In this case, the part of the stop valve no longer has to be dimensioned for adopting the total amount of hydraulic fluid consumed by the working hydraulics that are connected to the priority valve. On the contrary, the part of the stop valve arrangement only has to handle the share of the hydraulic fluid used for the steering.
[0020] Preferably, the stop valve arrangement has several valve functions, which are combined in one single change-over valve. Thus, the change between the primary steering valve and the secondary steering valve can be realised by changing over the change-over valve. It is no longer required to activate several valves at the same time.
[0021] Preferably, the change-over valve is made as a slide valve. This is a relatively simple solution, as merely a displacement of the slide is required to open or close the individual paths leading to the primary steering valve or the secondary steering valve, respectively.
[0022] Preferably, the steering valve arrangement, the valve, the compensation valve and, in some cases, the stop valve arrangement are combined in one unit. This simplifies the manufacturing. The unit can be pre-assembled and fitted in a vehicle as a complete unit. The combination reduces the space required.
[0023] It is preferred that the unit is integrated in or flanged onto the steering motor arrangement. Thus, the pipe paths between the unit and the steering motor arrangement can be kept small. An additional space requirement does practically not occur.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] In the following the invention is described on the basis of preferred embodiments in connection with the drawings, showing:
[0025] FIG. 1 a first embodiment of a hydraulic steering in a schematic view,
[0026] FIG. 2 a second embodiment of the hydraulic steering,
[0027] FIG. 3 a third embodiment of the hydraulic steering.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] A hydraulic steering 1 shown in a schematic view in FIG. 1 comprises a steering motor arrangement 2 with a steering motor 3 . The steering motor 3 is connected to a steering valve arrangement 4 , in the embodiment shown having one single steering valve 5 . The steering valve 5 is made as a slide valve.
[0029] The steering valve 5 is supplied with pressurised hydraulic fluid by a first pump 6 . The first pump 6 is driven by a combustion engine, which also drives the vehicle provided with the steering 1 . The first pump 6 is connected to a valve 8 , here in the form of a priority valve. The valve 8 has a slide 9 , which is acted upon in the opening direction by a spring 10 . The opening direction is the direction, in which a passage between an inlet 11 of the valve and an outlet 12 of the valve 8 connected to the steering valve is further opened.
[0030] In the opposite direction, that is, in the closing direction, the slide 9 is acted upon by the pressure at the outlet 12 of the valve 8 . The valve 8 has a second outlet 13 connected to merely schematically shown working hydraulics 14 .
[0031] In the opening direction the slide 9 is also acted upon by the pressure in the one of the working pipes A, B, which is supplied with pressurised hydraulic fluid via the steering valve 5 . For this purpose, two load-sensing pipes 15 , 16 are connected to the outlet of the steering valve 5 . Both load-sensing pipes 15 , 16 are connected to a two-way valve 17 . A control pipe 18 extends from the two-way valve 17 to the slide 9 of the valve 8 .
[0032] Due to this embodiment the valve 8 has two tasks. Firstly, as mentioned, it serves as a priority valve, which gives the steering 1 a higher priority than the working hydraulics 14 with regard to the supply with pressurised hydraulic fluid. Secondly, the valve 8 has a pressure compensation function, that is, the pressure across the steering valve 5 is kept constant so that it corresponds to the force f sp1 of the spring 10 .
[0033] A second pump 19 is driven by an electric motor 20 . Via a non-return valve 21 it supplies a hydraulic accumulator 22 . A pressure control valve 23 ensures that the hydraulic accumulator 22 is not overloaded.
[0034] A control device, not shown in detail, turns on the motor 20 , when the pressure in the hydraulic accumulator 22 sinks below a predetermined value, and turns the electric motor 20 off, when the pressure in the hydraulic accumulator 22 exceeds a second predetermined value.
[0035] The first pump 6 is also connected to the hydraulic accumulator 22 via a non-return valve 24 . This makes it possible to fill the hydraulic accumulator 22 with pressurised hydraulic fluid, also when the second pump 19 is not working.
[0036] The hydraulic accumulator 22 is connected to an inlet 25 of a compensation valve 26 , whose outlet 27 is connected to the steering valve 5 . The outlet 27 of the compensation valve 26 ends in a section of the pipe 28 between a non-return valve 29 and the steering valve 5 , the non-return valve 29 being located in the pipe between the valve 8 and the steering valve 5 and opening in the direction of the steering valve 5 .
[0037] In the opening direction the compensation valve 26 is acted upon by the force f sp2 of a spring 30 and by the load-sensing pressure, that is, the outlet of the two-way valve 17 . In the closing direction the compensation valve 26 is acted upon by the pressure at its outlet 27 . Also here it applies that the opening direction of the compensation valve 26 is a direction, in which the compensation valve 26 assumes a smaller throttling resistance, whereas the closing direction is the direction, in which the throttling resistance at the compensation valve 26 increases.
[0038] The steering 1 now works as follows:
[0039] In the “normal” situation the first pump 6 will supply pressurised hydraulic fluid. This hydraulic fluid reaches the steering valve 5 through the valve 8 and the non-return valve 29 . From here it is led to the steering motor 3 in dependence of the desired steering direction. As long as no hydraulic fluid is used, it can be led to the working hydraulics 14 , when the slide 9 of the valve 8 is displaced to the left by the pressure at the outlet 12 of the valve 8 against the force of the spring 10 and the pressure at the outlet of the two-way valve 17 .
[0040] With this switching the valve 8 also ensures that the pressure drop across the steering valve 5 is constant. In its function as a priority valve the valve 8 also has the function of a compensation valve.
[0041] The force f sp1 of the spring 10 is larger than the force f sp2 of the spring 30 .
[0042] The second motor 19 is only activated, when the pressure in the hydraulic accumulator 22 sinks below a predetermined value. The hydraulic accumulator 22 does not have to be excessively large. It is sufficient, when it contains a volume that can ensure an emergency steering for a few seconds. Usually, for this purpose a volume of a few litres, for example two litres, will be sufficient.
[0043] As the force f sp1 of the spring 10 is larger than the force f p2 of the spring 30 , the compensation valve 26 will remain closed, as long as the first pump 6 supplies sufficient pressurised hydraulic fluid.
[0044] If the first pump 6 fails, the priority valve 8 is displaced to the shown position, so that the connected working hydraulics 14 is cut off from the supply. At the same time, the vehicle can still be steered by the steering valve 5 , as this steering valve 5 now receives hydraulic fluid from the second pump 19 via the compensation valve 26 , which also ensures that the pressure across the steering valve 5 remains constant. As the compensation valve 26 is supplied by the same load-sensing pressure from the control pipe 18 , the transition of the supply from the first pump 6 to the second pump 19 takes place automatically and is practically not noticed by the driver.
[0045] In the steering 1 according to FIG. 1 it is assumed that the steering valve 5 works without faults. When, however, also considering a possible fault in the steering valve, an additional safety is desired, a steering 1 can be used, which is shown in FIG. 2 . Here the same elements have the same reference numbers as in FIG. 1 .
[0046] The steering valve arrangement now has two steering valves 5 a , 5 b , the steering valve 5 a being located in the same position as the steering valve 5 according to FIG. 1 . For an explanation of the function of the steering valve 5 a , reference is made to the explanation of the steering valve 5 according to FIG. 1 . The steering valve 5 a is also called “primary” to distinguish it from the secondary steering valve 5 b.
[0047] The secondary steering valve 5 b is connected to the hydraulic accumulator 22 via the compensation valve 26 and to the outlet of the motor 19 . Between the secondary steering valve 5 b and the steering motor 3 is located a stop valve arrangement 31 , interrupting, as shown, or releasing a pipe 33 between the secondary steering valve 5 b and the steering motor 3 by means of a part 32 , and releasing, as shown, or interrupting a pipe 35 between the primary steering valve 5 a and the pump 6 or a tank 36 , respectively, by means of another part 34 .
[0048] Changing over the two parts 32 , 34 of the stop valve arrangement 31 also permits changing over the supply from the first pump 6 to the second pump 19 .
[0049] However, such a change-over is only required in full, if also the primary steering valve 5 a is defective. When the primary steering valve 5 a still works satisfactorily, a failure of the first pump 6 will only require changing over the secondary steering valve 5 b so that the second pump 19 is connected to the stop valve arrangement 31 . Further to the two parts 32 , 34 , the stop valve arrangement 31 comprises a stop valve 37 , which connects the second pump 19 to the inlet of the primary steering valve 5 a , when the secondary steering valve 5 b has changed over. Also in this case, the compensation valve 26 is located between the second pump 19 and the primary steering valve 5 a.
[0050] The compensation valve 26 is controlled via its own load-sensing circuit 38 , which takes a load-sensing signal from the pipe 33 . In this way, it is possible to act upon the compensation valve 26 with the pressure ruling at the steering motor 3 without risking that the load-sensing pressure for the compensation valve 26 has been otherwise distorted, particularly by the control pipe 18 .
[0051] In the embodiment according to FIG. 2 the part 34 of the stop valve arrangement 31 has to be dimensioned so that it can also adopt or manage the amount of hydraulic fluid supplied to the working hydraulics 14 .
[0052] FIG. 3 shows a modified embodiment, in which this is no longer required. Here, the part 34 of the stop valve arrangement is located between the valve 8 and the primary steering valve 5 a . Otherwise, the same elements have the same reference numbers as in FIGS. 1 and 2 .
[0053] Also the part 32 of the stop valve arrangement is now provided in a different place, namely between the secondary steering valve 5 b and the steering motor 3 . Otherwise, however, the mode of operation is the same.
[0054] To avoid having to activate the secondary steering valve 5 b with a functional primary steering valve 5 a , but failure of the first pump 6 , the stop valve 37 is now located in a pipe, which branches off between the compensation valve 26 and the secondary steering valve 5 b and leads to the pipe 28 between the non-return valve 29 and the primary steering valve 5 a.
[0055] As shown also in FIG. 2 , the parts 32 , 34 of the stop valve arrangement can, in a manner of speaking, be realised in a valve, for example by means of one single valve slide.
[0056] All valves, in particular the steering valve 5 or the steering valves 5 a , 5 b , respectively, the valve 8 and the compensation valve 26 can be assembled in one common valve block. In the embodiments according to FIGS. 2 and 3 also the stop valve arrangement 31 and the stop valve 37 can be integrated in this valve block. Such a unit can then be integrated directly in the steering motor 3 or flanged onto it.
[0057] While the present invention has been illustrated and described with respect to a particular embodiment thereof, it should be appreciated by those of ordinary skill in the art that various modifications to this invention may be made without departing from the spirit and scope of the present invention.
|
The invention concerns a hydraulic steering with a steering motor arrangement, a steering valve arrangement and a pressure supply comprising a first pump and a second pump. It is endeavoured to perform a change between the supplies by the pumps as unperceived as possible. For this purpose, the steering valve arrangement ( 4 ) is connected to the first pump ( 6 ) through a valve ( 8 ) with pressure compensation function and to the second pump ( 19 ) through a compensation valve ( 26 ).
| 1
|
BACKGROUND OF THE INVENTION
The present invention relates generally to sealing systems for multiple pane windows and more specifically to sealing systems for dual pane windows utilized in movable side glass of automotive vehicles.
The desire of the automotive industry to enhance the aerodynamic efficiency of automobile bodies has resulted in a great deal of attention being given to the design of movable side window systems for automobiles. It has been found desirable to provide for positioning the outer surface of the side windows in their closed positions in substantially coplanar relationship with the adjacent outer surfaces of the vehicle body. While some success has been achieved in defining this coplanar relationship, generally referred to as "flushness," it has been recognized that the lower edge of vertically movable vehicle side windows tend to be more offset from the adjacent vehicle body surfaces than the other edges of the window at the point in which the window is raised upwardly out of the interior of the vehicle door.
One recent response to this perceived deficiency is to provide a dual pane assembly for the side windows of a vehicle which is guided in raising and lowering along a weld flange created in the assembly of inner and outer panels of the door. U.S. Pat. No. 4,744,173 and U.S. Pat. No. 4,744,174 to Mesnel et al. illustrate this assembly. The sealing system proposed for use with this assembly, however, does not provide as effective a seal as is considered desirable. The sealing system exemplified in the patents to Mesnel et al. provides a guide member carried on the joint flange of the door which engages outer peripheral edges of the window panes in lip seal fashion. If the motion of a dual pane side window of an automotive vehicle is not accomplished by direct engagement on the door panel joining flange, as indicated in the exemplary patents to Mesnel et al, such a sealing system would be considerably less effective than that contemplated there since the guiding of the central portion of the seal within the window panes may not effect sliding sealing engagement.
It is accordingly an object of the present invention to provide a sealing system for slidably movable dual pane side windows of automotive vehicles which provides improved extended sealing surfaces between the dual pane window and the automotive vehicle body.
It is another object of the present invention to provide such a sealing system which facilitates stable positioning of the movable dual pane side window within the vehicle body.
SUMMARY OF THE INVENTION
To accomplish these objects a sealing system is provided in which a seal member is carried on a flange formed on the periphery of the vehicle door window aperture and provides bulbous seal portions for engaging the peripheral edges of the window panes and lip seal portions for engaging non-peripheral surfaces of the panes.
The sealing system may be advantageously incorporated into an automotive vehicle door in a manner in which the inner of the two window panes is carried in a secure relationship within a U-channel formed in the door.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and features of the invention will become apparent to those skilled in the automotive body sealing arts upon reading the following description with reference to the accompanying drawings in which like numbers refer to like parts throughout the several view and in which:
FIG. 1 is a perspective view of a automotive vehicle door having a dual pane movable side window;
FIG. 2a is a cross-sectional view taken along line 2--2 of FIG. 1 showing the sealing system of the present invention as installed with the vehicle door;
FIG. 2b is a view similar to FIG. 2 of an alternative embodiment of the sealing system of FIG. 2a; and
FIG. 2c is likewise a view similar to FIG. 2 showing another alternative embodiment of the sealing system of FIG. 2a.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The sealing system of the present invention is illustrated in the three preferred embodiments shown in the accompanying drawings. Each of the embodiments of FIGS. 2a, 2b and 2c are suited for use with a vertically movable dual pane window assembly, indicated generally at 10 in FIG. 1, operatively carried in an automotive vehicle door 12. As is customary, the window 10 is vertically movable between the upward closed position shown to a downward open position in which all or substantially all of the window 10 is concealed within the door 12. Mechanisms for effecting and controlling such movement are well known in the automotive body arts and no specific description of them is deemed necessary. For the purposes of this invention, it should be understood that the door 12 is a hollow structure formed by the joining of shaped inner and outer panels pierced by a window aperture, indicated at 14, to be closed by the window 10. In the door 12, as illustrated in FIG. 1, the lower edge 16 of the aperture 14 is open to receive the vertically movable window 10 and rear, top and side edges 18, 20, 22, respectively are preferably constructed according to FIGS. 2a, 2b or 2c to form the sealing system of the present invention to create a reliable and effective fluid seal between the window 10 and the adjacent body panels forming the door 12.
Turning now to FIG. 2a, one preferred embodiment of the sealing system of the present invention is illustrated generally at 24 as comprising a seal member 26 engaged between the window 10 and the door 12. The seal 26 is configured to efficiently and effectively cooperate with the window 10 and the door 12 when these components are constructed as shown in the drawings. The window 10 may be of the type disclosed in the above-mentioned patents to Mesnel et al. but necessarily comprises inner and outer panes 28, 30, respectively, which are held in fixed substantially parallel relationship by a spacer as indicated at 32. The spacer 32 may be adhesively secured between the panes 28, 30 or purely mechanical fastening and spacing means may be employed. The panes 28, 30 may be fabricated from any transparent or translucent material, such as glass or many of the plastics, and the two panes 28, 30 need not be of the same material. Furthermore, it will become apparent as the description progresses that the sealing system of the present invention may be employed with other types of closure panels, even opaque closure panels, which have the geometric configuration of the window 10 and that the description of the use of the sealing system of the present invention with the glass window pane is not intended to be limiting in any way Where the panes 28, 30 are formed of transparent material, the spacer 32 may be concealed by an opaque covering such as indicated at 34, generally extending peripherally about the window 10. The spacer 32 may likewise be a continuous member running peripherally about the rear, top and front edges 18, 20, 22, respectively, of the window aperture 14 spaced, inwardly from the outer peripheral edges 36, 38 of the inner and outer panes 28, 30, respectively, to define a channel 40 between the panes 28, 30.
The door 12 is illustrated as being constructed in conventional fashion of inner and outer panels 42, 44, respectively, which are joined together at their outer surfaces by a hem flange 45 and also by a internal pinch weld flange 46 which projects inwardly into the window aperture 14 and extends peripherally therearound along the rear top and front edges 18, 20, 22, respectively. The window 10 is positioned so that the pinch weld flange 46 is received within the channel 40 and the outer non-peripheral surface 48 of the outer pane 30 may be arranged in substantially coplanar fashion with outer surfaces, such as that indicated at 50 of outer panel 44. This effects the desirable flush appearance for the exterior of an automotive vehicle door 12; and the seal 26 is configured to be sealingly engaged between the window 10 and the door 12 in a manner consistent with a desire for flushness without the need to effect sealing contact with the window 10 on the outer surface 48 of outer pane 30.
The seal 26 is peripherally formed as an integral member of suitably flexible seal material, such as a natural or synthetic elastomer, and may be fabricated by coextrusion with a metallic stiffener, such as indicated at 52. The seal 26 essentially includes a mounting portion 54 having a slit or opening 56 for receiving the pinch weld flange 46. An outer bulb portion 58 extends from the mounting portion 54 and includes a cavity 60 running coextensive with the strip for increasing the compliance of the bulb portion 58 for effecting compressive sealing engagement with the outer peripheral edges 38 of the outer pane 30. A similarly configured inner bulb portion 62, having a cavity 64 is arranged on the other side of the mounting portion 54. An inner rib 66 is arranged in substantially parallel fashion with the mounting portion 54 to define a U-channel 68 for receiving the inner pane 28. A lip seal portion 70 extends from the free end 72 of the inner leg 66 to sealingly engage the outer surface 74 of the inner pane 28, and a similar lip seal portion 76 extends from the free end of the mounting portion 44 to sealingly engage the outer non-peripheral surface 78 of the inner pane 28. Thus, according to the embodiment shown in FIG. 2a for the sealing system of the present invention, in the closed position of the window 10, sealing engagement with the outer peripheral edges 36, 38 of the inner and outer panes 28, 30, respectively, is effected by the inner and outer bulb portions 62, 58, respectively, of the seal 26 while further sealing contact is made on the inner and outer non-peripheral surfaces 74, 78 of the inner pane 28 by lip seal portion 70, 76, respectively
Turning next to FIG. 2b, an alternative embodiment indicated generally at 24bof the sealing system of the present invention is illustrated in which the pinch weld flange 46b is positioned inwardly with respect to the window 10. In this embodiment, the seal member 26b comprises a mounting portion 54breceiving the pinch weld flange 46b and forming an outer leg of a U-channel, which includes a bulb portion 62b and whose other leg comprises a sealing rib 80. An outer bulb portion 58b cooperates with the outer pane 30 essentially identically as the outer bulb portion 58 of FIG. 2a, as does the inner bulb portion 62b with respect to the inner bulb pane 28. Lip seal portions 70b and 76b, likewise duplicate the functions of their numerical counterparts with respect to the inner pane 28. A third lip seal member 82, however, is extended from the sealing rib 80 to sealingly engage the inner non-peripheral surface 84 of the outer pane 30.
Turning lastly to FIG. 2c, another alternative embodiment indicated generally at 24c of the seal assembly of the present invention is illustrated in which a door 12c is formed of known three-piece construction in which a structural U-channel 86 is weldably secured between inner and outer panels 42c, 44c, respectively The seal member 26c cooperates with this modified door construction to provide a second mounting portion 88 which receives an inner pinch weld flange 90 while an inner mounting portion 92 is provided for receiving the inner pinch weld flange 94. The inner and outer mounting portions 88, 92 are joined by an inner bulb portion 62c for compressively sealingly engaging the outer peripheral edge 36 of the inner pane 28 and lip seal portions 70c, 76c extend from the mounting portions 88, 92, respectively, to sealingly engage the non-peripheral surfaces 74, 78 of the inner pane 28. Another lip seal portion 82c projects from the outer mounting portion 92 to sealingly engage the inner non-peripheral face 84 of the outer pane 30, and an outer bulb portion 58c is compressively sealingly engaged by the peripheral edge 38 of the outer pane 30. In addition to the efficient provision of the multiple sealing surfaces described in this third alternative embodiment, the positioning of the inner pane 28 between the sides of the U-channel 86 of the door 12c provides the additional advantage of structurally reinforcing the window 10 against lateral movement.
While only certain embodiments of the sealing system of the present invention have been described, others may be possible without departing from the scope of the appended claims.
|
A window sealing system for double plane movable automotive windows includes a seal having bulbous portions for compressively engaging peripheral edges of each glass pane sealing lips for engaging non-peripheral surfaces of the panes
| 1
|
BACKGROUND OF THE INVENTION
The invention relates to an apparatus for the reactive coating of a substrate with an electrically insulating material, for example silicon dioxide (SiO 2 ). It comprises an A.C. power supply which is connected to an electrode disposed in an evacuable coating chamber which in turn is electrically connected to targets to be sputtered. The sputtered particles thereof are deposited on the substrate while a process gas and a reactive gas are supplied to the coating chamber.
The problem in known processes for coating substrates by means of cathode sputtering using materials with a high affinity for the reactive gas is that aside from the substrate, parts of the apparatus like the inside wall of the process chamber or parts of diaphragms or the target surface are coated with materials that are not electrically conductive or only poorly conductive. This frequently entails an alteration of the process parameters and, particularly, electrical arcings which cause not only a frequent interruption of the process but also require a frequent cleaning or replacing of parts of the apparatus.
A sputtering apparatus (U.S. Pat. No. 3,860,507) is known which operates on radio frequency, preferably at 13.56 MHz, where two diametrically opposed targets are provided in the process chamber. These targets are connected to the two outputs of the secondary coil of an A.C. transformer via electrodes. The secondary coil has a central tapping which is electrically connected to the wall of the process chamber in such a manner that a glow discharge forms between the two targets.
Further, an apparatus is known (DE-OS 38 02 852) for coating a substrate with a material obtained from a plasma where the substrate is located between a first and a second electrode. The first electrode is connected to the first terminal of an A.C. power supply, and the second electrode to the second terminal of the A.C. power supply. In this case, the source of the alternating current is configured as a stray field transformer to which power is supplied from a shielded arc welding unit or a similarly controlled A.C. power supply. Moreover, the two electrodes can optionally be connected to a D.C. power supply.
Finally, a sputtering apparatus is known (DD 252 205 A1) which comprises a magnet system and at least two electrodes disposed thereabove which are made of the material to be sputtered and switched such that they alternatingly function as cathode and anode of a gas discharge. The electrodes are connected to a sinusoidal alternating voltage of preferably 50 Hz. Each electrode is associated with an independent magnet system where one pole of the one magnet system is also the pole of an adjacent magnet system. The electrodes are disposed in one plane.
SUMMARY OF THE INVENTION
It an object of the present invention to create an apparatus for sputtering materials with a high affinity for a reactive gas which allows a uniform and stable process and, further, operates trouble-free and, particularly, free of arcings even during extended periods of use while depositing insulating layers like SiO 2 , Al 2 O 3 , NiSi 2 -oxide, ZrO 2 , TiO 2 , ZnO, SnO 2 , Si 3 N 4 , for example. These layers are to exhibit a particular strong adhesion to the substrate.
This object is accomplished in accordance with the invention by means of electrodes which are electrically separated and also separated from the sputtering chamber but are still adjacent to each other. They are configured as magnetron cathodes where the cathode bases and the material of the target are electrically connected to the ungrounded outputs of an A.C. power source. For this purpose, the power supply has an output with two terminals which, for example, are the two ends of a transformer secondary coil.
BRIEF DESCRIPTION OF THE DRAWING
The sole FIGURE is a cross section through a sputtering apparatus with two magnetron sputtering cathodes.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The drawing shows the substrates 1, 1', 1" each of which is to be coated with a thin layer 2, 2', 2" of oxide (e.g. silicon dioxide or aluminum oxide). The targets 3, 3a to be sputtered are located opposite theses substrates 1, 1', 1" at like distanced A 1 , A 2 . Each target 3, 3ais connected to a cathode base 11, 11a accommodating a magnet yoke 11b, 11ceach having three magnets 19, 19a, 19b and 19c, 19d, 19e, respectively. Thetargets are made of Al, Si, Ti, Ta, Zn, Sn, Zr or compounds of these elements. The layers 2, 2', 2" are deposited by means of sputtering as Al 2 O 3 , AlN, SiO 2 , Si 3 N 4 , SiO x N y , TiO 2 , Ta 2 O 5 , SnO 2 , ZnO or ZrO 2 under the addition of oxygen or nitrogen, corresponding to the target material selected.
The polarities of the poles of the six magnets which are directed toward the target alternate so that the south poles of the two outer magnets 19, 19b and 19c, 19e together with the north poles of the respective inner magnet 10a 19a and 19d form approximate circular arc-like magnetic fields across the targets 3, 3a. These magnetic fields condense the plasma in front of the target so that it reaches its highest density where the magnetic field have the maxima of their circular arcs. The ions in the plasma are accelerated by the electric fields generated by an alternating voltage supplied by power supply 10. The adjacent magnetron cathodes 5, 5aassociated with respective targets 3, 3a enclose an angle of 110° to180° (shown as 180° in the FIGURE).
This power supply 10 has two terminals 12, 13 formed by the two ends of a transformer secondary coil 25 and connected to the two cathodes 5 and 5a. The two current conductors 8, 9 of the transformer secondary coil 25 are connected to respective targets 3, 3a.
Moreover, target 3, via a line 14, is connected to a grounded device 20 forthe sensing of effective voltage values. Line 21 connects this device 20 toa control 16 which in turn, via line 17, is connected to a control valve orflow regulator 18 regulating the flow of reactive gas such as oxygen or nitrogen contained in cylinder 22 to the distributing line 24 vacuum chamber 15, 15a. The flow of reactive gas is regulated by control 16 so that the measured voltage is identical to a desired voltage. Line 30 connects the control 16 to a flow regulator 28 which regulates the flow ofprocess gas such as argon contained in cylinder 23 to the distributing line24. The cathodes 3, 3a may also be provided with respective independent distributing lines 24, 24a, with an additional control line 17a and an additional flow regulator 18a.
Coating chamber 15, 15a has an annular or frame-like shielding plate or diaphragm 4 which is provided with a gap or slot 6 through which the process gas from distributing line 24, in direction of the arrow, can flowinto the coating chamber 15. The lower edge of diaphragm 4 is also surrounded by a cooling pipe 7 through which a coolant passes preventing an excessive heating of diaphragm 4.
During the sputtering, the frequency of the A.C. power supply 10 is selected such that the ions can still follow the alternating field. This is given at a frequency between approximately 1 KHz and 100 KHz. The device 20 for sensing the effective value of the voltage supplies, via line 21, supplies the discharge voltage tapped via line 14 as a direct voltage to control 16. Control 16 in turn, via line 17, actuates magnetic valve 18 to supply reactive gas in such a manner that the measured voltagedetermines the required amount of reactive gas.
|
A pair of magnetron cathodes in an evacuable coating chamber are each connected to an ungrounded output of an A.C. power supply. The discharge voltage of at least one of the cathodes is measured and the flow of reactive gas into the chamber is controlled so that the measured voltage is identical to a desired voltage.
| 2
|
BACKGROUND
Application Ser. No. 08/816,490 filed Mar. 13, 1997, now U.S. Pat. No. 5,707,280 as a continuation of Ser. No. 08/589,114 filed Jan. 19, 1996, now abandoned discloses crop inclusive poultry eviscerating method and apparatus in which the crop is loosened from its point of attachment to the neck cavity of the carcass before the crop is then removed from the carcass intact and still connected to the rest of the entrails when the entire bundle of entrails is withdrawn from the carcass. In carrying out this procedure, a hook-shaped dislodging tool enters a small access slit which has been prepared in the neck skin of the carcass. The tool captures the esophagus within the eyelet of its hook and then exerts a downward pulling force to pull the eyelet down around and past the crop, effectively disengaging the crop from the membranes that would otherwise hold it in place. Then, a removal tool enters the main body cavity from the opposite end of the carcass to capture the stomach and other organs within the interior loop of the tool. When the loop is withdrawn to extract the entrails, the loosened crop is pulled along with the other entrails by the unbroken esophagus that interconnects the stomach and the crop.
Accurately and precisely making the longitudinal access slit in the neck skin is very important. If the blade used in making the slit accidentally severs the esophagus, contaminants may be released into the meat and, moreover, the esophagus may be weakened to such an extent that it is unable to pull the crop from the neck area without breaking during the eviscerating step. Moreover, there is considerable bony structure within the neck itself and it is important that the knife blade avoids such structure as it pierces the skin and moves through its slitting stroke.
Pending application Ser. No. 08/792,928, filed Jan. 21, 1997 discloses a method and apparatus for preparing such an access slit in the neck skin. The fixture that holds the carcass during the slitting operation is provided with a neck fork that receives the neck to help locate the trunk of the carcass and the neck for the slitting stroke. However, the fork disclosed in this application is relatively wide, having arms that are spaced apart by a relatively large amount so that the neck is only loosely confined between the arms. Moreover, the wide spacing of the arms causes them to engage the carcass at the shoulder joints so that the contoured surfaces of the joints ride on the arms of the fork. Rather than securely centering the trunk of the carcass and the neck area, this tends to allow the carcass to move sideways as the shoulder joints roll on the fork arms, which permits the trunk and neck areas to move out of centered positions. The wide neck fork disclosed in the '928 application is also used on the cropper/eviscerator disclosed in the '490 application. It has been found that the wide neck fork in that machine sometimes allows the carcass to become off-center to such an extent that the hook of the crop dislodging tool has a difficult time snagging or picking up the esophagus at the point where it crosses the backbone of the carcass. Using only the neck through its engagement with the fork to center the lower end of the carcass has been found to allow the carcass to sometimes deviate from its centered position, which in turn makes it difficult for the dislodging hook to snag the esophagus.
One source of the problem in this respect is believed to come from the fact that the poultry carcasses are not consistently the same size. It has been found in particular that the dimensions at the base of the neck are subject to considerable variation between birds of different sizes. To accommodate such dimensional variances, the neck fork was made wide enough to receive the largest bird, but in the process that accommodation also built in room for error when smaller sized birds were being processed.
TECHNICAL FIELD
This invention relates to improvements in a holding fixture used in high-speed, automated poultry processing systems in which processing operations are performed on poultry carcasses while the carcasses are moving along a conveying line. More particularly, the invention relates to improved ways of centering, holding, and positioning the neck and shoulder area of a carcass on a processing fixture to facilitate operations such as cutting a longitudinal access slit in the skin of the neck and subsequently withdrawing all of the viscera, including the crop, from the carcass.
SUMMARY OF THE INVENTION
It has been found that, within the range of bird sizes typically being processed with this type of automated equipment, the distance between the shoulder joints of the birds tends to vary less than the distance across the base of the neck. Thus, the present invention achieves centering and secure holding of the lower trunk area of the carcass utilizing the shoulder joints of the carcass more than the neck of the carcass. In this respect, the present invention contemplates using a relatively narrow neck fork whose outer or outside width dimension is always less than the distance between the shoulder joints of the poultry carcasses to be processed such that the arms of the fork become disposed inside of the shoulder joints and bear outwardly against the joints when the carcass is in its final position on the fixture. This laterally outward pressure from the fork arms against the inside edges of the shoulder joints keeps the lower region of the trunk centered and stable, which in turn centers the neck for the slitting tool. Each arm of the fork is itself relatively narrow so as to fit snugly and securely into the space on each carcass between the base of the neck and the corresponding shoulder joint. During a slight lifting action by the neck fork against the carcass, the fork arms depress the muscle tissues between the neck and the shoulder joints so as to become firmly located with respect to the carcass.
The present invention also relates to the use of a special projection on the holding fixture at the base of the back of the neck that causes the backbone in that area to be presented somewhat more prominently to the dislodging hook inside the neck cavity during the eviscerating procedure. This permits the hook to scrape more positively against the backbone at the base of the neck so as to more assuredly snag the esophagus at the point where it crosses the backbone, thus increasing the chances that the crop will be adequately dislodged from the neck tissues as to permit removal during the viscera withdrawing stroke that follows. Preferably, the projection is a resilient projection to allow yieldable relief when carcasses of larger sizes are being processed, such birds having increased dimensions in the area of the base of the neck that would otherwise cause the dislodging hook to scrape against the backbone with excessive pressure. Having the projection resilient allows the scraping pressure to remain substantially constant, regardless of the dimensional variations that may be encountered between carcasses. Furthermore, in its preferred form, the projection is in the nature of a freely rotatable, toothed wheel in which each tooth is bendable and resilient.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary front elevational view of a poultry carcass holding fixture constructed in accordance with the principles of the present invention and forming a part of a piece of poultry processing equipment;
FIG. 2 is a fragmentary left side elevational view thereof;
FIG. 3 is a fragmentary vertical cross-sectional view thereof taken substantially along line 3--3 of FIG. 1;
FIG. 4 is a top plan view thereof;
FIG. 5 is a fragmentary front elevational view of the apparatus similar to FIG. 1 but showing a poultry carcass held in place on the fixture with the stabilizing arms clamped against the trunk of the carcass and the neck fork lifted up into its centering position;
FIG. 6 is a right side elevational view of the apparatus and carcass in the FIG. 5 condition;
FIG. 7 is a fragmentary front elevational view of the apparatus and carcass similar to FIG. 5 but having parts of the fork and carcass broken away to reveal the manner in which the narrow arms of the fork become pressed up into the space between the shoulder joints and the base of the neck;
FIG. 8 is a fragmentary front elevational view of a poultry holding fixture incorporating the narrow neck fork concepts of FIGS. 1-7 but also incorporating the resilient back pressing concepts of the present invention so that the fixture of FIG. 8 is especially adapted for use in a cropper/eviscerator of the type disclosed and claimed in the '490 application;
FIG. 9 is a left side elevational view thereof;
FIG. 10 is a top plan view thereof;
FIG. 11 is a fragmentary, vertical cross-sectional view of the fixture taken substantially along line 11--11 of FIG. 8; and
FIG. 12 is a fragmentary left side elevational view of the apparatus similar to FIG. 9 but illustrating the manner of use of the invention in which the lower trunk area of the carcass in the vicinity of the base of the neck is yieldably pushed outwardly by the resilient projection.
DETAILED DESCRIPTION
Slitter Locating Structure
The fixture 10 of FIGS. 1-7 is especially suited for use as part of the neck-slitting equipment disclosed and claimed in the '928 application referred to above. The '928 application is hereby incorporated by reference into the present application. Fixture 10 includes a block 12 and a pair of upright, tubular guides 14 and 16 that slidably support the block 12. A guide roller 18 projecting from the backside of the block 12 is received within a stationary cam track 20 on a fixed plate 22 of the processing machine to cause the block 12 to move up and down along the guides 14,16 as the fixture 10 moves relative to the plate 22 in a generally horizontal direction. It will be appreciated that the fixture 10 and the plate 22 form parts of a larger machine in which a series of the fixtures are continuously moving along a prescribed path of travel, such as a circle, to intersect with and engage a series of shackled poultry carcasses moving along an overhead conveying line.
The fixture 10 further includes a backrest 24 secured to the block 12 and projecting downwardly and slightly outwardly therefrom. The backrest 24 is in the nature of an elongated, generally rectangular in cross-section bar 26 that is fixed to the block 12 adjacent its upper end and is unsupported at its lower, outer end. The bar 26 has a flat smooth outer surface along its upper half and is provided with an elongated, longitudinally extending depression 28 along its lower half As illustrated in FIG. 6, the back and neck of the carcass are disposed to lie up against the backrest 24 during use, with the neck being positioned to fit into the depression 28 that is somewhat complementally shaped with respect to the neck.
The fixture 10 additionally includes a narrow neck fork 30 that is rigidly affixed to the backrest 24 at substantially the mid-point thereof and which projects downwardly and forwardly outwardly therefrom. The neck fork 30 includes a pair of left and right, laterally spaced apart arms 32 and 34 which define a mouth or receiving space 36 therebetween for the neck.
The arms 32 and 34 are mirror images of one another. Each includes a flat, straight inner section 36 closest to the backrest 24 that projects straight out from the backrest 24 as seen most clearly in FIG. 4. Adjacent the mid-point of each arm 32,34, the straight section 36 blends into an out turned, arcuate outer section 38 so that, when viewed in top plan as shown in FIG. 4, the fork 30 has a flared entrance to the receiving space 36 to facilitate ingress and egress of the neck of the carcass.
As seen from the cross-sectional illustration in FIG. 7, each of the arms 32,34 is relatively thin. Preferably, the thickness or width of each arm does not exceed six millimeters. Moreover, in the preferred embodiment, each arm 32,34 is generally semi-circular shaped, with the arcuate surface being disposed to the inside and the flat surface disposed to the outside.
Also in the preferred embodiment, the spacing between the inner sections 36 of the arms 32,34 is no less than twenty millimeters. The distance between the outside surfaces of the inner sections 36, i.e., the overall width of the fork 30 in the area where it receives the neck, is no greater than forty millimeters. A preferred dimension for the inside spacing of the arms is twenty-four millimeters, while the preferred dimension between the outside surfaces of the arms is thirty-six millimeters.
As illustrated in FIGS. 2 and 3 in particular, the fork 30 is angled somewhat downwardly and outwardly. To facilitate retention of the carcass up against the backrest 24 during use, each of the arms 32,34 is provided with a slight hump 40 on the upper edge of the arm at the approximate mid-point thereof. The hump 40 begins at the straight section 36 and finishes on the curve, outer section 38. As seen particularly in FIGS. 2 and 3, each of the arms 32,34 tapers to a rounded point 42 at the outermost end of its curved section 38.
The fixture 10 also includes stabilizing mechanism in the form of a pair of stabilizer arms 44 and 46. Such stabilizing mechanism preferably takes the form of that disclosed and claimed in U.S. Pat. No. 5,569,072 issued Oct. 29, 1996. The '072 patent is hereby incorporated by reference into the present specification for a full and complete understanding of the nature and operation of the stabilizer arms 44 and 46. Suffice it to point out that the arms 42,46 are pivotally carried by the block 12 for inward and outward swinging movement about pivots 48 and 50 under the control of a cam block 52 fixed to the upright guides 14 and 16. As the block 12 moves up and down on the guides 14,16, the cam block 52 causes the stabilizer arms 44,46 to operate.
When a carcass is placed on the fixture 10 as illustrated in FIGS. 5, 6 and 7, the trunk of the carcass becomes clamped between the stabilizer arms 44,46 while the neck is received within the neck fork 30. The block 12 moves upwardly along the guide rods 14,16 relative to the position illustrated in FIG. 1 which not only causes the stabilizer arms 44 to securely grip the carcass, but also causes the fork arms 32 and 34 to press up into the loose skin and tissue at the base of the neck, between the shoulder joints 54 and the neck 56 as illustrated in FIG. 7. See also FIGS. 5 and 6. With the fork arms 32,34 thusly positioned, the arms 32,34 tend to bear outwardly against the shoulder joints 54, precluding side-to-side shifting of the carcass.
The backrest 24, the neck fork 30, and the stabilizer arms 44,46 are all centered and symmetrical with respect to a center line 58 extending down the length of the fixture 10 as illustrated in FIG. 1. Consequently, when the carcass is held on the backrest 24 by the stabilizer arms 44,46 and the neck fork 30 as illustrated in FIGS. 5-7, the carcass is centered. This includes not only the main trunk portion of the carcass, but also the neck 56 such that, as illustrated in FIG. 5, a longitudinal slit 60 can be prepared in the neck skin slightly to one side of center by mechanism disclosed and claimed in the '928 application.
Cropper/Eviscerator Locating Structure
The fixture 110 of FIGS. 8-12 is especially suited for use in a cropper/eviscerator machine as disclosed and claimed in the '490 application. The fixture 110 is closely similar to the fixture 10, having the same mounting block 112, narrow neck fork 130, and stabilizer arms 144 and 146. However, unlike the backrest 24, the backrest 124 terminates at the neck fork 130 and does not have a lower neck-receiving portion. Moreover, the fixture 110 includes a special projection 162 at the lower end of the backrest 124 that helps to best position the lower trunk portion of the carcass for snagging of the esophagus by the dislodging tool during the evisceration process.
Unlike the backrest 24, the backrest 124 is vertically slotted at its lower end, presenting a slot 164. Preferably, the projection 162 is not only resilient but is in the form of a freely rotatable wheel. Thus, the slot 164 provides a means of attaching the projection wheel 162 to the backrest 124 via a pivot pin or spindle 166 for the wheel 162 that spans the slot 164. The wheel 162 is preferably constructed of a soft rubber material such as polyurethane having a durometer value of 32/38A. A series of bendable, resilient teeth 168 are spaced circumferentially about the periphery wheel 162 to serve as the portion of the wheel actually making physical contact with the back of the poultry carcass. As will be noted in FIGS. 9, 11 and 12, while most of the wheel 162 is housed within the slot 164, the front portion of the wheel 162 projects outwardly from and beyond the backrest 124 toward the carcass. The wheel 162 is located on the center line 158 of the fixture 110 as illustrated in FIG. 8.
In use, the fixture 110 functions substantially the same as fixture 10, except that the resilient projection 162 engages the back of the carcass at the base of the neck and pushes it out away from the backrest as illustrated in FIG. 12. The neck fork 130 settles into the soft tissue between the base of the neck and the shoulder joints of the carcass in the same manner illustrated in FIG. 7 with respect to fixture 10 such that the carcass is well-centered on the fixture 110 and well-secured in place. When the dislodging hook of cropper/eviscerator mechanism of the type illustrated in the '490 application enters the slit 60 (FIG. 5) of the poultry carcass, the esophagus in the area of the resilient wheel 162 will be presented prominently to the dislodging hook to increase the likelihood that the hook will snag the esophagus as intended. As the hook is dragged along the backbone at the base of the neck to snag the esophagus, the resiliency of the teeth 168 allows the carcass to be yieldably pushed in closer to the backrest 124 as may be needed to accommodate thicker back dimensions on larger birds. Thus, the pressure exerted by the hook against the backbone can be maintained essentially constant, regardless of the size of the birds being processed.
There are of course times when the eviscerating machine is operating without poultry carcasses being present. In those instances, the viscera withdrawing tool moves down to a point adjacent the lower end of the backrest 124, and then withdraws upwardly. By having the resilient projection 162 in the nature of a freely rotatable wheel, the removal tool can drag across the projection 162 without causing damage. Instead of being scraped by the tool, the wheel simply turns to the extent necessary to accommodate the moving tool.
Although preferred forms of the invention have been described above, it is to be recognized that such disclosure is by way of illustration only, and should not be utilized in a limiting sense in interpreting the scope of the present invention. Obvious modifications to the exemplary embodiments, as hereinabove set forth, could be readily made by those skilled in the art without departing from the spirit of the present invention.
The inventors hereby state their intent to rely on the Doctrine of Equivalents to determine and assess the reasonably fair scope of their invention as pertains to any apparatus not materially departing from but outside the literal scope of the invention as set out in the following claims.
|
The holding fixture has a narrow neck fork designed to fit entirely inside of and between the shoulder joints of the carcass so as to utilize the inside surfaces of the shoulder joints as a means of centering the carcass and precluding side-to-side movement thereof. Each arm of the fork is narrow enough to fit entirely between the neck and the corresponding shoulder joint. A modified fixture for use with a crop-inclusive eviscerator has a resilient projection on the backrest between the arms of the fork to yieldably push the backbone at the base of the neck out away from the backrest to facilitate snagging of the esophagus by a hook-shaped dislodging tool utilized as part of the eviscerator.
| 0
|
RELATED APPLICATIONS
The present application claims priority from Great Brittain Application Number 1414986.8, filed Aug. 22, 2014, the disclosure if which is hereby incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
The present invention concerns a landing gear assembly for an aircraft landing gear. More particularly, but not exclusively, the present invention concerns a landing gear assembly comprising a steering mechanism for steering at least one wheel of the landing gear and a deployment mechanism for moving a leg of the landing gear between a stowed position and a deployed position. The invention also concerns an aircraft landing gear, an aircraft and methods of operating an aircraft landing gear.
A typical prior art aircraft nose landing gear comprises a steering mechanism for steering at least one wheel of the landing gear and a deployment mechanism for moving a leg of the landing gear between a stowed position and a deployed position. Each of the mechanisms has an actuator associated with it to actuate the mechanism. The steering actuator actuates the steering mechanism to steer the at least one wheel. The deployment actuator actuates the deployment mechanism, including a foldable drag stay, to deploy or stow the landing gear. The deployment mechanism also typically comprises an uplock link for preventing the drag stay from folding when the landing gear leg is in the deployed position. The uplock link functions as a two-part linkage with an over-centre hinge, to lock it in place. There is also typically an uplock actuator that moves the uplock out of a locking position when the leg is to be moved to the stowed position. A typical prior art aircraft nose landing gear also comprises a centreing cam arrangement. This centreing cam arrangement ensures that a wheel of the landing gear is centred—i.e. orientated in a straight direction (in an orientation so that the aircraft would not be steered left or right, off its course—i.e. when the wheel is substantially parallel to the aircraft centre line) when in a “weight off wheel” situation. This means that when the landing gear is deployed and the aircraft then lands, the aircraft is not accidentally steered off course.
There is a desire to make landing gears as light as possible to reduce fuel burn, whilst still providing the required functionality and safety. The prior art landing gears may be considered to be heavier than desired.
The present invention seeks to mitigate the above-mentioned problems. Alternatively or additionally, the present invention seeks to provide an improved landing gear assembly for an aircraft landing gear.
SUMMARY OF THE INVENTION
The present invention provides, according to a first aspect, a landing gear assembly for an aircraft landing gear, the assembly comprising a steering mechanism for steering at least one wheel of the landing gear, a deployment mechanism for moving a leg of the landing gear between a stowed position and a deployed position, and an actuator arranged to actuate both the steering mechanism and the deployment mechanism.
The inventor has realised that the same actuator could be used for actuating both the steering mechanism and the deployment mechanism. In particular, it is noted that, when the aircraft is to be steered by the landing gear (when it is in a “weight on wheel” situation), the landing gear is always deployed, and when the landing gear is stowed, or being moved to be stowed, (when it is in a “weight off wheel” situation) the aircraft does not need to be steered by the landing gear. Having one actuator (and associated systems and pipework) instead of two, reduces the weight of the landing gear assembly, and thus decreases fuel burn of the aircraft. It also reduces the maintenance burden and reduces the drag and noise generated by the landing gear assembly, when the landing gear leg is deployed.
The present invention provides a landing gear assembly for an aircraft landing gear, the assembly comprising a steering mechanism for steering at least one wheel of the landing gear, a deployment mechanism for moving a leg of the landing gear between a stowed position and a deployed position, and a single actuator arranged to actuate both the steering mechanism and the deployment mechanism.
The landing gear assembly is preferably for an aircraft nose landing gear.
Preferably, the landing gear assembly further comprises a coupling mechanism for coupling the actuator to the steering mechanism and the deployment mechanism, wherein the coupling mechanism is arranged to couple the actuator to only one of the steering mechanism and the deployment mechanism at any one time. This ensures that the actuator can be coupled to only the appropriate mechanism in each appropriate situation.
The coupling mechanism is arranged to couple the actuator to each respective mechanism such that the respective mechanism is able to be actuated by the actuator. The coupling mechanism may do this by connecting the respective mechanism to the actuator. However, preferably, the coupling mechanism does this by preventing the other mechanism from being actuated by the actuator.
Preferably, the coupling mechanism is arranged to automatically couple the actuator to only one of the steering mechanism and the deployment mechanism at any one time. The automatic coupling is preferably achieved by mechanical action of the coupling mechanism.
Preferably, the landing gear assembly further comprises a coupling mechanism for coupling the actuator to the steering mechanism and the deployment mechanism, wherein the coupling mechanism is arranged to automatically couple (preferably by a mechanical action of the coupling mechanism) the actuator to only one of the steering mechanism and the deployment mechanism at any one time.
More preferably, the coupling mechanism is arranged to couple the actuator to the steering mechanism when the wheel is in a “weight on wheel” situation and to couple the actuator to the deployment mechanism when the wheel is in a “weight off wheel” situation. This ensures that the steering mechanism can be actuated when it is needed and the deployment mechanism can be actuated when it is needed.
More preferably, the coupling mechanism is arranged to automatically couple the actuator to the steering mechanism when the wheel is in a “weight on wheel” situation and to automatically couple the actuator to the deployment mechanism when the wheel is in a “weight off wheel” situation. The automatic coupling is preferably achieved by mechanical action of the coupling mechanism.
A “weight on wheel” situation is one in which the at least one wheel would be touching the ground and supporting at least a first amount of the weight of the aircraft. A “weight off wheel” situation is one in which the at least one wheel would be supporting less than the first amount of weight of the aircraft and the wheel is often not touching the ground. The first amount may be very small and may be zero or close to zero.
The automatic coupling of the coupling mechanism is preferably achieved by a mechanical action of the coupling mechanism as a result of a change between a “weight on wheel” and a “weight off wheel” situation.
Even more preferably, the coupling mechanism comprises a locking mechanism, comprising a locking element moveable between a steering locked position, in which the steering mechanism is prevented from steering the wheel, and a steering unlocked position, in which the steering mechanism is able to steer the wheel, wherein when the wheel is in a “weight on wheel” situation the locking element is (automatically) moved to the steering unlocked position and when the wheel is in a “weight off wheel” situation, the locking element is (automatically) moved to the steering locked position. This allows the “switch” between the mechanisms by the coupling mechanism to be provided by the locking mechanism.
Even more preferably, the locking element (automatically) moves from the steering locked position to the steering unlocked position under the action of the wheel being moved from a dropped position to a raised position relative to the locking element when the wheel changes from a “weight off wheel” to a “weight on wheel” situation and (automatically) moves from the steering unlocked position to the steering locked position under the action of the wheel being moved from the raised position to the dropped position relative to the locking element when the wheel changes from a “weight on wheel” to a “weight off wheel” situation. This allows the “switch” between the mechanisms by the coupling mechanism to be “automatic”, without user/pilot input being required.
The coupling mechanism may be arranged to convert linear motion of the actuator to rotational motion, in order to rotate a part of the steering mechanism.
Even more preferably, the coupling mechanism comprises a crank arm rotatable between first and second rotation positions by the actuator when the locking element is in the steering unlocked position, and prevented from rotating when the locking element is in the steering locked position. The crank arm being prevented from rotating provides that steering of the at least one wheel can be prevented.
Even more preferably, the crank arm is connected to the steering mechanism such that when the crank arm is in the first rotation position, the steering mechanism steers the wheel in a first direction and when the crank arm is in the second rotation position, the steering mechanism steers the wheel in a second different direction. This allows the rotation of the crank arm to enable steering of the at least one wheel.
Even more preferably, the crank arm is connected to the steering mechanism by a bevel gear arrangement such that rotational movement of the crank arm is converted to rotational movement of the steering mechanism.
Preferably, when in the steering locked position, the locking element acts on the bevel gear arrangement to prevent its rotation.
Additionally or alternatively, when in the steering locked position, the locking element acts on the steering mechanism to prevent its rotation.
The locking mechanism may comprise two or more locking elements; a first locking element may act on the bevel gear arrangement to prevent its rotation, and a second locking element may act on the steering mechanism to prevent its rotation.
Preferably, the locking element is part of a centring arrangement for centring the steering mechanism, such that the wheel is steered in a central direction (i.e. when the at least one wheel is centred—i.e. orientated in a straight direction (in an orientation so that the aircraft would not be steered left or right, off its course) when the wheel is in a “weight off wheel” situation. This means that when the landing gear is deployed and the aircraft then lands, the aircraft is not accidentally steered off course.
Preferably, the coupling mechanism comprises a lever arm connected at its first end to the actuator and moveable by the actuator between extended and retracted positions.
Even more preferably, the lever arm is rotatably connected at its second end to the crank arm such that when the lever arm is caused to extend and retract by the actuator, the crank arm is caused to rotate by the lever arm.
Even more preferably, when the crank arm is prevented from rotating by the locking element in the steering locked position, movement by the actuator of the lever arm between extended and retracted positions instead causes the landing gear leg to move between the deployed and stowed positions.
Preferably, the steering mechanism comprises a steering collar connected to the actuator and one or more torque links connected to the wheel.
Preferably, the deployment mechanism comprises a number of moveable links, including a lock link, connected between the actuator and the landing gear leg.
More preferably, the deployment mechanism further comprises a lock link actuator for moving the lock link.
According to a second aspect of the invention there is also provided an aircraft landing gear comprising the landing gear arrangement of the first aspect of the invention. The aircraft landing gear is preferably an aircraft nose landing gear.
According to a third aspect of the invention there is also provided an aircraft comprising the aircraft landing gear of the second aspect of the invention or the landing gear arrangement of the first aspect of the invention.
According to a fourth aspect of the invention there is also provided a method of operating an aircraft landing gear comprising the step of providing a landing gear arrangement, aircraft landing gear or aircraft of the first, second or third aspect of the invention.
According to a fifth aspect of the invention there is also provided a method of operating an aircraft landing gear comprising the steps of, in a first time period, placing a wheel of the landing gear on the ground such that the wheel is in a “weight on wheel” situation, thereby moving a steering locking element of the landing gear to a steering unlocked position (in which the steering mechanism is able to steer the wheel), and then using an actuator of the landing gear to steer the wheel, and, in a second time period, removing the wheel of the landing gear from the ground such that the wheel is in a “weight off wheel” situation, thereby moving the steering locking element to a steering locked position (in which the steering mechanism is prevented from steering the wheel), and then using the actuator to stow and/or deploy the landing gear.
According to a fifth aspect of the invention there is also provided a method of operating an aircraft landing gear comprising the steps of, in a first time period, placing a wheel of the landing gear on the ground such that the wheel is in a “weight on wheel” situation, thereby moving a steering locking element of the landing gear to a steering unlocked position (in which the steering mechanism is able to steer the wheel), and then using an actuator of the landing gear to steer the wheel, and, in a second time period, removing the wheel of the landing gear from the ground such that the wheel is in a “weight off wheel” situation, thereby moving the steering locking element to a steering locked position (in which the steering mechanism is prevented from steering the wheel), and then using the same actuator to stow and/or deploy the landing gear.
Preferably, the aircraft landing gear is an aircraft nose landing gear.
It will of course be appreciated that features described in relation to one aspect of the present invention may be incorporated into other aspects of the present invention. For example, the method of the invention may incorporate any of the features described with reference to the apparatus of the invention and vice versa.
DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will now be described by way of example only with reference to the accompanying schematic drawings of which:
FIG. 1 shows a side view of an aircraft nose landing gear according to a first embodiment of the invention, in a deployed “weight on wheel” situation;
FIG. 2 shows a side view of the aircraft nose landing gear, in a deployed “weight off wheel” situation;
FIG. 3 shows a side view of the aircraft nose landing gear being moved into a stowed position;
FIG. 4 a shows a side view of part of the aircraft nose landing gear in a deployed “weight on wheel” situation, whilst the wheel is being steered left;
FIG. 4 b shows a side view of part of the aircraft nose landing gear in a deployed “weight on wheel” situation, whilst the wheel is being steered centrally;
FIG. 4 c shows a side view of part of the aircraft nose landing gear in a deployed “weight on wheel” situation, whilst the wheel is being steered right;
FIG. 5 shows a perspective view of a centreing cam arrangement of the aircraft nose landing gear in a “weight on wheel” situation;
FIG. 6 a shows a side view of part of an aircraft nose landing gear according to a second embodiment of the invention in a “weight off wheel” situation;
FIG. 6 b shows a side view of part of the aircraft nose landing gear of FIG. 6 a in a “weight on wheel” situation; and
FIG. 7 shows a front view of an aircraft, including the aircraft nose landing gear of either the first or second embodiment.
DETAILED DESCRIPTION
FIG. 1 shows a side view of an aircraft nose landing gear 500 according to a first embodiment of the invention, in a deployed “weight on wheel” situation and FIG. 2 shows a side view of the aircraft nose landing gear 500 , in a deployed “weight off wheel” situation. The forwards direction 701 is shown. In addition, the ground surface 700 is also shown.
The landing gear 500 comprises a landing gear leg 501 , which is suspended from a fuselage 100 of an aircraft by a pivot point 506 .
In addition, an actuator 530 is also suspended from the fuselage 100 by a pivot point 531 behind the leg pivot point 506 . The actuator 530 itself will be explained in more detail in relation to FIGS. 4 a to 4 c . The actuator 530 is attached to the landing gear leg 501 , by a lever arm 532 (acting as an actuator rod), pivotally connected at pivot point 534 to a crank arm 533 . The crank arm 533 is pivotally connected to a bevel gear 515 located in the upper portion 505 of the landing gear leg 501 .
In the “weight on wheel” situation of FIG. 1 , the bevel gear 515 is located adjacent a steering disc 513 of a steering mechanism 510 . The steering disc 513 connected to a steering column 514 . The steering column 514 is rotatably housed in the landing gear leg 501 . Hence, pivotal movement of the crank arm 533 causes rotation of the bevel gear 515 which causes rotation of the steering disc 513 and steering column 514 . The steering column 514 is connected to a first torque link 512 at a lower portion 504 of the landing gear leg 501 . The first torque link 512 is pivotally connected to a second torque link 511 and that second torque link 511 is connected to a wheel 502 of the landing gear leg 501 at an axle 503 . Hence, rotation of the steering column 514 causes, through the torque links 511 , 512 , steering of the wheel 502 .
The wheel 502 is supported by a wheel strut 541 which extends upwards through the landing gear leg 501 and is slidably mounted in the steering column 514 . When in the “weight on wheel” situation of FIG. 1 , the wheel 502 and wheel strut 541 slide upwards in relation to the landing gear leg 501 and steering column 514 . When in the “weight off wheel” situation of FIG. 2 , the wheel 502 and wheel strut 514 slide downwards in relation to the landing gear leg 501 and steering column 514 .
The wheel strut 541 and steering column 514 are linked by a centreing cam arrangement (schematically shown as 542 ), which will be described in more detail in relation to FIG. 5 .
The landing gear 500 also comprises a deployment mechanism 520 comprising a two-part drag strut, comprising an upper part 521 pivotally connected at pivot point 525 b to a lower part 522 . The upper end of the upper drag strut 521 is suspended from the fuselage 100 at a pivot point 525 a behind the actuator pivot point 531 . The lower end of the lower drag strut 522 is pivotally connected to an upper portion 505 of the landing gear leg 501 by pivot point 525 c. The deployment mechanism 520 also comprises a two-part uplock, comprising a back part 524 and a front part 523 . The front end of the front part 523 is pivotally connected to the drag strut near (or at the same point) as the pivot point 525 b, at pivot point 526 a. The back 524 and front 523 parts are pivotally connected to each other at pivot point 526 b and the back end of back part 524 is pivotally attached to the upper portion 505 of the landing gear leg 501 by pivot point 526 c, above pivot point 525 c.
The “over-centre” uplock 523 , 524 is used to lock the drag strut 521 , 522 in the deployed position shown in FIGS. 1 and 2 . A second actuator 527 is used to move the uplock past the “over-centre” point to allow the drag strut 521 , 522 to move to stow the landing gear leg 501 . The stowing of the landing gear leg 501 will be described in more detail, in relation to FIG. 3 .
FIG. 4 a shows a side view of part of the aircraft nose landing gear 500 in a deployed “weight on wheel” situation, whilst the wheel 502 is being steered left. Here, the actuator 530 can be seen more clearly. It comprises an actuator block 537 fixed on an actuator rod (the lever arm 532 ). The block 537 is contained within an actuator chamber 538 of the actuator 530 . Hence, actuation of the actuator 530 moves the block 537 along the length of the actuator chamber 538 and thus effectively increases and decreases the length of the lever arm 532 extending from the actuator 530 . In FIG. 4 a , the actuator block 537 is located at the upper end of the actuator chamber 538 and hence a relatively large length of the lever arm 532 has been pulled within the actuator 530 . This means that the effective (protruding) length of the lever arm 532 is small. This causes the lever arm 523 to pull on the crank arm 533 and, by pivot point 534 , rotate the crank arm 533 in an anti-clockwise direction (as shown in FIG. 4 a ). This causes the bevel gear 515 to also rotate anti-clockwise. This then causes the steering disc 513 to rotate from left to right (as shown in FIG. 4 a —i.e. anti-clockwise if viewed from the top of FIG. 4 a ) and cause the steering column 514 to also rotate in that direction. This then causes the torque links 511 , 512 to rotate the wheel 502 so that it is steered in a left direction.
FIG. 4 b shows a side view of part of the aircraft nose landing gear in a deployed “weight on wheel” situation, whilst the wheel is being steered centrally. Here, the actuator block 537 is located substantially centrally in the actuator chamber 538 . The lever arm 532 has been effectively lengthened from FIG. 4 a , and therefore crank arm 533 and bevel gear 515 have been pivoted clockwise. This rotates the steering disc 513 and steering column 514 to rotate towards the right and also causes the torque links 511 , 512 to change the direction of the wheel 502 so that it is being steered in a central direction.
FIG. 4 c shows a side view of part of the aircraft nose landing gear in a deployed “weight on wheel” situation, whilst the wheel is being steered right. Here, the actuator block 537 has been moved further down the actuator chamber 538 to a lower end of it. The lever arm 532 has been effectively lengthened further from FIG. 4 b , and therefore crank arm 533 and bevel gear 515 have been pivoted further clockwise. This rotates the steering disc 513 and steering column 514 to rotate further to the right and also causes the torque links 511 , 512 to change the direction of the wheel 502 so that it is being steered in a right direction.
Hence, the steering direction of the wheel 502 can be controlled by the actuator 530 when in the “weight on wheel” situation.
FIG. 5 shows a perspective view of the centreing cam arrangement 542 of the aircraft nose landing gear 500 in a “weight on wheel” situation. The centreing cam arrangement is designed to do two things. Firstly, when there is a “weight off wheel” situation, the arrangement 542 ensures that the wheel 502 is orientated in a central orientation. This means that when the aircraft lands so that the wheel 502 controls the direction of the aircraft, the aircraft will not be steered off course by a wheel that is being orientated significantly left or right. This is achieved by the wheel strut 541 sliding downwards in relation to the steering column 514 when in a “weight off wheel” situation. This causes an internal downwardly facing notch 544 in the wheel strut 541 to fall into a corresponding internal upwardly facing groove 543 of the steering column 514 . It is also noted that each of the notch and groove 544 , 543 have corresponding tapered sides 546 , 545 to effect rotation of the steering column 514 (and therefore wheel 502 ) as the notch 544 and groove 543 line up.
Secondly, also when there is a “weight off wheel” situation, the arrangement 542 (and in particular, the notch 544 in groove 543 ) rotationally fixes the steering column 514 in relation to the wheel strut 541 so that the steering column 514 cannot rotate. This means that the steering disc 513 , bevel gear 515 and crank arm 533 also cannot rotate. Hence, when in a “weight off wheel” situation, lengthening and shortening of the lever arm 532 does not cause rotation of the crank arm 533 , but instead causes the landing gear leg 501 to be pulled on by the lever arm 532 (via crank arm 533 ) so that it pivots about pivot point 506 to pivot the leg 501 in a stowing direction 702 , as shown in FIG. 3 .
In order for this to happen, the uplock actuator has to also be actuated to move the uplock “over-centre” so that the two parts 523 , 524 of the uplock can collapse and allow the two parts of the drag strut 521 , 522 to also collapse, as shown in FIG. 3 .
FIGS. 6 a and 6 b show side views of part of an aircraft nose landing gear 600 according to a second embodiment of the invention. Here, corresponding similar elements to the first embodiment (which are not described again for efficiency) are labelled with a preceding “ 6 ” instead of a “ 5 ”. In this second embodiment, the wheel strut 641 is provided at an upper end with a downwardly pointing triangular member 680 . When in the “weight on wheel” situation of FIG. 6 a , the wheel strut 641 has been slid upwards in relation to the steering column 614 and hence triangular member 680 is above the bevel gear 615 and does not affect its ability to rotate. However, when in the “weight off wheel” situation of FIG. 6 b , the wheel strut 641 has been slid downwards in relation to the steering column 614 and hence triangular member 680 is adjacent to the bevel gear 615 . In fact, the point of the triangle lodges in between two projections (not shown) on the edge of the bevel gear 615 and prevent its rotation. Hence, the triangular member 680 is used to lock the bevel gear 615 , steering disc 613 and steering column 614 and prevent their rotation when in the “weight off wheel” situation. This ensures that actuation of the actuator 630 would cause deployment/stowage of the landing gear 60 , rather than steering of the wheel 602 , in a similar way to the centreing cam arrangement 542 of the first embodiment.
FIG. 7 shows a front view of an aircraft 1000 . The aircraft 1000 comprises a fuselage 100 , two wings 210 , 202 (each with one underwing engine) and a tailplane 300 . Each of the wings 201 , 202 is also provided with a main landing gear 401 , 402 . Finally, the aircraft 1000 is fitted with a nose landing gear according to either the first 500 or the second 600 embodiment.
Whilst the present invention has been described and illustrated with reference to particular embodiments, it will be appreciated by those of ordinary skill in the art that the invention lends itself to many different variations not specifically illustrated herein. By way of example only, certain possible variations will now be described.
The landing gear may be provided with two ways of rotationally fixing the steering column 514 , 615 ; one way using a notch 544 of the centreing cam arrangement 542 of FIG. 5 and another way of using a triangular member 680 as shown in FIGS. 6 a and 6 b.
The aircraft landing gear 500 , 600 may comprise more than one wheel 502 , 602 .
The aircraft landing gear 500 , 600 may be a nose landing gear or any other landing gear.
Any aircraft may be used with this invention, and not just (a particularly sized) commercial passenger airliner, as shown in FIG. 7 .
Where in the foregoing description, integers or elements are mentioned which have known, obvious or foreseeable equivalents, then such equivalents are herein incorporated as if individually set forth. Reference should be made to the claims for determining the true scope of the present invention, which should be construed so as to encompass any such equivalents. It will also be appreciated by the reader that integers or features of the invention that are described as preferable, advantageous, convenient or the like are optional and do not limit the scope of the independent claims. Moreover, it is to be understood that such optional integers or features, whilst of possible benefit in some embodiments of the invention, may not be desirable, and may therefore be absent, in other embodiments.
|
The present invention provides a landing gear assembly for an aircraft landing gear, the assembly comprising a steering mechanism for steering at least one wheel of the landing gear, a deployment mechanism for moving a leg of the landing gear between a stowed position and a deployed position, and an actuator arranged to actuate both the steering mechanism and the deployment mechanism. The invention also provides an aircraft landing gear, an aircraft and methods of operating an aircraft landing gear.
| 1
|
1. FIELD OF THE INVENTION
The present invention relates to novel tris-hydroxyaryl phosphites which are useful as stabilizers and antioxidants for organic materials.
2. BRIEF DESCRIPTION OF THE PRIOR ART
It is known in the art that certain hindered phenolic phosphites are useful as stabilizers for organic materials. In particular, U.S. Pat. No. 3,407,737 discloses certain tertiary-alkyl-substituted-para-hydroxyphenyl phosphites having the formula
(L--O--).sub.x (M--O--).sub.y P
wherein M is a hydrocarbon group, x is from 1 to 3, y is from 0 to 2, x plus y equals 3, and L is a teritary-alkyl-para-hydroxyphenyl group of the formula ##STR2## wherein R and R' are tertiary alkyl groups, n is 1 or 2, m is 0 or 1, and n plus m is not greater than 2. These compounds are disclosed to be useful as stabilizers for polypropylene or other polymers. Included in the compounds as disclosed are those in which y is 0, that is, those of the formula ##STR3## wherein R and R' are tertiary alkyl groups, n is 1 or 2, m is 0 or 1 and n plus m is not greater than 2. These compounds are disclosed to be useful as stabilizers for polypropylene or other polymers. When n is one and m is zero, the chemicals are derived from mono(tertiary-alkyl)hydroquinones, and the tertiary alkyl group may be in the 2- or 3-position in the phosphite, preferably in the 3-position. When n plus m equals two, the chemicals are derived from di(tertiary-alkyl)hydroquinones in which the tertiary alkyl groups are preferably in the 2- and 5-positions.
SUMMARY OF THE INVENTION
The present invention comprises a group of tris-(3-hydroxy-4,6-di-t-alkylphenyl)phosphite compounds having the formula ##STR4## wherein R and R' may be the same or different and are tertiary alkyl groups containing from 4 to usually not more than 12 carbons atoms (e.g., tertiary-butyl, tertiary-pentyl t-octyl, t-dodecyl). These compounds are, surprisingly and unexpectedly, found to be useful as stabilizers and antioxidants for organic materials such as thermoplastics, elastomers, hydraulic fluids, fluid lubricants and greases. They are also found to have excellent thermal and hydrolytic stability.
The compounds of the present invention are preferably made from 4,6-di-t-butylresorcinol and phosphorus trichloride in the presence of pyridine, alkylpyridines, quinolines or aryl phosphines as the catalyst and aliphatic or aromatic hydrocarbons or halogenated hydrocarbons as the solvent.
The stabilizer and antioxidant of the present invention can be readily incorporated into plastic material by various standard procedures. In one technique the dry stabilizer in powdered form is mixed with a powdered or granular plastic and the mixture is mixed, milled, molded and/or extruded, at elevated temperatures if required. In another procedure an aqueous suspension or emulsion of finely divided polymeric material may be admixed with a suspension or emulsion of the stabilizing agent. Alternatively, it is possible to spray or mix a polymeric material in powdered or granular form with a solution or dispersion of the stabilizing agent in an appropriate solvent, such as hexane or xylene. It is also possible to incorporate the stabilizing agent in a finished article by introducing the plastic material into a bath containing the stabilzing agent in an appropriate liquid solvent and permitting the plastic material to remain in the bath for some time until the plastic has been properly treated. Thereafter, the material is dried to remove any of the remaining solvent. Plastic material in the form of fibers and films may also be sprayed with a solution or suspension of the stabilizing agent in a solvent or dispersant by any standard technique.
The plastic material should contain a stabilizing amount of the stabilizing agent; that is, the amount of stabilizing agent sufficient to prevent deterioration and embrittlement of the plastic material. The amount of stabilizing agent to be used will depend to a large extent upon the amount of exposure to which plastic is subjected and the nature of the plastic to be treated. The agent is generally added to an amount of between 0.01 to 5 percent by weight of the plastic material and preferably between 0.1 and 4 percent by weight.
As a stabilizing agent and antioxidant for plastics, the compounds of the present invention impart protection against heat and oxidation degradation to numerous plastic materials. These materials include polyethylene, polypropylene, polystyrene, polyvinyl acetate, polyvinylchloride, copolymers of vinyl chloride and vinylidene chloride, cellulose resins, such as nitrocellulose, ethylcellulose, and cellulose acetate, and numerous other materials. The agent can be used alone or together with other additives, such as fillers, pigments, etc.
The compounds of the invention may be used as the sole stabilizer or in mixture with other heat, oxidation or light stabilizers, e.g., with other phenolic antioxidants, with thio-di-propionates, or with other phosphites.
DETAILED DESCRIPTION
The invention will be illustrated more clearly by the following examples.
EXAMPLE 1
To a stirred charge of 133.2 g. (0.6 m.) of 4,6-di-t-butylresorcinol, 200 ml. of xylene, and a catalytic amount of 2,4-lutidine (1.3 g.) was added dropwise, during 22 minutes, 28.0 g. (0.2 m.) of phosphorus trichloride at 40°-45° C. Shortly after the addition of PCl 3 was started, heavy evolution of hydrogen chloride began. The slurry was held at 40° C. for another 1.0 hr. A moderate flow of nitrogen was then started through the reactor and the charge was heated to 120° C. in 1.0 hr., then held at 120°-125° C. for 2.5 hrs. At the end of this period there was very little hydrogen chloride evolved. The mixture was cooled to 25° C. and filtered. The cake was washed with 50 ml. of xylene and vacuum-dried at 140° C. to give 92.3 g. of a white solid, a 66.5% yield of tris-(3-hydroxy- 4,6-di-t-butylphenyl)phosphite, (hereinafter referred to as "Compound I"); m.p. (Mettler apparatus) 277.6° C.; elemental analysis: 4.4%P (calculated for I: 4.47%P). This compound shows some solubility in methanol, isopropanol, methyl isobutyl ketone and chlorotoluene.
EXAMPLE 2
To demonstrate the efficacy of the compounds of the present invention as high termperature process stabilizers for polypropylene, a sample of polypropylene (SHELL 55XX) was tumble-mixed with 0.05 percent by weight of Compound I, then mill-mixed for 10 min. at 171° C. (340° F.). A similar sample of SHELL 55XX polypropylene was tumble-mixed with 0.05 percent by weight of a known stabilizer, tetrakis[methylene 3-(3'-5'-di-t-butyl-4-hydroxphenyl)propionate]methane, which is commerically available from Ciba-Geigy Corporation under the trademark IRGANOX 1010 (hereinafter referred to as "Compound II"). The stocks were then removed from the rolls, cooled and chopped. The samples were then submitted to a multiple extrusion test (in a Brabender extruder) at 289° C. (550° F.), with melt index determinations being made on the polymer after each extrusion. The results are given in Table 1. It will be seen from Table I that Compound I was clearly superior.
TABLE I______________________________________Melt Index (g./10 min.) No. of ExtrusionsAdditive 0 1 2 3 4 Initial Color______________________________________Compound I 7.3 7.8 13.5 23.3 36.2 Off-whiteCompound II 7.1 9.4 18.9 45.4 69.0 Off-white______________________________________
EXAMPLE 3
To demonstrate the efficacy of the compound of the present invention as both a long term heat stabilizer and an antioxidant for polypropylene, a sample strip of polypropylene containing about 0.15 percent by weight Compound I and having dimensions of 0.25 inches by 2.0 inches by 0.02 inches was bent around an 1/8 inch diameter mandrel in a circulatory air oven, the temperature of which was maintained at about 130° C. This sample passed 800 hours of such exposure without failure.
EXAMPLE 4
To demonstrate the efficacy of the compounds of the present invention as an antioxidant for lubricants, SAE 10 mineral oil was mixed with Compound I. The mixture was 1 percent by weight Compound I. At 177° C. (350° F.) in air; and after 24 hours there was no visible sludge formation and only a slight color change. After 48 hrs. the color was dark, but there still no sludge formation. A sample of this SAE 10 mineral oil without Compound I showed considerable sludge formation under the same conditions.
EXAMPLE 5
A 50-gal. reactor was charged with 164.5 lb. heptane, 263 g. of triphenylphosphine as the catalyst, and 112.5 lb. of 4,6-di-t-butylresorcinol. The stirred charge was purged with nitrogen at 0.4 CFM, heated to 40° C., and 24.26 lb. of phosphorous trichloride was added during 20 minutes. When the evolution of HCl gas subsided (after 3 hrs.), the charge was purged with nitrogen at 0.7 CFM, heated to 90° C. (boiling point), and refluxed for 2 hrs. Finally, the reactor was cooled to 3°-5° C. and the slurry was centrifuged. The wet cake of product was washed with heptane and dried at 115° C./38 Torr to give 104.0 lb. (88.7% yield) of white product, capillary m.p. 286° C.
|
A group of phenolic phosphite compounds having the formula ##STR1## wherein R and R' may be the same or different and are tertiary alkyl groups containing from 4 to 12 carbon atoms. These compounds are disclosed to be useful as stabilizers and antioxidants in various organic materials.
| 2
|
BACKGROUND OF THE INVENTION
This invention relates to an economical process for recovery of terephthalic acid (TPA) from various polyester waste materials.
The extensive use of polyesters and the need for disposal of polyester waste has created a great problem for many industries. In the past, polyester waste has often been used for landfills or has been incinerated because there was no economical recovery process available or the contaminants caused severe difficulties in its reapplication.
Various processes have been proposed for the recovery of TPA from various waste materials but they are very expensive, often incomplete and some release undesirable gases which pollute the atmosphere and, in general, they have not enjoyed commercial success. The most common way is to depolymerize the polyester with alkali as shown in U.S. Pat. Nos. 3,953,502 and 3,956,088.
It is the main object of this invention to provide an economical and industrially feasible process for processing all kinds of polyethylene terephthalate (PET) type waste material and for obtaining marketable TPA at low cost with substantially complete recovery.
It is intended to deal solely with solid waste material in large volumes regardless of its main origin. The solid waste scrap materials can be classified into four groups.
1. Silver-bearing films (X-ray film, exposed/non-exposed films and microfilms)
2. Regular films (non-photographic, with or without another plastic coating)
3. Textiles (crude polymer, yarn and fabrics)
4. Bottles (clear or colored)
A general procedure is submitted herewith but is not limited as representative of a process embodying the features of this invention.
SUMMARY OF THE INVENTION
Briefly described, the general procedure in accordance with the practice of this invention comprises the following steps:
Step 1
The PET scrap (chips, granules, compressed or in any convenient form) is placed into a vessel which is corrosion resistant (glass lined or hevac type) equipped with sufficient agitation and with a heater. Sufficient water and concentrated sulfuric acid in a volume ratio of 2 to 8.5-13 are added under constant mixing, at atmospheric pressure and room temperature. Heat is applied in a cold climate, if necessary. Within 5 to 30 minutes under constant mixing the solid waste materials will be completely liquified (depolymerized). They are then diluted with an equal volume of cold water. The diluted liquid is then rapidly filtered.
The solid material is collected in the filter, the liquid material (ethylene glycol; water; excess acid and some impurities) is discarded (waste disposed).
Step 2
The collected solids, containing the TPA and impurities, are suspended in water in a convenient tank at room temperature, then treated with potassium, ammonium or sodium hydroxide, to raise the pH to 6 to 13. In this step the TPA will dissolve and the impurities will be precipitated. The solution may be dark brown- black in color, depending on the amount of impurities and the pH. The lower pH range avoids the formation of fine precipitate which results from decomposition of any vinylidene chloride present on some films. Thus it is easier to filter but the yield of acid recovered is the same. After filtration to remove the fine precipitate, the residue (undissolved scrap material, if any, and impurities) is discarded as solid waste. The liquid is then collected and must be clear, although it may be light brownish in color (if dark colored, it must be treated with activated charcoal and refiltered from the charcoal). The obtained solution is then acidified with diluted or concentrated sulfuric acid to a pH of 0-2 to cause precipitation of TPA.
Step 3
The TPA is filtered and washed with water until acid- and salt-free. The washed TPA is then dried, preferably at 105°-110° C. (electric, gas or hot air dryer) to constant weight, then ground or pulverized and packed.
The following reactions occur during the recovery process. ##STR1##
DETAILED DESCRIPTION
The following examples will clearly show the feasibility of the process.
For TPA recovery from silver-bearing polyester film scrap, the silver is removed from the polyester type base by any known process. The silver-free and dry weighed scrap film (chips, granules or any other form) contains not less than 98% of polyester scrap. The other 2% can be a coating (vinylidene chloride), paper, acetate base scrap but no metals of any kind. The scrap film is charged into an open or closed chemical vessel, which is equipped with a heater and mixing means and is corrosion resistant. The size of all equipment is directly proportional to the volume. After the vessel is charged with the scrap, water and concentrated sulfuric acid are pumped in with constant mixing. Within 5 to 30 minutes at room temperature and atmospheric pressure, the solid waste material depolymerizes (is liquified). The depolymerization, reaction is exothermic. After depolymerization, the volume is doubled with cold water, then the liquid is filtered and all solids collected on the filter. The filtrate is discarded. The empty vessel is then ready for the next batch.
The collected solid material from the filter is suspended in water in a suitable tank under constant agitation, neutralized with an alkali hydroxide (solid KOH, NaOH or concentrated NH 4 OH) and the pH of the solution adjusted to between 6-13. Lithium hydroxide could be used but it is too expensive for economical recovery. The hydroxides of calcium, barium, magnesium, or strontium could also be used but complications may arise because of their double valency or the formation of sulfates.
The obtained solution which is brown colored, is then filtered on a fine filter to remove all undissolved materials (vinylidene chloride polymer, small amounts of undissolved film chips and other impurities) or precipitated materials. The obtained solids constitute the only solid waste material. The filtrate, which must be completely clear and light yellow-brownish in color (if the solution is very dark in color, activated charcoal filtration is required) is acidified with sulfuric acid (concentrated or diluted) and the acidity of the solution adjusted to about pH 0-2 to insure total precipitation of the terephthalic acid which is then filtered and washed acid- and salt-free with cold water.
The clean acid is then dried, preferably at 105° C. and ground and packed in lined (plastic) bags or drums.
EXAMPLE 1
A sample of scrap was used which contained a large amount of silver (over 5% by wt.) but having a 100% PET base.
An 11 gram sample was first treated at room temperature with 50 ml. dilute nitric acid to remove the silver. Then the dilute acid was removed and the film chips were washed with 2×25 ml cold water. This is a pre-treatment for the above scrap and not part of the present invention.
10 g of the dried silver-free scrap was then treated with 2.0 ml water and 11.0 ml concentrated sulfuric acid (95-97% pure) at atmospheric pressure and room temperature. The resins were depolymerized in 2-5 minutes, then the reaction mixture was diluted with 13.0 ml cold water under constant agitation and then filtered. The obtained liquid was clear and was discarded.
The obtained precipitate was then suspended in 50 ml water and 9 g of 85% KOH was added to dissolve the crude TPA and to precipitate the impurities at an elevated pH of 11-13. A dark brown precipitate formed in the solution indicating that the impurities had reacted. The solution mixture was then filtered through a fine filter which is capable of removing all the precipitate and undissolved particles. This is very important. The clear, yellowish-brown filtrate was acidified with 9 ml of conc. H 2 SO 4 to obtain a solution having a pH of 2 and to precipitate TPA. The obtained solid TPA was then filtered, washed with cold water until acid- and salt-free (K 2 SO 4 ). The clean acid was dried at 105° C. The dried TPA weight was 7.56 g or 75.6% yield. It was white in color and better than 99% pure. ##EQU1##
If the impurities in the scrap material amount to more than 2% (paper, acetate base or other), the weight of the precipitate after the alkali treatment and filtration must be determined by drying to constant weight at 105° C. and the scrap sample weight must be corrected.
EXAMPLE 2
100 g of clean silver-bearing polyester waste chips containing less than 3% silver impurities, were treated with 20 ml water and 110 ml conc. sulfuric acid and the procedure of Example 1 was followed. The obtained TPA weighed 82.56 g, representing an 82.56% yield.
EXAMPLE 3
1000 g of a clean silver-bearing sample containing less than 3% silver impurities, was treated with 200 ml water and 1100 ml conc. sulfuric acid and the procedure of Example 1 was followed. The obtained TPA weighed 759.25 g, representing a 75.93% yield.
EXAMPLE 4
A silver-bearing type scrap material which contained 3.5% silver and a large amount of acetate base (10%) impurities was used.
100 g of the above sample was treated with 20 ml water and 110 ml concentrated sulfuric acid and the procedure of Example 1 was followed. The obtained TPA weighed 65.5 g, representing a 65.5% yield. The residue weighed 10.1 g. The corrected yield was 72.8%.
The following Examples 5-1 to 5-6 illustrate the amount of acid required to depolymerize the scrap material in reasonable time and with no additional heat. The room temperature was 25° C. and atmospheric pressure was used. In each case the sample weight was 100 g. All chips were silver-free, 100% PET base, previously dried to constant weight. All chemicals were analytical grade. The purity of the obtained acid was better than 99% as compared with pure analytical grade TPA. Only the yield, not the purity, of the TPA is effected if less acid is used as in Ex. 5-1 and 5-2. The results are shown in the following table.
______________________________________ ml conc. Time TPA yieldEx. ml H.sub.2 O H.sub.2 SO.sub.4 (min) in g______________________________________5-1 20 85 30 77.35-2 20 90 25 77.75-3 20 100 15 78.05-4 20 110 5 78.05-5 20 120 5 78.05-6 20 130 5 78.5______________________________________
The above experiments clearly show that if not enough acid is used, more time is required to depolymerize the materials. If heat is applied, the time can be shortened but the economy of the process will be off-set. If the time is kept constant, the sample will not depolymerize and good TPA recovery is not obtained. The best results were obtained when 110 ml conc. sulfuric acid were used with 20 ml water. Thus, the preferred volume ratio of acid to water is 11 to 2, but a ratio of 8.5-13 to 2 gives good results.
EXAMPLE 6
The material used was non-silver-bearing PET film scrap of light blue color.
1000 g. of the scrap film, originally from a 60 inch wide roll) was cut into small pieces, put into a container which contained 200 ml water and 1100 ml conc. sulfuric acid. Under constant stirring the film was depolymerized at room temperature and atmospheric pressure within 5 minutes. After depolymerization, the mixture was diluted with 1300 ml cold water and then filtered. The filtrate was discarded. The solid material from the filter was suspended in water and then alkali was added to elevate the pH to 11 under constant mixing. The solution was filtered, and the clear liquid was acidified with sulfuric acid to pH 0-3. The precipitated TPA was filtered, washed acid- and salt-free with cold water to neutral pH and dried at 105° C. The obtained TPA weighed 829.70 g corresponding to 82.97% yield.
Note: The above scrap material contained only 0.5 to 1.5% by weight of a vinylidene chloride polymer coating and a very small amount (0.2%) of a blue dye as impurities.
EXAMPLE 7a
The material used was textile scrap.
100 g of scrap was put into a container which contained 20 ml water and 100 ml of conc. sulfuric acid. Under constant agitation the material was depolymerized within 10 min. The solution was then diluted with an equal volume (120 ml) of cold water and then filtered. The solid material was suspended in water and neutralized with NaOH. The resulting solution was very dark colored but clear. 30 g of activated charcoal was added and the mixture filtered. The resulting solution was clear and very light in color (yellowish-brown). This solution was acidified to pH 2 and the precipitated TPA was filtered off and washed. The dried TPA was white and weighed 73.75 g, representing a 73.75% yield.
EXAMPLE 7b
The material used was polyester scrap yarn or crude fabric containing some oil as a protective agent.
100 g of yarn was put into a container which contained 20 ml water and 100 ml conc. sulfuric acid. The yarn very rapidly depolymerized under constant stirring. The solution was diluted with 120 ml water and then filtered. The solid material from the filter was dispersed in water and then neutralized with KOH to a pH between 10 and 13. The alkaline solution was filtered to yield a very light yellowish colored clear filtrate. This was acidified with 20 ml conc. sulfuric acid to precipitate TPA. The TPA was filtered and washed acid- and salt-free and then dried at 105° C. The dried TPA weight of 84.35 g, corresponded to an 84.35% yield.
Note: The TPA obtained from textile yarn (staple or monofilament) has the highest purity, 99.6 or better.
EXAMPLE 8
A previously used polyester beverage bottle was separated from the metal cap and the polyethylene reinforcement bottom part. The remainder was crushed to a small size to reduce the volume. The crushed bottle scrap contained paper from the label and glue, as well as a little dye as impurities.
100 g of the crushed scrap was put into a container which contained 25 ml water and 130 ml conc. sulfuric acid. Under constant mixing at room temperature, the material was depolymerized within 10 min. The mixture was diluted with 160 ml cold water and then filtered.
The filtered solid materials were suspended in water and neutralized; then the pH was adjusted to between 11 and 13 with conc. ammonium hydroxide (28-30%). It was necessary to decolorize the solution with activated charcoal because of the dye in the bottle and decomposition of the paper and glue. The obtained clear light-colored solution was then acidified with conc. sulfuric acid (diluted sulfuric acid is preferred if large enough equipment is available). The precipitated TPA was filtered, washed free of ammonium sulfate with cold water to neutral pH, then dried at 105° C. 76.4 g of dried TPA was obtained, corresponding to a 76.4% yield.
Note: All yields were based on the actual weight of the scrap material but the yield was actually much higher, considering that the available TPA from the polyester polymer is equal to or around 85.6% or less because of the presence of impurities.
The quality of the recovered TPA was checked by infrared spectrophotometer or by titration against pure analytical grade TPA.
Regardless of the type of scrap material and the method used, the purity of the recovered TPA was always better than 99%. The yields clearly indicate the capability, simplicity and adaptability of the process.
It should be understood that the use of a filter to separate solids from liquids in the above examples is only illustrative. Decantation or centrifugation may also be used.
Waste Disposal
After depolymerization, the formed ethylene glycol can be simply decomposed with activated sludge to form water and CO 2 . The excess acid part can be neutralized completely. These techniques are well-known in the art.
|
Polyester scrap such as film (plain or silver-bearing), fabric, yarn or bottles, based primarily on polyethylene terephthalate, is depolymerized at room temperature and atmospheric pressure with a mixture of concentrated sulfuric acid and water to form crude terephthalic acid which is purified by dissolving in alkali solution, filtering to remove impurities, acidifying the filtrate to recover terephthalic acid in high yield with a purity of at least 99%.
| 8
|
BACKGROUND OF THE INVENTION
This invention relates to an apparatus for detecting the duration of voice.
In order to recognize separately pronounced words or series of words by a pattern matching method or other similar methods, it is required to correctly detect the duration of each voice generated word or a series of words. If a word is pronounced or spoken when the ambient noise is relatively small, for instance, when the S/N ratio is 30 dB or more and a wideband microphone is used to derive a corresponding voice signal, the duration of the voice generated word or series of words can easily be detected by determining the period during which its amplitude and the number of its zero intersections remain above a predetermined value.
When the ambient noise is large or changes at a high rate, however, it is impossible to correctly detect the duration of a voice generated word or series of words, no matter what data-processing has been carried out to determine the proper threshold value. If the threshold value is set relatively small, a noise larger than the threshold value may frequently be generated, and a so-called "addition error" may occur many times. Conversely, if the threshold value is set relatively large, a voice component whose level is lower than the threshold value may fall out, and a so-called "fall-off error" may occur many times. If the non-voice period can be determined, the threshold value can be changed according to the ambient noise level. In general, however, a non-voice period can not be properly determined. It is therefore extremely difficult to correctly detect the duration of an input voice generated word.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an apparatus which can correctly detect the duration of a voice generated word or series of words.
According to one aspect of this invention, an apparatus for detecting the duration of voice is provided which comprises sampling means for sampling the input voice signal and generating a time-sequence of voice parameters; memory means, connected to said sampling means, for storing the time-sequence of voice parameters; first determining means for determining based on the time-sequence of voice parameters an interval which is divided into three periods, an estimated voice period, a first non-voice period preceding said voice period and a second non-voice period succeeding said voice period; means for forming a histogram based on the voice parameters generated during said interval to divide the voice parameters into non-voice class and voice class; second determining means for determining a threshold value based on the average of voice parameters in the non-voice class; and third determining means for determining the voice duration based on the threshold value and the voice parameters generated during said interval and stored in said memory means.
In one embodiment of this invention, a time interval which includes a voice period and non-voice period is first detected based on a time-sequence of voice parameters for the voice signal. Then, the histogram of the voice parameters pertaining to that period of time is determined. The average value of the voice parameters pertaining to the non-voice period is calculated from the voice parameter distribution. A threshold value is then determined in accordance with the mean value thus calculated, thereby effectively accomplishing the above-mentioned object of this invention.
The time sequence of voice parameters for the voice signal is used in order to detect the duration of an input voice generated word. When a human looks at a graph showing the time sequence of voice parameters, the duration of the input voice generated word can be recognized correctly. This is because whether each voice parameter belongs to a voice period or a non-voice period can easily be determined and, at the same time, an optimum threshold value for detecting the duration of the input voice can easily be determined. Thereafter, in accordance with the threshold value it can be determined whether or not each voice parameter pertains to the duration of the input voice generated word. Further, it can also be determined if voice parameters pertaining to the voice period are successively generated for more than a preset period of time. Based on the data thus provided, the duration of the input voice generated word is determined. This process in which a human perceives the duration of an input voice generated word is applied to the voice duration detecting apparatus of a voice recognition system, thus enabling the apparatus to detect correctly the duration of an input voice generated word.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a circuit diagram of a voice duration detecting apparatus according to one embodiment of this invention;
FIG. 2 shows a waveform illustrating a time sequence of short-time-energy parameters of an input signal;
FIG. 3 shows a waveform of moving average derived from the time sequence of short-time-energy parameters;
FIG. 4 shows a histogram of the short-time-energy parameters of an input signal shown in FIG. 2;
FIGS. 5A ad 5B are a flow chart for forming the histogram shown in FIG. 4;
FIG. 6 is a flow chart for determining a threshold value corresponding to the average of voice parameters in a non-voice period; and
FIGS. 7A and 7B are a flow chart for determining a true voice duration based on the threshold value and voice parameters.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
There will now be described a voice duration detecting apparatus according to one embodiment of this invention with reference to the accompanying drawings. Here, short-time-energy data E are derived from an input voice signal as voice parameters. However, other voice parameters may be used to serve the same purpose.
First, a moving average E or a plurality of successive short-time-energy data E shown in FIG. 2 is calculated as described later with reference to FIG. 1, and is compared with a predetermined value ER to detect time points A1 and B1 shown in FIG. 3. At the time point A1, the moving average E becomes larger than the predetermined value ER for the first time, and at the time point B1, the moving average E becomes smaller than the predetermined value ER after the time point A1. That portion of the input voice which is defined by the time points A1 and B1 may be the most reliable portion as a voice period. The time point A1 is estimated as a starting point for determining the duration of the input voice signal, and the time point B1 as the end point for determining the duration of the input voice signal.
The determination of the moving average of the voice parameters pertaining to the period between the estimated starting and end points of the input voice signal is significant in the following respect. As well known, the short-time-energy data is a relatively effective parameter for distinguishing a voice period and a non-voice period. However, if an input voice has been generated where the ambient noise is relatively large, it probably contains a pulsative noise which has an instantaneously great energy. Therefore, such a pulsative noise may be contained in that portion of the input voice signal which is defined by the time points A1 and B1 if the energy data E is used to detect the estimated starting and end points of the input voice signal duration. This is why the moving average of the voice parameters (or short-time-energy data) are calculated, thereby suppressing pulsative noises which are contained in the input voice signal and thus obtaining a graph of the moving average as shown in FIG. 3. Thus, using the moving average of the voice parameters which have been calculated in the above-mentioned process, it becomes possible to correctly detect the duration of an input voice regardless of pulsative noises. Further, a time point M at which the short-time-energy data E is the largest during the period between the time points A1 and B1 is detected as a time point at which it is most probable that a true voice duration covers.
Two non-voice periods Nu of, for example, 100 to 200 msec are provided, one starting at a time point A2 and ending at the time point A1 and the other starting at the time point B1 and ending at a time point B2. The period between the time points A2 and B2 is the histogram calculation period. Each non-voice period may be set to 100 to 200 msec. The histogram calculation period therefore consists of the estimated non-voice period between the time points A2 and A1, the estimated voice period between the time points A1 and B1 and the estimated non-voice period between the time points B1 and B2. The voice parameters pertaining to the histogram calculation period are used to calculate and provide the histogram as shown in FIG. 4. Next, a threshold value is used to divide a plurality of short-time-energy data E into two classes in accordance with the histogram. That is, energy data E are divided into a non-voice class where the energy data E is smaller than the threshold value EO and a voice class where the energy data E is greater than the threshold value EO. More specifically, a between-class variance σ B is determined and then an optimum threshold value EO which makes the between-class variance σ B maximum is determined. According to the optimum threshold value EO and the histogram of the non-voice class where E<EO, the mean value EN of the energy data E in the non-voice region is determined. A predetermined value is added to the mean value of the energy data EN to compensate for the fluctuation of the energy data E, and the added value is used as a proper threshold value EP for detecting the duration of an input voice signal.
In order to obtain the optimum threshold value EO for dividing the distribution of energy data E into a voice class and a non-voice class, the reference value may be varied from the minimum value of energy E to the maximum value of the energy data E, and the between-class variance σ B is determined. Then, the optimum threshold value EO is determined which causes the between-class variance σ B to be maximum. This method, however, is very complicated. Since the σ B -E characteristic curve has only one inflection point, this inflection point may be considered to be the maximum between-class variance σ B . Thus, the threshold value corresponding to the maximum between-class variance σ B may be regarded as the optimum threshold value EO.
The optimum threshold value EP may be obtained by a gray level histogram of the energy data E as follows:
Step 1: Divide a group of energy data E into two classes, background noise class C1 and voice class C2, using a between-class variance as a reference value for evaluating either class.
Step 2: Obtain the average EN of the energy data E of frames which fall within the background noise class C1.
Step 3: Add a predetermined margin α to the average EN, thus obtaining the threshold value EP.
The steps mentioned above will now be described more in detail.
Suppose energy data E may have discrete values (e-1): e=1, 2, . . . , L. Table H(e) which defines a gray-level histogram of the energy data E having a value (e-1) shows the number Ne of frames in which the energy data E has the same value during a period (between the time points A2 and B2). Then, the relation of N and Ne (e=1, 2, . . . , L) is: ##EQU1## where N is the number of frames existing during the period between the time points A2 and B2.
To simplify the matter, the gray-level histogram is regarded here as a histogram normalized by N (or a probability density Pe), which is given: ##EQU2##
Suppose that, using a value k as a threshold value, the values of the energy data E are divided into background noise class C1 which includes the energy data having a value of S1 (=1, 2, . . . , k) and voice class C2 which includes the energy data having a value of S2 (=K+1, K+2, . . . , L). Probability ω1 of class C1 and probability ω2 of class C2 are given as follows: ##EQU3##
Expectation μ T of e during the period between the time points A2 and B2, expectatin μ 1 of e for C1 and expectation μ 2 of e for C2 will be given as follows: ##EQU4##
Variance σ B between the classes C1 and C2 is determined as follows:
σ.sub.B =ω1(μ.sub.1 -μ.sub.t).sup.2 +ω2(μ.sub.2 -μ.sub.T).sup.2 (9)
As equation (9) shows, the greater the between-class variance σ B is, the more clearly the classes C1 and C2 are separated from each other. Let equations (3) to (7) be put into equation (9). Then, the following equation is obtained: ##EQU5##
To determine the optimum threshold value for separating the background noise class C1 from the voice class C2, it is necessary to evaluate the between-class variance σ B for every value that k may have, i.e. k=1, k=2, . . . , k=L. Thus far the gray-level histogram has been regarded as a normalized one. In practice, however, the table H(e) shows how often the energy data having the same value e is obtained. Accordingly, it is required to change the equation (10) as follows: ##EQU6##
Let equations (12), (13) and (14) be put into equation (11). Then: ##EQU7##
σ B is evaluated for every value that k may have, i.e. k=1, k=2, . . . , k=L. The value of k (k=e 0 ) at which σ B has the greatest value is used as the threshold value for dividing the energy data E into the background noise class C1 and the voice class C2. The average value of energy data E in the background noise class C1, i.e. the average E N , is given: ##EQU8##
Needless to say, there is indeed a frame or frames of noise having an energy level greater than EN which is the average value of energy data E in the background noise class C1. If EN is directly used as the threshold value EP for detecting the second-stage voice period, an addition error will be made when consecutive frames have energy data greater than EN. This is why a predetermined value α is added to EN, thus obtaining the threshold value EP. Hence, EP is expressed as follows:
EP=EN+α (17).
EP can be efficiently obtained in the following manner.
Step A: Read out data from the histogram table H(e) (e=1, 2, . . . , L) to calculate B(k) and C(k) for every value that e may have and write B(k) and C(k) in work tables, B(k) and C(k) being given as follows: ##EQU9## Step B: Calculate μ T , using the following equation: ##EQU10## Step C: Use the values B(k) and C(k) to rewrite equation (15) as follows: ##EQU11## Evaluate σ B 2 of equation (21), using the values written in the work tables, thereby determining the value of k (=e 0 ) at which σ B becomes maximum. If σ B has the same maximum value when e 1 ≦k≦e m , use (e m -e 1 )/2 as value e 0 .
Step D: Calculate the average EN of background noise, using the following equation:
EN=C(e.sub.0)/B(e.sub.0) (22)
Step E: Calculate the threshold value EP, using the following equation:
EP=EN+α.
The starting point A and the end point B of an input voice signal is determined as explained hereinafter. To detect the starting point A, the time sequence of energy data E is examined in reverse direction from the time point M, and the time A when the energy data E falls below the threshold value EP is detected. It is further examined whether or not the energy data E remains less than EP for a predetermined period N1. Period N1 is, for example, about 200 to about 250 msec. If the energy data E remains less than EP for the period N1, the time A is considered as the starting point A. In this case, even if the energy data E becomes greater than EP and is kept greater than EP for a period which is shorter than a predetermined period N2, it is considered that the input voice contains pulsative noise components, and the time point A is considered as the starting point A of the input voice duration.
If the energy data E becomes greater than EP after having fallen below EP and is kept greater than EP for a time longer than the period N2, another voice period within the same voice duration is considered to exist. Then, time at which the energy data E becomes less than EP is regarded as time A, and a non-voice period N1 is detected. This process is repeated until the starting point A of the input voice is detected.
The end point B of the input voice is detected in a similar fashion. In this case, the time sequence of energy data E is examined in the forward direction from the time point M.
FIG. 1 shows a circuit of a voice duration detecting apparatus according to one embodiment of this invention. The voice duration detecting apparatus includes electric/acoustic converting device 2, such as a wide band microphone, for converting a voice or utterance to an electrical signal and 16 band-pass filters F1 to F16 for receiving a voice signal from the microphone 2 through an amplifier 4. The band-pass filters F1 to F16 have different frequency band widths sequentially varying from a low frequency region to a high frequency region. The output signals of the band-pass filters are supplied to an analog multiplexer 6 and adder 8. The output signal of the adder 8 is supplied as a seventeenth input signal to the analog multiplexer 6. That is, the multiplexer 6 receives in a parallel fashion short-time-energy signals in the 16 frequency band widths in a range from the low to the high frequency region and short-time-energy signal of the whole of the voice input signal.
The output signals for each frame of the analog multiplexer 6 are serially supplied to an analog/digital converter 10, converted to corresponding short-time-energy data E1 to E17, and then fed to a buffer memory 12, multiplexer 14 and AND circuit 16. The output data of the AND circuit 16 is supplied to, for example, an 8-stage shift register 18. The output data in the respective stages of the shift register 18 are added at an adder 20 and then the output of the adder 20 is divided by a 1/8 divider 22 into one-eighth parts. The output data of the 1/8 divider 22 is compared by a comparator 24 with a reference value ER. The output terminal of the comparator 24 is coupled respectively through AND gates 30 and 32 to the up-count terminals of an 8-scale counter 26 and 4-scale counter 28 and through an inverter 36 and AND gate 38 to the reset terminal of the 4-scale counter 28 and up-count terminal of a 25-scale counter 34. The output terminal of the 4-scale counter 28 is coupled to the reset terminal of the 25-scale counter 34 and the output terminals of the 8-and 25-scale counters 26 and 34 are coupled to the set and reset terminals of a flip-flop circuit 40, respectively. The output terminal of the flip-flop circuit 40 is connected to a central processing unit 42 and address register 44. The CPU 42 includes a random access memory having buffer memory areas 42-1 to 42-3 for storing histogram data, energy data and address data and working memory area 42-4 for storing calculation data.
The voice duration detecting circuit further includes an address counter 46 for counting the output pulses of a timing control circuit 47 and a selector 48 for causing the address data from CPU 42 and address counter 46 to be selectively supplied to an address designation circuit 50 which functions to designate an address of the buffer memory 12. The timing control circuit 47 produces 17 pulses in each frame of 10 m seconds. These seventeen pulses occur in a period of, for example, 1 m second so that a vacant period of 9 m seconds may be provided in each frame. The address counter 46 produces address data corresponding to the contents, and also a pulse signal C17 each time the seventeenth pulse in each frame is counted.
There will now be described the operation of the voice duration detecting apparatus shown in FIG. 1.
First, the memory areas 42-1 and 42-4 are cleared and the first address for the memory areas 42-2 and 42-3 are designated.
A voice or utterance having energy distribution as shown in FIG. 2 is supplied to the wide-range microphone 2 which in turn produces a corresponding electrical voice or utterance signal to the amplifier 4. An output signal of the amplifier 4 is supplied to the band-pass filters F1 to F16 which smooth the input signal and allow the signal components having frequencies in the respectively allotted frequency band widths to be supplied to the analog multiplexer 6 and adder 8. An output signal from the adder 8 is also supplied to the analog multiplexer 6. In response to an output pulse from the timing control circuit 47, the analog multiplexer 6 time-sequentially produces short-time-energy signals corresponding to output signals from the band-pass filters F1 to F16 and the adder 8 in this order. The short-time-energy signals are sequentially supplied to the A/D converter 10 which in turn produces corresponding digital energy data E1 to E17 as voice parameters to the buffer memory 12, multiplexer 14 and AND circuit 16. In this example, the energy data E17 is set to an integer ranging from 0 to (L-1).
Since, in the initial state, the selector 48 is set to permit address data from the address counter 46 to be supplied to the address designation circuit 50, the address designation circuit 50 may designate the address location of the buffer memory 12 in accordance with the address data from the address counter 46 and the buffer memory 12 may store the energy data from the A/D converter 10 in designated address locations. The AND gate circuit 16 is enabled each time the address counter 46 produces a pulse signal C17, that is, each time the last pulse is generated in each frame from the timing control circuit 47. This causes the energy data E17 corresponding to the output signal from the adder 8 to be supplied to the 8-stage shift register 18 through the AND gate 16. The shift register 18 is driven in response to an output pulse from the timing control circuit 44 so as to shift energy data E17j to E17(j+7) generated in successive frames. The energy data E17j to E17(j+7) stored in the shift register 18 are added together in the adder 20 and divided by 8 in the 1/8 divider 22 to generate a moving average Ej for the energy data E17j to E17(j+7) as shown in FIG. 3. As is clearly seen from FIG. 3, pulse noise having been included in the energy distribution of FIG. 2 is eliminated by taking the moving average. The moving average Ej is compared with the reference value ER in the comparator 24 which produces a high level output signal when detecting that the moving average Ej becomes equal to or larger than the reference value ER. As far as the moving average Ej is smaller than the reference value ER, the flip-flop circuit 40 is kept reset and all the AND gates 30, 32 and 38 are kept disabled.
When it is detected that the moving average Ej from the 1/8 divider 22 becomes equal to the reference value ER, that is, a starting point A1 shown in FIG. 3 is reached, the comparator 24 produces a high level output signal to enable the AND gate 30. The AND gate 30 permits a pulse signal C17 generated from the address counter C17 to be supplied to the 8-scale counter 26. When the 8-scale counter 26 has counted eight pulses, that is, when a time point A11 is reached it produces an output signal to set the flip-flop circuit 40 which in turn produces a high level output signal SPS. The high level output signal SPS from the flip-flop circuit 40 is supplied as a latch signal to the address register 44 so that the address register can store an address data which is generated from the address designation circuit 50 and corresponds to a time point A11 shown in FIG. 3. In response to the high level output signal SPS from the flip-flop circuit 40, CPU 42 produces a high level output signal to the multiplexer 14 and selector 48 so that energy data can be transferred from the buffer register 12 to CPU 42 through the multiplexer 14 and address data can be supplied from CPU 42 to the address designation circuit 50 through the selector 48. At this time, CPU 42 calculates the address location for a point A2 based on the address data stored in the buffer register 44. Then, as will be described later, CPU 42 stores in the memory area 42-1 histogram data for energy data generated between the points A11 and A2. This operation may be effected in one frame that is, in a vacant period between a C17 pulse in one frame and a C1 pulse in the next frame, and after this operation, CPU 42 produces a low level output signal to the multiplexer 14 and selector 48 so that CPU 42 may receive energy data from the A/D converter 10 through the multiplexer 14 and the address designation circuit 50 will receive address data from the address counter 46 through the selector 48. Each time energy data are generated in each succeeding frame from the A/D converter 10, CPU 42 generates and stores histogram data in the memory area 42-1.
In the same manner as described above, short-time-energy data corresponding to the voice signal shown in FIG. 2 are successively stored in the buffer memory 12. When it is detected that the moving average Ei becomes smaller than the reference value ER, that is, an estimated end point B1 shown in FIG. 3 is passed, the comparator 24 produces a low level output signal to disable the AND gates 30 and 32 and enable the AND gate 38. This causes the 25-scale counter 34 to start counting C17 pulses supplied through the AND gate 38. When 25 pulses are counted, that is, a point B2 is reached, the 25-scale counter 34 produces an output signal indicating that the voice interval has been preliminarily determined by the points A1 and B1. The output signal of the 25-scale counter 34 is supplied to the CPU 42 and to the flip-flop circuit 40 to reset the same. However, if a moving average larger than the reference value ER is detected after the point B1 is detected, the counting operation of the 25-scale counter 34 is interrupted and the 4-scale counter 28 starts the counting operation. If, in this case, an output signal from the comparator 24 is kept at a high level for a period longer than a preset period, the 4-scale counter 28 continues to count C17 pulses. When having counted four C17 pulses, the 4-scale counter 28 produces an output signal indicating that another voice section appears in the same voice interval, and resets the 25-scale counter 34. Thereafter, the same operation as described before is continuously effected so as to detect a preliminary end point of the voice interval. However, in a case where an output signal from the comparator 24 is kept at a high level only for a short time and the 4-scale counter 28 stops its counting operation before counting four pulses, the 4-scale counter 28 is reset and, at the same time, the 25-scale counter 34 starts its counting operation and supplies an output signal when the 25-scale counter 34 comes to have contents of "25".
In response to an output signal from the 25-scale counter 34, CPU 42 stops forming histogram data and determines final starting and end points A and B based on the histogram data as will be described later.
Referring now to FIG. 5, a description of the flow chart for forming a histogram by the CPU 42 will be given hereinafter. The buffer memory areas 42-1 to 42-3 (FIG. 1) are initialized by setting the value i, which indicates the frame number, to 1, the value EMX to 0 and the value H(e) to 0. The value of e is an integer from 1 to L. After initialization is set up, it is checked if an output signal SPS is generated from the flip-flop circuit 40. If it is detected that a high level output signal SPS is generated, an address data ADRl which is generated at the time point A11 to designate the address location for a 17-th energy data E17 of one frame and is stored in the address register 44 is read out, and address data ADR2 and ADR3 are derived based on the address data ADR1 and respectively written into first address location ADL1 of the address buffer memory area 42-3 and ADR register (not shown). The address data ADR2 indicates the address position of a first energy data E1 in that frame which includes the 17-th energy data E17 generated at the time point A11. The address data ADR3 indicates the address position of a first energy data E1 in that frame which includes a 17-th energy data E17 generated at the time point A2. The address data ADR2 and ADR3 are respectively derived as follows:
ADR2=ADR1-16 (23)
ADR3=ADR1-{(8+25)×17+16} (24)
The address data stored in the ADR register is written into the address table location ADR(i) of the address buffer memory area 42-3 in a step STP1. Since the address data ADR3 is the first one, it is written into the address table location ADR(1). Then, the value of 16 is added to the address data stored in the ADR register and the result is written into the second address location ADL2 of the memory area 42-3. Thus, the address data indicating the address position of energy data E17 in the same frame can be obtained in the second address location ADL2. Next, it is checked if the address data stored in the second address location of the memory area 42-3 is larger than the memory capacity MC of the buffer memory 12. When it is detected that the former is not larger than the latter, CPU 42 produces a selection signal SL of high level and at the same time transfers the address data stored in the second address location of the memory area 42-3 to the address register 44. On the other hand, when it is detected that the address data is larger than the memory capacity MC, the memory capacity MC is subtracted from the address data and the result is written into the second address location ADL2 of the memory area 42-3, and then the same operation is effected. Thereafter, energy data E17 is read out from the buffer memory 12 in accordance with the address data stored in the address register 44. Then, the selection signal SL is set low, the energy data E17 read out from the buffer memory 12 is written into the energy table location TE(i) of the buffer memory area 42-2. The value of 1 is added to the energy data E17 stored in the energy table location TE(i) to obtain a value e which is used as an address data to designate an address location of the histogram buffer memory area 42-1. CPU 42 increments the histogram data H(e) in an address location designated by the value e.
Next, it is checked if the energy data E17 stored in the energy table TE(i) is not larger than the contents in the EMX register (not shown). If it is detected that the former is not larger than the latter, the value in the i register is incremented and the value of 17 is added to the address data in the ADR register, and the result of addition is written into the ADR register. Thus, the address position of a first energy data E1 in the next frame can be designated. On the other hand, when it is detected that the energy data E17 is larger than the contents of the EMX register, the values i and E17 now obtained are respectively stored in the M register and EMX register. Then, the same operation is effected. Thereafter, it is checked if the address data in the ADR register is larger than the address data ADR2. When it is detected that the address data is not larger than the address data ADR2, the step STPl is effected again. On the other hand, when it is detected that the address data in the ADR register becomes larger than the address data ADR2, that is, it is detected that formation of histogram for the energy data E17 between the time points A11 and A2 is completed, then it is checked in a step STP2 if the 25-scale counter 34 produces a high level output signal EPS. If it is detected that a high level output signal EPS is generated, the process of forming the histogram is terminated, and the next process for determining the threshold EP is started. On the other hand, where a high level output signal is not produced, energy data E17 is derived from the A/D converter 10 when a C17 pulse is generated in the succeeding frame. Then, the address data in the ADR register is written into the address table location ADR(i), the energy data E17 now read out is written into the energy table TE(i), and the value of 1 is added to the energy data E17 now obtained to make the new value e. Histogram data H(e) in an address location designated by the new value e is incremented by 1.
Next, it is checked if the newly detected energy data E17 is greater than the contents in the EMX register. Where the former is not greater than the latter, then the value i is incremented by 1 and the value of 17 is added to the contents of the ADR register, the result is stored in the ADR register, and then the step STP2 is effected again. On the other hand, where the newly detected energy data E17 is greater than the contents in the EMX register, the values i and E17 are respectively written into the M register and EMX register. Thereafter, the same operation is effected.
After completing the formation of histogram, the maximum energy data E17 is stored in the EMX register, the value i indicating the frame number which includes the maximum energy data E17 is stored in the M register, address data between the time points A2 and B2 are stored in the address table locations ADR(1) to ADR(N) of the memory area 42-3, energy data E17 between the time points A2 and B2 are stored in the energy table locations TE(1) to TE(N), and histogram data H(1) to H(L) are stored in the first to L-th address positions of the memory area 42-1. If X number of energy data E17 have the same value E(S), the histogram data of X will be stored in the S-th address position of the memory area 42-1. Thus, the histogram data H(e) corresponding to a graph shown in FIG. 4 can be obtained in the memory area 42-1.
Referring now to FIGS. 6, the process for determining the threshold value EP will be explained. First, the histogram data H(1) is transferred to B(1) and C(1) registers of the working memory area 42-4. Data B(2) to B(L) and C(2) to C(L) are calculated by using equations (18) and (19) and sequentially incrementing the value of k, and the data B(2) to B(L) are stored in B(2) to B(L) registers (not shown) of the working memory area 42-4 and the data C(2) to C(L) are stored in C(2) to C(L) registers (not shown) of the working memory area 42-4. In this case, the data B(L) indicates the number N of frames between the time points A2 and B2. Then, μ T is calculated using equation (20) and stored in a μ T register.
Next, SGO, DSO and DPO registers (not shown) in the memory area 42-4 are cleared and k is set to 1. Then, it is checked in a step STP3 if the histogram data H(k) is 0. When it is detected that the histogram data H(k) is 0, data SGO is set in an SGN register. Then, data DSN is calculated by subtracting data SGO from data SGN and stored in a DSN register, and data SGN is set in the SGO register. On the other hand, when the histogram data H(k) is not equal to 0, σ B 2 (k) is calculated using equation (21) and set in the SGN register. Then, the same operation is effected. Thereafter, it is checked if data DSN is 0 or not. When data DSN is equal to 0 it is checked in a step STP4 if k is less than L. Where k is less than L, k is incremented by 1 and the step STP3 is effected again. When it is detected that data DSN is not equal to 0, then it is checked if data DSN is positive or not. When data DSN is positive, data DSN is set in the DSO register and the value k being used is set in the DPO register in a step STP5. Then, the step STP4 is again effected. When it is detected that data DSN is not positive, then it is checked if data DSO is positive or not. When data DSO is not positive, the step STP5 is effected again. On the other hand, when it is detected that data DSO is positive, then the value k is added to DPO data, the result of addition is divided by 2, and an integral portion of the result of division is used as e 0 at which σ B takes the maximum value as shown in FIG. 4. Then, the average EN of energy data in background noise class C1 is calculated using equation (22) and is stored in EN register. The average EN is added to a constant α to make a threshold value EP. On the other hand, if it is detected in the step STP4 that k is equal to L, that is, it is detected that a proper value of k at which σ B takes the maximum value is not determined, then a constant EC is used as a threshold value EP.
Referring now to FIG. 7, the flow chart for determining the true voice duration will be explained.
First, SCNT and NCNT count registers and SW register in the working memory area 42-4 are cleared, and address data in the M register is set in the i register. Then, if it is detected in a step STP6 that SW data is set at 0, it is checked in a step STP7 if energy data in the energy table location TE(i) is smaller than the threshold value EP. Where the former is not smaller than the latter, the value i is decremented by 1, and the step STP6 is effected again. This operation is repeatedly effected until the energy data in the energy table location TE(i) is detected in the step STP7 to be smaller than the threshold value EP, that is, until a time point A shown in FIG. 2 is reached. When it is detected in the step STP7 that the energy data in the energy table location TE(i) is smaller than the threshold value EP, the value of 1 is set in the SCNT and SW registers, and then the value i is decremented by 1. Thereafter, the step STP6 is effected again. If it is detected in the step STP6 that SW data is set at "1", it is checked in a step STP8 if energy data in the energy table location TE(i) is smaller than the threshold value EP. Where the former is smaller than the latter, the value of 1 is added to the sum of SCNT and NCNT data and the result of addition is stored in the SCNT register, and then the NCNT register is cleared. It is checked in a step STP9 if SCNT data is equal to or larger than a preset value NS which is, for example, 25. When it is detected that SCNT data is smaller than the value NS, the value i is decremented by 1 in a step STP10. Next, when the value i is detected to be equal to or larger than 1, the step STP6 is again effected, and when the value i is detected to be smaller than 1, the time point A is determined to be the true starting point and the value i is set to 1. Then, in a step STP11, the value i is added to the SCNT data and the result of addition is stored in an STAP register as data representing the time point A shown in FIG. 2. The step STP11 is also effected when the SCNT data is detected to be equal to or larger than the value NS in the step STP9.
When it is detected in the step STP8 that the energy data in the energy table location TE(i) is not smaller than the threshold value EP, the NCNT data is incremented by 1, and then it is checked if the NCNT data is equal to or larger than a preset value NU which is, for example, 4. When the former is smaller than the latter, the step STP10 is effected. On the other hand, when it is detected that the former is equal to or larger than the latter, that is, another voice section is detected, the NCNT and SCNT count registers and the SW register are all cleared to determine that the time point A should not be taken as the true starting time point, and then the step STP10 is effected.
After the step STP11 is effected, that is, the starting point A is detected, the SCNT, NCNT and SW data are all set to 0, and data in the M register is set in the i register. Then, it is checked in a step STP12 if the SW data is set at 0. Where the SW data is set at 0, it is checked if energy data in the address table location TE(i) is smaller than the threshold value EP. When it is detected that the former is not smaller than the latter, the step STP12 is effected after the value i is incremented by 1. This operation is repeatedly effected until the energy data is detected to be smaller than the threshold value EP, that is, a time point B shown in FIG. 2 is detected. Then the SCNT and SW data are set to 1, and the step STP12 is effected after the value i is incremented by 1.
When it is detected in the step STP12 that the SW data is set at 1, then it is checked in a step STP13 if energy data in the energy table location TE(i) is smaller than the threshold value EP. Where the former is smaller than the latter, the value of 1 is added to the sum of the SCNT and NCNT data and the result of addition is stored in the SCNT register. After this, the NCNT data is set to 0. Then it is checked in a step STP14 if the SCNT data becomes equal to or larger than the value NS. Where the SCNT data is smaller than the value NS, the value i is incremented by 1 in a step STP15. Thereafter, it is checked in a step STP16 if the value i is larger than N. When the value i is detected in the step STP16 to be equal to or smaller than N, the step STP12 is effected. On the other hand, when it is detected that the value i is larger than N, the time point B is determined to be the true end point and the value N is set into the i register. Then, the SCNT data is subtracted from the value i, in a step STP17, to provide ENDP data which is set in an ENDP register and represents the time point B shown in FIG. 2. The step STP17 is also effected when it is detected in the step STP14 that the SCNT data is equal to or larger than the value NS.
Further, when it is detected in the step STP13 that the energy data in the energy table location TE(i) is not smaller than the value EP, the NCNT data is incremented by 1, and then it is checked if the NCNT data is equal to or larger than the value NU. Where the NCNT data is smaller than the value NU, the step STP15 is effected again. On the other hand, when it is detected that the NCNT data is equal to or larger than the value NU, that is, another voice section is detected then the SW, NCNT and SCNT registers are all cleared to determine that the time point B should not be taken as the true end time point, and then the step STP15 is effected again.
After the true starting and end points are properly determined, CPU42 reads out energy data from the buffer memory 12 by sequentially designating addresses defined by the true starting and end points, and then tansfers the energy data to a voice recognition circuit (not shown).
Even if the ambient noise is large or even if the level of the ambient noise changes very much, the apparatus according to the invention can easily and correctly detect the duration of an input voice signal. In addition, the apparatus is simple in structure as illustrated in FIG. 1. Furthermore, the apparatus operates stably giving it great practical value. Still further, the algorithm for detecting the starting point A and the end point B of the input voice signal is therefore simple. The apparatus of the present invention can thus achieve accurate detection and is therefore highly reliable.
The present invention is not limited to the embodiment described above. For example, as voice parameters there may be used estimated errors calculated by LPC analysis, the correlation coefficient of the input voice or the like. The algorithm for calculating the distribution of voice parameters may be replaced by other algorithms. A variety of modifications are possible within the scope of the present invention.
|
The detection of voice (speech) signal presence in input signal-plus-noise is improved by more accurate determination of the decision threshold, which is determined by first finding a medium-length interval consisting of noise-signal-noise (no-signal, signal, no-signal), then calculating a histogram (energy probability distribution) for the interval, then finding the maximum value of variance of the histogram as the optimal threshold, plus an arbitrary offset.
| 6
|
This is a continuation of co-pending application Ser. No. 883,973 filed on July 10, 1986, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus for insertion of an object into a close clearance hole. Specifically, the invention relates to such apparatus utilizing a double taper starter system wherein a first taper is provided to align the part radially and a second taper is provided to align the part angularly. Apparatus in accordance with the present invention includes a first taper; a narrow section of length such that with the part tilted to the angle of the first taper, clearance in the hole is maintained;, a cut-back segment of either constant diameter or reverse taper geometry; and a second taper of approximately the same size and shape as the first taper. The apparatus of the present invention can be advantageously used in mechanized assembly processes, the assembly of shafts into bearings, and in thermally assembled or regular interference fits.
2. Description of the Relevant Art
Assembly of objects into mating holes can be quite difficult, especially when the ratio of part diameter to part diametrical clearance within the hole is greater than about 500 to 1. Until the insertion has proceeded to a significant fraction of the diameter, these close fits are subject to jamming due to misalignment. Such jamming can result in gouging and scraping the surfaces of the parts. If the parts are massive, a jammed part can be difficult to remove. Delicate bearing materials and thin surface coatings are quite susceptible to assembly damage. In applications where rapid assembly is required, such as in thermal shrink fits or interference fits and automated assembly processes, jamming of close clearance fits can be a catastrophic problem.
Perhaps the most common solution used for this problem is a single taper on either member. Although a single taper solves the radial alignment problem, once the assembly is inserted past the tapered portion the angular alignment problem is similar to an assembly with no taper. Even where both members arm tapered, the problem still exists. While it is noted that long, very shallow single tapers can decrease the frequency and severity of jamming, the excessive starter section lengths required are not acceptable for many practical applications.
Attempts by others to provide apparatus for insertion of an object into a close clearance hole have failed to provide a design suitable for use where the ratio of part diameter to part diametraly clearance within the hole is high or where it is desired to quickly assemble the parts or protect a surface coating. Accordingly, it is therefore desirable to provide an apparatus which allows the assembly of objects in a close clearance hole which can be used in rapid assembly and which minimizes the frequency and severity of jamming when parts are assembled.
SUMMARY OF THE INVENTION
The present invention provides an apparatus for insertion of an object into a close clearance hole which can be used in various assembly processes and which significantly reduces the frequency and severity of jamming due to misalignment of the assembled parts. In addition, the apparatus of the present invention allows rapid assembly of parts with minimum damage to delicate surface coatings.
The apparatus of the present invention is a starter for the insertion of an object into a hole which includes a first taper to align the part radially; a narrow section of length such that with the part tilted to the angle of the first taper, clearance in the hole is maintained; a cut-back segment of either constant diameter or reverse taper geometry; and a second, taper of approximately the same size and shape as the first taper to align the part angularly.
The first taper is used for radial alignment. After the part is turned or bored, the width of the narrow section following the taper can be adjusted by varying the length of the cut-back segment. The narrow section width is sized such that the mating part can be misaligned up to the limiting angle of the first taper without interference. The cut-back segment can be a reverse taper if necessary, especially for applications where gross initial angular misalignments are present. Once insertion has proceded beyond the cut-back segment, the second taper begins to align the part angularly. Once through the second taper, the part is sufficiently started in the hole to avoid jamming.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will further be illustrated by reference to the appended drawings which illustrate particular embodiments of the apparatus for insertion of an object into a close clearance hole in accordance with this invention.
FIG. 1 is a side prospective view of the male type apparatus for insertion of an object into a close clearance hole in accordance with the present invention.
FIG. 2 is a side sectional view of a female type apparatus in accordance with the present invention.
FIGS. 3A-3D are side perspective views of a male type apparatus in accordance with the present invention depicting stages of assembly using the apparatus.
FIG. 4 is a side perspective view of an alternate embodiment of a male type apparatus with a reverse taper cut-back segment in accordance with the present invention.
FIG. 5 is a sectional view of an alternate embodiment of a female type apparatus with a reverse taper cut-back segment in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
It will be understood that the present invention can be implemented in a number of different ways within the scope of the claims appended hereto. The presently preferred embodiments of this invention will now be described.
Turning now to the drawings, FIG. 1 illustrates a male type apparatus for insertion of an object into a close clearance hole 10 in accordance with the present invention. As shown in FIG. 1, apparatus 10 is basically cylindrical in shape. However, apparatus 10 could be a member of virtually any shape for insertion into a hole of a basically equivalent shape.
Apparatus 10 as shown is cylindrical in shape having first taper 12, a narrow cylindrical section 14, a cutback segment 16 and a second taper 18. Apparatus 10 is for insertion of object 10 into hole 22.
Hole 22 can be defined in any mating member or body into which object 20 is to be inserted. As can be appreciated, apparatus 10 may be a starter section and may be affixed and removed from object 20. Alternately, apparatus 10 may be unified with object 20 and be formed as an integral portion thereof through any suitable forming method.
Apparatus 10 can be employed for a variety of applications. For example, assembly of shafts into bearings of large machinery is an important application. Many times air bearing clearances are limited to that which is assembleable. In addition, assembly time is often an important factor. Interference of its, those involving a male part with a larger diameter than the female hole, are used extensively in machines. Where the part, cannot be mated by pressing the part in by force, thermal shrink fits are often used. Typically, the male part is cooled to decrease its outer diameter while the female part is heated to enlarge its inner diameter. The parts are then rapidly assembled and develop an interference fit as the temperatures equalize. If the parts jam, however, there is often a total loss to the parts.
The apparatus of the present invention has also been successfully used in therma) interference assemblies in the female version, where temperatures and tins clearances were limited by material constraints. Since time is limited in many assemble processes, the apparatus of the present. Invention has numerous applications. In the past, clearances were often enlarged to allow assembly of parts by machine. This enlargement of clearances worked to the degradation of product quality. The present invention allows use of preferred close clearances and in addition, the apparatus for the present invention has been used effectively where delicate coatings or surfaces exist on the assembled parts.
As illustrated in FIG. 1, apparatus 10 includes a first taper 12. First apex 12 is used to align the part or object 20 radially. Accordingly, first taper 12 should have its forward end small enough to allow the object to get situated in the hole. The retaining variables for the first taper are then the angle and length of the taper. If the angle of the taper is too steep, the cylindrical segment length will be prohibitively thin. Therefore, the taper length is generally from one-third to one times the diameter of the object. A large assembly has been done with a one to ten taperlength to diameter ratio. The assembly was successful but difficult to initially line up and chattered during assembly. Thus, a good general rule is that the first taperlength should be approximately one-half times the diameter of the part or object. The taper angle should be a adjusted to accommodate the length of the first taper and to satisfy forward clearance needs.
The narrow section 14 of apparatus 10 has a length such that the mating object can by misaligned up to the angle of the first taped, generally 2° to 3° , without interference. The limiting angle of the first taper is thus the maximum angle at which the object can be misaligned in the hole without interference. If L is the length of the narrow section 14, theta (θ) is the taper angle of the first taper, and C is the radial clearance of the mating part within the hole, trigonometry yields that: sine θ=2L. Rearranging the equation yields that: L=2C/sine θ. Accordingly, the acceptable length of the narrow section is less than twice the radial clearance divided by the sine of the forward taper angle.
The cut-back segment 16 as shown is of length equal to that of the first taper. However, cut-back segment 16 could be of any suitable length and diameter, it being understood that the length and diameter of segment 16 influences the limiting angle of insertion as described in connection with the narrow section 14. Therefore, segment 16 should be of length and diameter to allow the limiting angle to be achieved by tilting the object to the taper angle of the first taper. As shown in FIG. 1 cut-back segment 16 is of the same cylindrical diameter as the forward end of the first taper.
The second taper 18 is generally identical to the first, preferably being approximately one-half of the diameter of the object in length. The length from the large end of the first taper to the large end of the second taper of the apparatus in accordance with the present invention is preferably approximately one diameter. The overall length of the apparatus is preferably approximately one and one-half times the diameter.
The sizing heretofore discussed for the various components of the present apparatus are simply guidelines to which the actual dimensions may vary with the application and ratio of clearance to diameter. Generally, the higher the ratio of diameter to diametral clearance to the object within the hole, the shallower the taper and the longer the segments. In addition, lubrication may be applied to the object or the receiving hole to assist in the assembly, if desired.
FIG. 2 illustrates a female type apparatus in accordance with the present invention. As shown, apparatus 40 includes first taper 42, narrow section 44, cut-back segment 46 and second taper 48. In FIG. 2, part 52 is to be mated in hole 50. Similar guidelines for the sizing of the various components of the apparatus can be used as described above in connection with FIG. 1.
FIGS. 3A-3D illustrate the insertion of an object in a close clearance hole using the apparatus of the present invention. Broken line 21 and broken line 23 designate the centerlines of the object to be inserted and the receiving hole respectively. FIG. 3A illustrates apparatus 10 being radially aligned in the hole by first taper 12. FIG. 3B illustrates insertion of the object past cut-back segment 16 into hole 22. In FIG. 3C, second taper 18 is being used to angularly align the part in the hole 22. In FIG. 3D, part 20 is aligned in hole 22 for insertion.
FIG. 4 illustrates an alternate type male embodiment of the apparatus of the present invention. As shown in FIG. 4, apparatus 60 includes first taper 62, narrow section 64, reverse taper 66 and second taper 68. Reverse taper 66 as shown in FIG. 4 is identical in size to first taper 62 and second taper 68. However, reverse taper 66 could be of any suitable taper size with varying degrees of taper angle as long as reverse taper 66 meets the general sizing criteria as described in connection with FIG. 1.
FIG. 5 illustrates the female type embodiment of an alternate configuration of the apparatus. As shown in FIG. 5, apparatus 80 includes first taper 82, narrow section 84, reverse taper 86 and second taper 88. Apparatus 80 is used to mate part 92 in hole 90.
In the male configuration, the apparatus permitted the assembly of a 4.0 inch diameter shaft into a hole with 0.0011 inch radial clearance. Repeated assemblies have been smooth with no detectable damage to the precision ground bearing bronze bore liner. In the female configuration, the apparatus permitted the rapid two second assembly of a 20.0 inch long, 7.0 inch diameter steel cylinder into an aluminum sleeve with an assembly clearance of only 0.006 inches. Since this was an interference fit assembly, the aluminum part was heated to provide assembly clearance. Thus, delays due to jamming might allow cooling before assembly is completed which could cause a catastrophic jam.
The present invention has been described in connection with specific embodiments. However, it will be apparent to those skilled in the art that variations from the illustrated embodiments may be undertaken without departing from the spirit and scope of the invention. For example, the sizing of the various components could be altered as described above. In addition, the apparatus could be of any size and shape for the insertion of variously sized and shaped objects into variously sized and shaped holes. These and other variations will be apparent to those skilled in the art in view of the above disclosure and are within the spirit and scope of the invention.
|
Apparatus for insertion of an object into a close clearance hole utilizing a double taper starter system. The apparatus includes a first taper to align the object radially; a narrow section of length such that with the object tilted to the angle of the first taper, clearance in the hole is maintained; a cut-back segment of either constant diameter or reverse taper geometry; and a second taper of approximately the same size and shape as the first taper to align the object angularly. The apparatus of the invention can be advantageously used in mechanized assembly processes, the assembly of shafts into bearings, and in thermally assembled or regular interference fits.
| 8
|
BACKGROUND OF THE INVENTION
1. Field of the Invention:
This invention relates to an apparatus for applying a length of tape to a reusable envelope closure. More particularly, the envelope has a closure flap provided with a piece of tape dispensed by the apparatus of the present invention capable of adhering a plurality of times to the main body of the envelope without losing its effectiveness.
2. Description of the Prior Art:
Canadian Pat. No. 745,888, issued Nov. 8, 1966, discloses a reusable envelope in which a flap of the envelope is adhered to the main body. An aperture is punched in the flap and covered by an adhesive material, such as the well known adhesive tape marketed under the trademark SCOTCH TAPE. A second tape is fixed on the main body of the envelope which has a glossy surface. The position of this tape is beneath the closure flap of the envelope when the closure flap is in its closed position. When the tacky surface of the adhesive tape comes in contact with the glossy surface of the tape on the main body, a good reliable bond is formed to seal the envelope. However, the tacky surface of the adhesive tape and closure flap may be pulled away from the glossy surface of the tape on the main body to break the bond and the glossy surface retains very little or no tacky material from the adhesive tape. Therefore, the closure may be resealed a number of times.
U.S. Pat. No. 3,906,844, issued Sept. 23, 1975, discloses an apparatus for producing the envelope closure illustrated in Canadian Pat. No. 745,888. The envelopes having already been formed without the reusable closure, are fed in spaced relation along a conveyor. The apparatus includes means operative to open the closure flap of each envelope as the envelope is being moved along the conveyor, means to cut an opening in the flap, a first tape dispensing means for fixing on the main body of the envelope a band of material having a glossy surface, the band of material being disposed in a position corresponding to the closure flap opening when it is sealed to the main body, and a second tape dispensing means for applying and fixing an adhesive tape on the flap over the opening to form the reusable closure seal for the envelope.
The same tape dispensing apparatus in U.S. Pat. No. 3,906,844 is used to apply both the adhesive tape and glossy band to the envelope. The apparatus includes a tape supply roll from which the tape is fed to a rotatable applicator wheel, while suitable tension is maintained on the tape. A rotatable knife whose axis is in the same horizontal plane as the axis of the applicator wheel is provided so as to rotate in a direction opposite to the applicator wheel. The knife has an edge which is capable of engaging the applicator wheel to transversely cut the continuous band of tape. After a desired length of tape is cut, a suction device retains the length of tape against the outer periphery of the applicator wheel until the tape meets the main body of the envelope or the closure flap having the opening, as the case may be, to apply the tape to the envelope. The tape must be capable of sliding relative to the circumference of the applicator wheel in order to assure delivery of a length of tape which is suitable to overlap the opening cut in the flap, or alternatively, of a length to traverse the main body of the envelope and no more. A feed control to accomplish this is not disclosed.
SUMMARY OF THE INVENTION
In contrast to the tape dispensing apparatus disclosed in U.S. Pat. No. 3,906,844, the tape dispensing apparatus of the present invention provides an entirely different feed mechanism for the tape from a supply roll to the envelope. A draw roll in contact with the sticky side of the tape draws the tape by friction from the supply roll. A rotary knife cuts the tape to the precise desired length by cutting against a stationary knife. Movement of the draw roll is synchronized by a gear train with rotation of the rotary knife so that the length of tape desired is accurately cut. The length of tape cut may be changed by simply changing the gear ratio between the draw roll and the rotary knife.
Just before the tape is cut, the tape is fed from the draw roll between a convex and concave roller which forms the tape into a V-shape to give it more rigidity during the feeding process to the knife to assure complete accuracy in the length of tape cut. The rotary knife flattens the tape again just before it is cut. The precisely cut length of tape is then fed to a vacuum roll which applies it to the envelope closure flap or envelope main body, as the case may be.
The tape dispensing apparatus of the present invention also includes sensing means to detect the absence of an envelope on a conveyor beneath the vacuum applicator roll. When this condition is sensed, an electric clutch and brake are activated to stop the draw roll from drawing tape from the supply until envelopes on the conveyor once again pass beneath the tape dispensing apparatus. In this manner, no tape is wasted during the application process.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects and advantages of the present invention will become more apparent from the following description and claims, and from the accompanying drawings, wherein:
FIG. 1 is a schematic diagram illustrating the sequence of operations of forming a reusable envelope, in which process, the tape dispensing apparatus of the present invention is employed;
FIG. 2 is a side view in elevation of the tape dispensing apparatus of the present invention employed in the process illustrated in FIG. 1;
FIG. 3 is a cross sectional view taken substantially along the plane indicated by line 3--3 of FIG. 2; and
FIG. 4 is a side view in elevation of tape dispensing apparatus of the present invention as seen from the right-hand side of FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings in detail, wherein like numerals indicate like elements throughout several views, FIG. 1 schematically illustrates a sequence of operations for forming an envelope 10 provided with a reusable tape closure. Rather than the envelopes being preformed, as in the prior art, the process illustrated forms the envelope from a blank 12.
Envelope blanks 12 are fed by a feeding apparatus 14 to a gumming station A wherein selected portions of the seal flap are gummed if desired and dried at station B. The blanks 12 are then collected and refed at station C onto a moving, endless conveyor belt 22.
Blanks 12 are then aligned at station D on belt 22 and fed to a printing station E where suitable indicia may be printed on the blank, as desired. A hole 24 is then punched in the top closure flap 26 of blank 12 at station F. Opposed side flaps 18 and 20 of blank 12 are then scored and folded over one another at station G, the gummed portion of side flap 20 underlying side flap 18 and adhesively connected thereto. Each blank 12 is then fed beneath the tape dispensing apparatus 50 of the present invention at station H wherein a band of adhesive 28 having a glossy upper surface is attached to the main body of the folded blank 12. Closure flap 26 is then closed and a second piece of adhesive tape 30 having a downwardly facing tacky surface is applied by a second tape dispensing apparatus 50 over opening 24 in the closure flap 26 to adhesively connect flap 26 to the main body of the finished envelope 10 by creating a seal between tapes 30 and 28 through opening 24. Simultaneously, bottom flap 16 is folded over side flaps 18 and 20 and adhesively connected thereto to complete reusable envelope 10. The envelopes 10 are then collected at station K and stacked for delivery.
The tape dispensing apparatus 50 of the present invention, used at stations H and J, is illustrated in detail in FIGS. 2 to 4, inclusive.
Tape dispensing apparatus 50 includes a pair of vertical, substantially planar side frames 52 and 54 mounted by a horizontal plate 56 on the frame of the envelope forming machine above conveyor 22 at stations H and J. Mounting plate 56 is attached by any suitable means to the frame of the envelope forming machine. The side frames 52 and 54 are connected together at their top by suitable bolts 58.
Mounted between side frames 52 and 54, in suitable bearings, is a rotatable shaft 68 which has a tape drive gear 62 fixed thereto along with a draw roll drive gear 66. Gear 66 is in meshing engagement with an idler gear 64 mounted on a shaft 60 rotatably mounted on side frame 54. Idler gear 64 is also in meshing engagement with a draw roll feed length change gear 70 fixed to a shaft 72 rotatably mounted between side frames 52 and 54. Tape drive gear 62 is in meshing engagement with an idler gear 74 mounted on a shaft 140 rotatably supported between side frames 52 and 54. Idler gear 74 is in meshing engagement with a gear 76 fixed to a shaft 78 extending between side frames 52 and 54 and mounted in suitable bearings. Gear 76 is used to rotate a convex rotary knife holder 80 mounted on one end of shaft 78.
Also mounted on shaft 140 is a gear 82 in meshing engagement with a gear 84 mounted on one end of a shaft 86, which is retained by collar 88. Through suitable gearing gear 84 rotates shafts 92 and 98. The outer end of shaft 92 carries a convex roller 94. A concave roller 96 mounted on a shaft 98 rotatably mounted on side frame 52 is positioned near the outer diameter of convex roll 94.
Tape T is fed from a tape supply roll S. The tape T is fed around the circumference of an idler pulley 100 with the sticky adhesive side out, mounted on the end of an idler arm 102 fixed by bolts 104 to the side frame 52 of the tape dispensing apparatus 50. Idler pulley 100 reverses the tape so that its sticky side is facing downwardly as it passes about the idler pulley 100. The sticky side of the tape T comes in contact with the outer circumference of a draw roll 106, which feeds the tape T between the convex roller 94 and concave roller 96 which forms the tape into a V-shape to rigidify it for handling and cutting purposes.
Mounted on side frame 52 of tape dispenser 50 is a stationary knife holder 108 mounting a stationary knife blade 110 which has a slight shear angle on its outer free edge. Rotary knife holder 80 includes a rotary knife blade 112. Tape T is fed between the stationary knife blade 110 and the rotary knife blade 112 and is cut to a desired length by the edge of the rotating knife blade pushing the tape T against the shear edge of stationary knife blade 110. Rotary knife blade 112, having a planar surface contacting tape T just before it is cut, flattens the end of tape T. Once it is cut, the cut length of tape T is drawn onto a vacuum roll 114 mounted on a shaft 116. Vacuum roll 114 is hollow and is connected to a suitable plenum for inducing suction in the interior of the roll. The outer circumference of the roll includes holes 118 therethrough, which enables the vacuum induced in the roll to be present at the outer circumference of the roll 114.
Vacuum roll 114 picks up the cut length of tape T on its non-sticky side and reverses it while rotatably advancing the cut length of tape into contact with the main body of the envelope 10 on conveyor 22 at station H, or over the opening 24 in the closure flap 26 at station J. The flattened end of tape T enables it to be retained by the vacuum on roll 118, and the roll flattens the remainder of the tape T as it applies it to envelope 10.
The tape T is dispensed by placing tape drive gear 62 in meshing engagement with a gear 120 connected to the drive of the envelope forming machine. Gear 120 rotates gear 62, which in turn will rotate shaft 68 to turn gear 66. Gear 66 is in meshing engagement with idler gear 64. Therefore, rotation of gear 66 will cause rotation of gear 64 which will in turn through its meshing engagement with the draw roll feed length change gear 70, attached to shaft 72, cause shaft 72 to rotate. Draw roll 106, which is fixed to shaft 72, will turn, pulling tape T from roll S by friction and feeding the tape T threaded around its circumference, between concave and convex rolls 96 and 94, respectively.
Draw roll 106 pushes tape T between rollers 96 and 94, which bend and rigidify the tape, to the cutting blades 110 and 112. Rotation of shaft 140 by gear 74 in meshing engagement with gear 62, will also cause gear 82 to rotate. Gear 82 is in meshing engagement with gear 84, mounted on shaft 86 retained by collar 88. Suitable gears on shaft 92 and 91 rotate rollers 94 and 96 at a surface speed slightly greater than roll 106 causing tape T to be drawn off of roll 106. Roll 96 can be adjusted to roll 94 to change tension on tape T between rolls 94, 96 and roll 106. Rolls 94 and 96 feed tape to the stationary knife blade 110 and rotary knife blade 112.
Tape drive gear 62 also being in meshing engagement with idler gear 74, can drive rotary knife gear 76 to cause rotary knife holder 80 to rotate on shaft 78 to rotate rotary knife blade 112 to cut the tape T against the edge of stationary knife blade 110 as the tape T is fed by draw roll 106 between concave and convex rollers 96 and 94. Since rotary knife holder 80 is convex, tape T can be fed more rapidly around the holder 80.
By changing the ratio between idler gear 64 and draw roll feed length change gear 70, different lengths of tape can be cut by rotary knife blade 112 relative to stationary knife blade 110, at will. By changing the gear arrangement, the speed of rotation of draw roll 106 on shaft 72 can be varied relative to the speed of rotation of shaft 78 mounting rotary knife holder 80, since the driving gear ratio between idler gear 74 and rotary knife rotation gear 76 remains constant. Similarly, the meshing gears 82 and 84 drives rollers 96 and 94, will also retain the rollers 96 and 94 at their original speed relative to rotation of draw roll 106 so that only the rate of rotation of draw roll shaft 72 can vary the length of tape T fed to the cutting blades during one revolution of holder 80. Therefore, depending on the ratio between gears 64 and 70, the length of tape T which is cut can be varied.
Provision is also made for sensing the absence of an envelope 10 on conveyor 22 to stop the feeding of tape T thereby preserving tape and precluding the tape from being applied to conveyor 22.
This is accomplished by mounting an electric clutch 130 on the end of shaft 72, and an electric brake 138.
Torque is transmitted to roll 106 from shaft 72 when electric power is applied to terminals 132 and 134 activating electric clutch 130. Roll number 106 is stopped by removing electric power from clutch 130 and applying electric power to brake 138. The braking torque is transmitted through gear 150 on the outside of brake to gear 151 on the outside of roll 106.
Switching the electric power from clutch 130 to brake 138 and return is accomplished by a specially designed electronic system consisting of an envelope sensor mounted on the conveyor upstream from the tape applicator, a synchronizing sensor 146, a control latch and relay, control amplifier and power supply for the system.
The synchronizing sensor is normally the sensing roll 142. When the envelope sensor senses an envelope at the same time the synchronizing sensor detects the synchronizing notch 144, the control latches and sends electric power to clutch 130 locking shaft 72 to roll 106 and remains latched until such time that the envelope sensor does not detect an envelope at the same time the synchronizing sensor detects synchronizing notch 144. The control then switches the power from the clutch to the brake stopping roll 106. The control stays in this mode until synchronizing of the two sensors is resumed.
|
Apparatus for feeding and applying a length of an adhesive tape to a reusable envelope closure. Tape is fed from a supply roll by a draw roll which is in contact with the adhesive surface of the tape to frictionally advance the tape between a stationary knife blade and a rotary knife blade. The tape is cut to a desired length by the cooperating edges of the knife blades and delivered to a vacuum roll which transports the cut length of tape to the envelope and presses it onto the envelope to form a part of the reusable closure. A cooperating convex and concave roller forms the tape into a V prior to it being cut to rigidify it as it is cut. Means are also provided to vary the length of tape which is cut and to stop operation of the apparatus upon sensing the absence of an envelope beneath the apparatus.
| 1
|
FIELD OF THE INVENTION
The present invention relates to image and video processing generally and, more particularly, to a method and/or apparatus for adaptive video enhancement gain control.
BACKGROUND OF THE INVENTION
Video enhancement techniques are used to make video appear sharper. One type of video enhancement technique involves enhancing edges or high frequency elements of the video. Conventional edge enhancement uses a high pass filter (HPF) or band pass filter (BPF) and an adder with filtering gain control. The conventional technique for enhancing edges is based on the Mach band effect. Edge enhancement is achieved by increasing the simultaneous contrast of the edge. The variation of the simultaneous contrast needs to be clamped into a limited range to avoid undershoot or overshoot (i.e., for an 8 bit unsigned quantization system, the limits are 0 and 255).
Referring to FIG. 1 , a graph 10 is shown illustrating an example of over emphasized artifacts that can occur with the conventional enhancement technique. An input signal, captured from a monochrome image with a quantization range of zero to ten, can have a black region having a range from zero to less than two, a visible (or perceivable) region having a range from two to eight and a white region having a range from greater than eight to ten. From a perceptual view, the pixels located in the black region or the white region are not distinguishable.
An enhanced output signal (i.e., mixed original and a gain controlled output of a HPF or BPF) can have overshoot and undershoot conditions (i.e., pixel values greater than 10 or less than 0, respectively). The overshoot and undershoot conditions can be corrected by clamping circuitry. However, some pixels that were in the black region or the white region in the input signal (i.e., pixels 2, 4, 16 and 18) can be shifted into the visible region (i.e., the range from two to eight) after enhancement. The pixels with values shifted into the visible range cause artifacts (i.e., noise in the black and white regions). In general terms, the enhancement can cause white flakes in the black region and grey flakes in the white region.
To reduce the over emphasized artifacts a filtering gain control scheme is used. However, the artifacts will be highlighted if the gain control is not set properly. Unfortunately, a proper setting of the filtering gain is very difficult because the HPF or the BPF operates based on the frequency component of the video and ignores the amplitude component of the video.
Referring to FIGS. 2(A-C) , graphs are shown illustrating characteristics of a high pass filter. Input signals presented to a high pass filter can have different DC (direct current) values (illustrated in FIG. 2A ). However, the output of the high pass filter is related to frequency response and phase relationship and independent of the DC value of the input (as illustrated in FIG. 2B ). The outputs of the high pass filter can be identical for the input signals with different DC values ( FIG. 2C ).
The conventional techniques have disadvantages of emphasizing pixels that human vision can not distinguish and causing artifacts. The filtering gain adjustment is based on frequency domain response (filter output) only and ignores the time domain characteristic of the input signal (i.e., the DC value).
It would be desirable to have a method and/or apparatus for adaptively controlling the filtering gain to avoid artifacts.
SUMMARY OF THE INVENTION
The present invention concerns an apparatus comprising a first circuit and a second circuit. The first circuit may be configured to determine frequency of occurrence information for a range of gray levels from luminance data of an input signal. The second circuit may be configured to selectively adjust enhancement for at least one portion of the range of grey levels based upon the frequency of occurrence information.
The objects, features and advantages of the present invention include providing a method and/or apparatus for adaptive video enhancement gain control that may (i) provide a filtering gain that emphasizes only pixels in a perceptual luminance range (PLR), (ii) reduce over emphasized artifacts, (iii) implement a perceptual luminance range histogram (PLRH), (iv) use the PLRH to provide an energy distribution of the perceptual luminance range, (v) set reference limits to avoid artifacts, (vi) implement a hysteretic filter to reduce artifacts caused by abrupt histogram change, (vii) adaptively control filtering gain to achieve a sharper result for different applications, (viii) provide a Gaussian curve gain distribution built into a look-up table (LUT), (ix) achieve luminance equalization adaptively and without causing color distortion, and/or (x) achieve a variable peaking gain by simply modifying the shape of the Gaussian curve in the LUT.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects, features and advantages of the present invention will be apparent from the following detailed description and the appended claims and drawings in which:
FIG. 1 is a graph illustrating an example of an enhanced version of an input signal obtained using a conventional edge enhancement technique;
FIGS. 2(A-C) are graphs illustrating high pass filter characteristics;
FIG. 3 is block diagram illustrating a circuit in accordance with a preferred embodiment of the present invention;
FIG. 4 is a more detailed block diagram illustrating an example of a PLRH block of FIG. 3 ;
FIG. 5 is a more detailed block diagram illustrating an example of a WPHF block of FIG. 3 ;
FIG. 6 is a function diagram illustrating an example of a weight processor and hysteretic filter blocks of FIG. 5 ;
FIG. 7 is a diagram illustrating an example of a Gaussian curve gain distribution in accordance with the present invention;
FIG. 8 is a more detailed block diagram illustrating an example of an output circuit of FIG. 3 ;
FIG. 9 is a graph illustrating an example of an enhanced version of the input signal of FIG. 1 obtained using an enhancement technique in accordance with the present invention; and
FIGS. 10(A-B) are histograms illustrating an example of dynamic contrast in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention generally focuses on a human visual aspect of edge enhancement. The present invention generally uses a perceptual luminance range (PLR) instead of a whole quantized range to implement a PLR histogram (PLRH). For example, while the whole quantized range may be, in one example, from 0 to 255 (8-bit), the PLR may range, in one example, from about 64 to about 192. The PLR may be implemented with a range that may be adjusted (programmable). The PLRH is a histogram of the perceptual luminance range that generally provides an energy distribution of an image. Using the PLRH, a weight processor and hysteretic filter (WPHF) may be configured to assign a perceptual filtering gain based on a predetermined Gaussian curve gain distribution. In one example, the Gaussian curve gain distribution may be implemented in (built into) a look-up table (LUT). The LUT may be used to adaptively adjust the filtering gain.
Referring to FIG. 3 , a block diagram is shown illustrating a circuit 100 in accordance with a preferred embodiment of the present invention. In one example, the circuit 100 may be implemented as a video enhancement circuit (or block). The circuit 100 may have an input 102 that may receive a signal (e.g., INPUT) and an output 104 that may present a signal (e.g., OUTPUT). The signal INPUT may comprise a video signal. The signal OUTPUT may comprise an edge enhanced version of the signal INPUT. In one example, the signals INPUT and OUTPUT may comprise a luminance (Y) component of the respective video signals. The circuit 100 may be configured to generate the signal OUTPUT in response to the signal INPUT using adaptive gain control.
In one example, the circuit 100 may comprise a circuit (or block) 106 and a circuit (or block) 108 . In one example, the circuit 106 may be implemented as an adaptive video enhancement gain control system. The circuit 108 may be implemented as a video enhancement output circuit. The circuit 106 may have an input 110 that may receive the signal INPUT and an output 112 that may present a signal (e.g., CONTROL). The signal CONTROL may be implemented as a control signal. The signal CONTROL may be configured to adaptively control a filtering gain of the circuit 108 . The circuit 106 may be configured to generate the signal CONTROL in response to the signal INPUT. The circuit 108 may have an input 114 that may receive the signal INPUT, an input 116 that may receive the signal CONTROL and an output that may present the signal OUTPUT. The circuit 108 may be configured to generate the signal OUTPUT in response to the signals INPUT and CONTROL.
In one example, the circuit 106 may comprise a circuit (or block) 120 , a circuit (or block) 122 and a circuit (or block) 124 . The circuit 120 may be implemented, in one example, as a perceptual luminance range histogram (PLRH) generating circuit. The circuit 122 may be implemented, in one example, as a weight processor and hysteretic filter (WPHF) block. The circuit 124 may be implemented, in one example, as a look-up table (LUT). The circuit 120 may have an input that may receive the signal INPUT and an output that may present a number of signals (e.g., B 0 . . . Bn). In one example, the signals B 0 . . . Bn may represent individual bin (or slot) values of the perceptual luminance range histogram. The circuit 122 may have an input that may receive the signals B 0 . . . Bn and an output that may present a signal (e.g., MEAN). The signal MEAN may be configured to indicate a center value or mean of a distribution curve for the values of the perceptual luminance range histogram. For a Gaussian curve (e.g., a normal distribution curve) the curve function may be expressed by Equation 1 below:
F ( x )=1 /σ×sqr (2π)×( e −0.5((x−μ)/σ)2) Eq. 1
where the value μ represents the mean of x and the variable σ represents the standard deviation of x.
The circuit 124 may have an input that may receive the signal MEAN and an output that may present the signal CONTROL. The circuit 124 may be configured to generate the signal CONTROL in response to the signal MEAN. In one example, the circuit 124 may contain entries representing samples of a predetermined distribution curve (e.g., a Gaussian curve). For example, the entries stored in the circuit 124 may be determined using Equation 1 above. In one example, the circuit 124 may be configured to set a center value of the distribution curve in response to the signal MEAN. In one example, the preloaded samples in the circuit 124 may be determined for a gain curve for a particular standard deviation (e.g., σi). In another example, the preloaded samples may be determined for a number of different gain distribution curves for a number of different standard deviations (e.g., σ 1 -σn).
In one example, the circuit 108 may comprise a circuit (or block) 130 , a circuit (or block) 132 , a circuit (or block) 134 and a circuit (or block) 136 . The circuit 130 may be implemented, in one example, as either a high pass filter (HPF) or a band pass filter (BPF). The circuit 132 may be implemented, in one example, as a delay circuit. The circuit 134 may be implemented, in one example, as a gain control circuit. The circuit 136 may be implemented, in one example, as an adder circuit.
The circuit 130 may have an input that may receive the signal INPUT and an output that may present a signal (e.g., F_INPUT) to a first input of the circuit 134 . The circuit 134 may have a second input that may receive the signal CONTROL and an output that may present a signal (e.g., F_GAIN) to a first input of the circuit 136 . The circuit 132 may have an input that may receive the signal INPUT and an output that may present a signal (e.g., D_INPUT) to a second input of the circuit 136 . The circuit 136 may have an output that may present the signal OUTPUT. The circuits 130 - 136 may be implemented using conventional techniques.
The signal INPUT may be fed through a HPF/BPF (e.g., the circuit 130 ) and a delay device (e.g., the circuit 132 ) that is configured to compensate for a delay of the HPF/BPF. The signal F_INPUT may be used to select a multiplier for a gain of the circuit 134 to generate the signal F_GAIN. The signal F_GAIN may be summed with the signal D_INPUT by the circuit 136 . An output of the circuit 136 may present the enhanced result as the signal OUTPUT.
Referring to FIG. 4 , a more detailed block diagram is shown illustrating an example of a PLRH generating circuit 120 in accordance with a preferred embodiment of the present invention. In one example, the circuit 120 may comprise a plurality of circuits (or blocks) 140 a - 140 n and a plurality of circuits (or blocks) 142 a - 142 n . The circuits 140 a - 140 n may be implemented, in one example, as range selector circuits. In one example, the circuits 140 a - 140 n may be configured to determine whether an input signal falls within a range between predetermined limits. The circuits 142 a - 142 n may be implemented as counter circuits. In one example, the circuits 142 a - 142 n may comprise 16-bit counter circuits.
Each of the circuits 140 a - 140 n may have a first input that may receive the signal INPUT, a second input that may receive a signal (e.g., LL 0 -LLn, respectively) and a third input that may receive a signal (e.g., UL 0 -ULn, respectively). The signals LL 0 -LLn may be implemented as lower limit values for respective bins (or slots) of the PLRH. The signals UL 0 -ULn may be implemented as upper limit values for respective bins (or slots) of the PLRH. Each of the circuit 140 a - 140 n may be configured to generate an output indicating when a value of the signal INPUT is within the respective range set by the respective signals LL 0 -LLn and UL 0 -ULn.
Each of the circuits 142 a - 142 n may have a first input that may receive an output of a corresponding one of the circuits 140 a - 140 n and a second input that may receive a signal (e.g., VS). In one example, the signal VS may be configured to reset the circuits 142 a - 142 n . In one example, the signal VS may comprise a vertical sync signal of a video stream. Each of the circuits 142 a - 142 n may have an output representing a slot (or bin) value of the perceptual luminance range histogram. For example, the circuit 142 a may have an output that may present a signal (e.g., B 0 ) representing a value of a first bin 0 . The circuit 142 b may have an output that may present a signal (e.g., B 1 ) representing a value for a second bin 1 . The circuit 142 c may have an output that may present a signal (e.g., B 2 ) representing a value for a third bin 2 . The circuit 142 n may have an output that may represent a signal (e.g., Bn) representing a value for an nth bin n. The PLRH may provide the energy distribution of the signal INPUT in the form of a histogram of the PLR. The depth and number of bins may be programmable to fit different applications. The output of the circuit 120 may be normalized. The PLRH generally provides a precise way to present the energy distribution of the signal INPUT.
Referring to FIG. 5 , a more detailed block diagram is shown illustrating an example of a weight processor and hysteretic filter (WPHF) circuit 122 in accordance with a preferred embodiment of the present invention. In one example, the circuit 122 may comprise a circuit (or block) 150 and a circuit (or block) 152 . The circuit 150 may be implemented as a weight processor circuit. The circuit 152 may be implemented as a hysteretic filter circuit. In one example, the circuit 152 may be implemented as a low pass filter (LPF). Each of the signals B 0 . . . Bn may be presented to a respective input of the circuit 150 . The circuit 150 may have an output that may present a signal to an input of the circuit 152 . The circuit 152 may have an output that may present the signal MEAN.
In one example, the circuit 150 may comprise a number of registers 154 a - 154 n , a number of multiplier circuits (or blocks) 156 a - 156 n and an adder circuit (or block) 158 . Each of the registers 154 a - 154 n may contain a respective weighting factor or weight (e.g., W 0 -Wn). Each of the weights W 0 -Wn may be applied to (e.g., multiplied with) a corresponding one of the signals B 0 -Bn received from the circuit 120 . In one example, each of the weights W 0 -Wn may be programmable.
Each of the multiplier circuits 156 a - 156 n may have a first input that may receive a respective one or the signals B 0 -Bn from the circuit 120 and a second input that may receive a respective one of the weights W 0 -Wn from a corresponding one of the registers 154 a - 154 n . Each of the multiplier circuits 156 a - 156 n may have any output that may present a signal to a corresponding input of the adder circuit 158 . The adder circuit 158 may have an output that may present a signal to an input of the hysteretic filter 152 .
Referring to FIGS. 6( a - b ), a function diagram is shown further illustrating an example of the operation of the circuit 122 of FIG. 5 . The circuit 122 generally performs a weight processor function 150 and a hysteretic filtering function 152 (illustrated in FIG. 6( a )). The weight processor 150 may be configured to manipulate normalized histogram data by multiplying each of the signals B 0 -Bn by a respective one of the programmable weight values W 0 -Wn. The manipulated data (signed) may be summed by the adder 158 and the output of the adder 158 fed into the hysteretic filter 152 . The weight processor 150 may be further configured to provide a value or parameter (e.g., μ). In one example, the parameter μ may provide mean-like deviation information that may be used by the LUT 124 . In one example, the hysteretic filter 152 may be implemented as a low pass filter (LPF). The LPF may be configured to smooth the accumulated weight and avoid artifacts due to abrupt changes in the PLRH received from the circuit 120 .
Referring to FIG. 7 , a graph is shown illustrating a Gaussian curve shaped gain distribution in accordance with the present invention. In one example, the LUT 124 may be implemented as a Gaussian curve shaped gain distribution table. The output of the circuit 122 generally provides information for determining a position and a shape of the Gaussian curve gain distribution. For example, the circuit 122 may be configured to provide a parameter (e.g., σ) and the parameter μ. The parameter σ may be used to determine a peak (or center) amplitude of the Gaussian curve gain distribution. For example, the value σ may be used to select among a plurality of predetermined Gaussian curve gain distributions. The parameter μ may be used to determine the position of the center of the Gaussian curve gain distribution. For example, the center of the Gaussian curve may be shifted right when μ>0 and shifted left when μ<0.
In general, the center of the Gaussian curve provides the maximum gain. Since the center of the Gaussian curve provides the maximum gain, the present invention may also provide a kind of luminance equalization effect, without generating color distortion. The feature of dynamic luminance equalization of the PLR is generally based on adaptive parameter selection and the Gaussian curve distribution look-up table (LUT) 124 . By selecting different values of σ, a different peak of the Gaussian curve may be obtained. The samples of the Gaussian curve and variations of the parameters μ and σ generally determine the size of the LUT 124 .
Referring to FIG. 8 , a more detailed block diagram is shown illustrating an example of an edge enhancement output circuit (or block) 108 and LUT 124 in accordance with a preferred embodiment of the present invention. In one example, the circuit 124 may comprise a circuit (or block) 160 and a circuit (or block) 162 . The circuit 160 may comprise a number (e.g., an integer N) of Gaussian curve registers. The circuit 162 may comprise a selector (or multiplexer) circuit. In one example, the circuit 162 may be configured to select a center point of a gain curve. For example, the circuit 162 may be configured to select a number (e.g., an integer M) of values from the number of Gaussian curve registers 160 . The selected values may be presented to the circuit 108 as the signal CONTROL. In one example, the integer M may be less than the integer N.
The circuit 134 may comprise a circuit (or block) 164 and a circuit (or block) 166 . The circuit 164 may be implemented as a slot selector (or multiplexer) circuit. The circuit 166 may be implemented as a peaking gain multiplier circuit. The circuit 164 may have a number (e.g., M) of first inputs, corresponding to the outputs of the circuit 124 , that may receive the signal CONTROL.
The circuit 164 may have a second input that may receive the signal INPUT and an output that may present a signal to first input of the circuit 166 . The circuit 166 may have a second input that may receive the signal F_INPUT and an output that may present the signal F_GAIN. The circuit 166 may be configured to generate the signal F_GAIN in response to the signal F_INPUT and the output of the circuit 164 .
Referring to FIG. 9 , a graph is shown illustrating enhancement using a technique in accordance with the present invention. In general, the settings and definitions, such as black and white range, HPF coefficients and input signal used to generate the enhanced output signal illustrated in FIG. 9 are the same as used in FIG. 1 . In general, the present invention provides better quality enhancement than conventional techniques. The artifacts shown in FIG. 1 are reduced or eliminated and may be ignored. The present invention generally does not scarify the enhancement in the PLR. For example, the present invention generally avoids shifting a sample from the white region (e.g., having a value greater than 8 to 10) into the PLR (e.g., values ranging from 2 to 8) which produces an artifact (noise) that looks like a grey scratch on a white board.
The artifacts shown in FIG. 1 can be amplified by an interpolation processes, such as de-interlacing and horizontal or vertical scaling. Since the present invention may avoid generation of the artifacts and enhance the sharpness of an input signal, the present invention may be useful for iDTV and HDTV applications.
Referring to FIGS. 10( a - b ), histograms are shown illustrating an example of dynamic contrast in accordance with a preferred embodiment of the present invention. FIG. 10 a generally illustrates the original histogram of the signal INPUT. FIG. 10 b generally illustrates a normalized histogram generated in accordance with the present invention. The histogram of FIG. 10 b generally has a more even energy distribution than the histogram of FIG. 10 a . Although the present invention generally does not equalize the PLR, the present invention generally has an advantage of not causing chrominance distortion (artifacts) because the invention may apply, in one example, a finite impulse response (FIR) filter gain based upon a Gaussian curve. The center of the Gaussian curve is generally determined based upon the perceptual luminance range histogram. By applying a filter gain based upon a Gaussian curve centered according to the perceptual luminance range histogram equalization may be achieved.
The present invention generally provides advantages over conventional enhancement techniques that may include, but are not limited to, (i) providing a filtering gain that emphasizes only pixels in the PLR, (ii) reducing over emphasized artifacts using adaptive gain control, (iii) providing a PLRH describing an energy distribution of the PLR that can be used to set reference limits to avoid the artifacts, (iv) providing a hysteretic filter that may reduce a “breath scream” artifact that may be caused by abrupt histogram changes, (v) providing a LUT, or similar device, that may be configured to adaptively control the filtering gain to achieve a sharper result for different applications, (vi) providing a Gaussian curve gain distribution built into a LUT and adjusted to adaptively achieve luminance equalization without color distortion, and/or (vii) providing a peaking gain that may be varied by simply modifying the shape of the Gaussian curve in the LUT.
The functions illustrated by the diagram of FIGS. 3-8 may be implemented using a conventional general purpose digital computer programmed according to the teachings of the present specification, as will be apparent to those skilled in the relevant art(s). Appropriate software coding can readily be prepared by skilled programmers based on the teachings of the present disclosure, as will also be apparent to those skilled in the relevant art(s).
The present invention may also be implemented by the preparation of ASICs, FPGAs, or by interconnecting an appropriate network of conventional component circuits, as is described herein, modifications of which will be readily apparent to those skilled in the art(s).
The present invention thus may also include a computer product which may be a storage medium including instructions which can be used to program a computer to perform a process in accordance with the present invention. The storage medium can include, but is not limited to, any type of disk including floppy disk, optical disk, CD-ROM, magneto-optical disks, ROMs, RAMs, EPROMs, EEPROMs, Flash memory, magnetic or optical cards, or any type of media suitable for storing electronic instructions.
While the invention has been particularly shown and described with reference to the preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made without departing from the spirit and scope of the invention.
|
An apparatus comprising a first circuit and a second circuit. The first circuit may be configured to determine frequency of occurrence information for a range of gray levels from luminance data of an input signal. The second circuit may be configured to selectively adjust enhancement for at least one portion of the range of grey levels based upon the frequency of occurrence information.
| 6
|
TECHNICAL FIELD
The invention relates to devices indicating the status of a fuse or circuit breaker and providing a visual indication thereof, particularly such devices for use in multi-phase electrical systems.
BACKGROUND OF THE INVENTION
Fuse status indicators have long been known including fuse status indicators for multi-phase electrical systems commonly used to power heavy equipment in industrial applications. Often such indicators utilized a neon lamp or other lamp associated with each fuse which would illuminate when the fuse was blown or other malfunction failed to provide an electrical connection for one of the lines of the three-phase or multi-phase system to the load.
Frequently, such prior fuse status indicators included one or more push button switches for testing the indicator light; otherwise there might be a blown fuse or other fault which would go undetected. Recently, more complicated fuse status indicator circuits utilizing LED indicator lights rather than neon lamps have been employed but they also have generally produced only a "fuse bad" indication and if the fuse status indicator itself was defective then a blown fuse or other fault might go undetected.
Examples of such prior fuse status indicator circuits are shown in U.S. Pat. No. 4,857,896 to Brooks, dated Aug. 15, 1989; U.S. Pat. No. 5,343,192 to Yenisey, dated Aug. 30, 1994; and Statutory Registration No. H248 to Middlebrooks, published Apr. 7, 1987.
Other low voltage electrical systems have sought to provide fuse status indicators for multiple DC loads and their associated fuses which would indicate a particular blown fuse or other fault by failure of the associated LED to be illuminated upon closing a test switch. Such a system is shown in U.S. Pat. No. 4,281,322 to Nasu et al., issued Jul. 28, 1981. This circuit is clearly not adaptable for use in a high-voltage AC multi-phase power system.
SUMMARY OF THE INVENTION
The present invention provides a fuse status indicator for multi-phase electrical power circuits which includes substantially identical sub-circuits for each of the three or more phases of the power system, and hence for each of the line fuses (or circuit breakers) of the system. It will be understood that the term "fuse" as used herein includes any low-current responsive line interrupters, such as circuit breakers, magnetic or thermally operated disconnects or the like.
The fuse status indicator of the invention utilizes low voltage indicator lights, such as LED's, which are nevertheless very bright. Power consumption and internal heating in the device is further reduced by pulsing the indicator lights with a low duty cycle current at an attention attracting frequency of two flashes per second, for example. Novel current limiting and voltage regulating circuitry permits the logic circuitry and LED's with their 3-5 volt voltage requirement to be reliably operated over wide ranges of line voltages in power systems. At the same time, the fuse status indicator is sensitive to relatively low voltage (approximately 10-15 VAC) across an open fuse thereby assuring fault detection in cases where an indicator such as a high voltage neon lamp would be ineffective. The power consumption in the fuse indicator is approximately 7 VAC maximum (for high line voltage, e.g. 600 VAC phase-to-phase). This is important to reduce heat generation in the device and improve reliability.
A very important feature of the fuse status indicator according to the invention is that in nearly all cases for each phase there will be a flashing lamp indication which will be green for a normal condition and red for a fault condition. Thus, it is unnecessary to test for lamp or LED circuit failure with a push-button test switch because either absence of a flashing green light or presence of a flashing red light (or both) represents a fault indication.
In a three-phase system, the fuse status indicator requires only six connecting wires, three at the line side of the fuse and three at the load side of the fuse. The installation is simple and essentially foolproof and no additional power source is required since the power consumed is received from the three-phase power line. dr
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view of the fuse status indicator showing the display panel thereof;
FIG. 2 is side elevational view of the fuse status indicator of FIG. 1;
FIG. 3 is a schematic circuit diagram showing the connection of the fuse status indicator of FIGS. 1 and 2 with respect to the three fuses of a three-phase power line;
FIG. 4 is a block diagram of the circuitry of the fuse status indicator of FIGS. 1-3 useful in explaining the operation thereof;
FIG. 5 is a detailed circuit diagram showing a preferred embodiment of circuitry for the fuse status indicator of FIGS. 1-4;
FIGS. 6-11 are illustrations of display conditions of the display panel shown in FIG. 1 for various normal or fault conditions that may be encountered.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings, and particularly to FIGS. 1 and 2, a fuse status indicator 11 is shown having a display panel 20 which has visibly arranged LED's 21-26 appropriately labelled to show normal or fault conditions for each of the three lines of the three-phase power supply. LED's 21, 22, and 23 are green LED's serving as indicators for normal condition for lines 1, 2, and 3 respectively of the three-phase power supply. LED's 24, 25, and 26 are red LED's for indicating a fault condition in a respective one of the three lines of the three-phase power supply.
A connector 13 on the back of fuse status indicator 11 accommodates a six conductor cable 15 with suitable high voltage insulated conductors for connection to a fuse box and the load and line terminals therewithin.
FIG. 3 shows a simplified circuit diagram wherein the fuse status indicator 11 is connected by cable 15 to line side terminals 57, 58 and 59 and to load side terminals 27, 28, and 29. Terminals 57 and 27 are bridged by fuse 31; terminals 58 and 28 are bridged by fuse 32; and terminals 59 and 29 are bridged by fuse 33. Fuse status indicator 11 may be mounted on a wall 9 of a fuse box or may be mounted remotely therefrom.
FIG. 4 is a block diagram useful in explaining the structure and function of the electrical circuits including integrated circuits and discrete circuit elements comprising the three phase fuse status indicator. Indicated at L1, L2, and L3 are the line inputs from a conventional three phase power source which, for the purposes of this explanation, will be considered to have a voltage in the range of 208-600 VAC phase-to-phase (50/60 Hz), for example a nominal voltage of 400 volts. The apparatus of the invention is capable of operating with power systems of substantially higher voltage or substantially lower voltage while maintaining the advantages of low threshold voltage sensing, low power consumption, and low heat generation.
Power from the three phase power line connections L1, L2, and L3 is conducted through respective fuses 31, 32, and 33 to an electric motor 47 or other three phase energy consuming load.
A pseudo-load 45 is connected with a three phase connection to terminals F1, F2, and F3, situated at the load end of respective fuses 31, 32, and 33. An output from pseudo-load 45 is connected to a capacitance discharge circuit 46 and from thence to an input of each of power supplies 41, 42, and 43. As will later be more fully explained, this arrangement provides power for the logic circuits and the indicators in all required situations without the need for an independent power source, such as a battery.
Using line L1 as an example, it will be noted that power supply 41 has an independent ground or negative conductor electrically connected to a terminal 57 on the line side of fuse 31. The same arrangement exists for power supply 42 and terminal 58 and for power supply 43 and terminal 59. Each of the lines L1, L2 and L3 of the three phase power supply has a respective logic circuit 51, 52, and 53 associated therewith. Logic circuit 51 is powered by power supply 41; logic circuit 52 is powered by power supply 42; and, logic circuit 53 is powered by power supply 43.
Each of the logic circuits 51, 52, and 53 includes a pulse circuit 61, 62, and 63, respectively, so that output of the logic circuits 51, 52, and 53 to indicators 21, 22, 23, and 24, 25, 26 is not in the form of a continuous current, but is, rather, in the form of a pulse with a low-duty cycle, thereby reducing power consumption and reducing heat buildup in the circuits.
As previously explained, green LED's 21, 22, and 23 are used to indicate normal function for each of the three phases while red LED's 24, 25, and 26 are indicators of abnormal function with respect to one or more phases. While the function of the apparatus illustrated in FIG. 4 could be accomplished by various known circuit techniques, there are advantages of economy and efficiency associated with the preferred circuitry utilized, as illustrated in FIG. 5.
FIG. 5 shows circuit details corresponding to the explanatory block diagram of FIG. 4. It will be noted that the circuit shown in FIG. 5 comprises three substantially identical sub-circuits, each one having inputs and outputs relating to a particular one of the three phases. Although the operation of each of the sub-circuits will, at times, be affected by current or voltage signals of the other phase or phases, it is convenient to describe in detail just one of the sub-circuits, namely that associated with L1 or phase one, and input terminals 57 and 27. It should be noted that fuses 31, 32, and 33 and motor 47 shown in FIG. 4 are not shown in FIG. 5 because they are not part of the fuse status indicator circuit. The fuse for phase one would be electrically connected between line 1 input L1 and line 1 fuse load terminal F1. Fuses for the other three phase lines would be connected in a similar manner between L2 and F2 and between L3 and F3. Terminals 28 and 29 for lines 2 and 3 correspond to terminal 27 for line 1 and terminals 58 and 59 for lines 2 and 3 correspond to terminal 57 for line 1. A voltage sense input for the line 1 fuse 31 may be seen in FIG. 5 at terminals 27 and 57 connected to the F1 terminal at the load end of fuse 31 and the L-1 terminal at the line end of fuse 31. Diode 73, diode 80, and diode 87 perform half-wave rectification and capacitors 163, 167, and 171 provide a filtering or voltage holding function to convert a voltage sense input to D.C. voltage at PIN 1 of the quad-NAND integrated circuit chips which include NAND logic elements 1A through 1D, 2A through 2D, and 3A through 3D.
Capacitors 163, 167, and 171 are charged through respective resistors 106, 117, and 128 and the junction between each capacitor and its corresponding resistor is connected to pin 1 of NAND element 1A, 2A, or 3A respectively. NAND element 1A switches on red LED 24 whereas that function is performed for red LED 25 by NAND element 2A and for red LED 26 by NAND element 3A. The output from pulse circuit 61 is connected to pin 2 of NAND element 1A and there is a similar connection to pin 2 of NAND elements 2A and 3A.
Red LED 24 will come on when a high level is on pin 1 and also on pin 2 of NAND element 1A causing its output to go low. This is the well-known function of a NAND circuit element which has a high output at all times except when both input 1 and input 2 are high. It will be noted that LED 24 and also LED's 25 and 26 will not be on continuously in the presence of a voltage sense input, because the pulse circuit 61 (and corresponding circuitry for LED 25 and LED 26) produces a pulsed output with a low-duty cycle thereby causing a flashing indication from red LED 24 (and corresponding LED 25 and LED 26 for phases 2 and 3).
The operation of pulse circuit 61 and corresponding circuity for phases 2 and 3, is generally conventional except for the manner in which diode 77 produces the asymmetric pulse-wave form with low duty cycle and appropriate timing. Diodes 84 and 91 perform a similar function for phases 2 and 3. The NAND element 1C and the NAND element 2B are operated as inverters by connecting their two inputs together (and the same arrangement is used with NAND elements 2B and 2C and with NAND elements 3B and 3C). Capacitors 164, 168, and 172 provide feedback for the pulse oscillators while the arrangement of resistor 111 with resistor 110 (also resistor 122 with resistor 121 and resistor 133 with resistor 132) causes different effective resistance paths in a respective circuit for different directions of current flow, thereby producing the desired asymmetric low-duty cycle pulse wave form.
The pseudo-load 45 in FIG. 5 is formed by resistors 101 and 104 in phase 1, resistors 115 and 112 in phase 2 and resistors 123 and 126 in phase 3. The pseudo-load assures operation of the phase status indicator circuit even if all load was disconnected (from terminals F1, F2 and F3). Capacitance discharge element 46 comprises resistor 156 allowing for slow discharge of power supply capacitors. This provides a safety factor to eliminate shock hazard after power has been cut off. Power supply 41 comprises the elements within the dashed lines and similar independent power supplies are present for phase 2 and phase 3. Power supply 41 will be described with the understanding that the phase 2 and phase 3 circuits operate in a similar manner.
Capacitor 161 is a current limiting capacitor and is connected to the center of the Y-connected pseudo-load circuit and, together with resistor 107, provides a limited value of current to power supply 41. This function is provided by capacitor 165 and resistor 118 for phase 2 and capacitor 169 and resistor 129 for phase 3.
The current in power supply 41 is rectified by diode 72 and voltage regulation is provided by zener diode 76. The positive voltage provided by power supply 41 is present at terminals V+1. Additional overvoltage protection is customarily built into the internal circuitry of the quad NAND chip. The positive voltage of power supply 41 is also provided to terminals of resistor 108 and resistor 109 in the output of the respective NAND elements 1A and 1D.
In phase 2 and phase 3 the function of diode 72 is provided by diode 79 and diode 86; of diode 71 is provided by diode 78 and diode 85; of zener diode 76 is provided by zener diode 83 and zener diode 90; of positive terminals V+1 is provided by terminals V+2 and V+3; of resistor 108 is provided by resistor 119 and resistor 130; and of resistor 109 is provided by resistor 120 and resistor 131. Capacitor 162 (and capacitors 166 and 170) serve to reduce voltage fluctuations for the respective indicator circuits.
The function of the green LED's 21, 22, and 23 are provided in the following fashion. As previously seen with NAND element 1A and red LED 24, the operation of NAND element 1D will not permit LED 21 to be on except when both pins one and two are high. As previously seen, pin 2 will be high only during the pulse output from pulse circuit 61, whereas pin 1 will be high when the output of NAND element 1A is high (And red LED 24 is off.). Thus, the logic provided by the connection of NAND elements 1A and 1D (and also NAND elements 2A and 2D and NAND elements 3A and 3D) is such that green LED 21 (or 22, or 23) will be flashing on when, and only when, the corresponding red LED 24 (or 25 or 26) is off. That is to say, the green LED's will be on only when their respective voltage sense inputs do not detect a blown fuse or other fault.
Exemplary values for electronic components are given below in Table I and also shown in FIG. 5.
TABLE I______________________________________REFERENCE NUMBER VALUE NOTE______________________________________ 71 1N4007 72 1N4007 73 1N4007 76 5.6 V 77 1N914 78 1N4007 79 1N4007 80 1N4007 83 5.6 V 84 1N914 85 1N4007 86 1N4007 87 1N4007 90 5.6 V 91 1N914101 1/2 W102 1/2 W103 1 W MOR104 MFR105 332 k MFR106 MFR107 2 W MOR108 150109 150110 330 k111 4.7 M112 1/2 W115 MFR117 MFR118 2 W MOR119 150120 150121 330 k122 4.7 M123 1/2 W124 1/2 W125 1 W MOR126 MFR127 MFR128 MFR129 2 W MOR130 150131 150132 330 k133 4.7 M156 1/2 W161 630 V F162 10 V163 50 V164 50 V165 630 V166 10 V167 50 V168 50 V169 630 V170 220 μF171 50 V172 50 V______________________________________
FIGS. 6 through 11 illustrate the type of display present for various conditions of the system which the fuse status indicator monitors, as seen in FIG. 6, condition normal, fuse good, with good electrical contact across fuse for line 1. The same indication for the same condition would be given for line 2 or line 3, in this case green flashing LED. FIG. 7 shows an indication for fuse-load fault; namely the green LED dark and the red LED flashing. This is an indication of an unconnected or blown fuse, a bad connection on the load side, or both.
FIG. 8 shows the indication for a line side fault, namely a flashing red LED with reduced intensity. This indication can result from a bad connection on the line side of the fuse with or without a blown fuse; it may also indicate phase voltage loss with motor regeneration together with an unconnected or blown fuse.
FIG. 9 shows the indication of a phase voltage fault, namely both green and red LED's dark. This indication can result from a phase voltage loss with no motor regeneration with or without an unconnected or blown fuse. It is also an indication of a possible failure or malfunction within the fuse status indicator.
FIG. 10 shows the indication of a double fault, for example in lines 1 and 2, namely both red LED's flashing and green LED's dark. This indication can result from two unconnected or blown fuses, misconnected wires being interchanged on the line side or on the load side. Misconnected wires will produce this indication whether or not there are one or two unconnected or blown fuses.
FIG. 11 shows the indication of a multiple fault, namely all three LED's flashing. This indication can result from three unconnected or blown fuses, or where line side connections do not correspond to load side connections. When load side connections do not correspond to line side connections, this indication may result whether or not there are one or more unconnected or blown fuses.
It is important to note that all three lights flashing green is the only "normal" indication and a fault is indicated by presence of any red flashing lights or absence of any green flashing lights. Such fault indication will also be produced by a failure within the fuse status indicator itself, so that it may be replaced promptly.
While a preferred embodiment of the invention has been described in detail, it will be appreciated that many variations of the three-phase fuse status indicator may be employed according to the invention. For example, indicators other than LED's may be used, other logic circuitry may be used, and different integrated circuit components may be employed. The fuse status indicator could be adapted for use in multi-phase systems other than three-phase systems, if that were desired.
Variations and modifications to the invention, in addition to those shown, suggested or described herein, may be implemented by those skilled in the art and, accordingly, it is to be understood that the scope of the invention is not limited to those embodiments of the invention shown, described, or suggested but is rather to be determined by reference to the appended claims.
|
There is disclosed a multi-phase fuse status indicator having a green "good" and a red "bad" indicator LED for each line fuse of the respective phases, the current to the LED's being pulsed to cause them to provide a blinking indication. Power used for the logic circuit for the LED's and the LED's themselves and the related heat dissipation is less than 10 watts and is supplied from the power lines connected through the fuses regardless of the fuses' condition. Only two simple conductor connections are required from the fuse status indicator to each fused line of the multi-phase power system.
| 7
|
Subsets and Splits
No community queries yet
The top public SQL queries from the community will appear here once available.